LACROSSE MESH AND RELATED OBJECTS AND METHODS

Lacrosse mesh having a hybrid arrangement, which includes at least two components of different material types or properties. Yarns or strands of the mesh can be provided with a high level of twist, such as above 100 TPM. In some configurations, individually twisted yarns or strands are combined and twisted in the same or a different direction than the individual twist. In some configurations, one material has a higher modulus, better absorption or adhesion properties, or different levels of thermal shrinkage than the other material(s). In some configurations, some yarns or portions of the mesh (warp or weft) are more tightly knitted and other yarns or portions of the mesh to be more loosely knitted. In some configurations, the more loosely knitted yarns or portions have a higher level of thermal shrinkage and tighten in response to heating of the mesh.

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Description
INCORPORATION BY REFERENCE OF PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference and made a part of the present disclosure.

BACKGROUND

1. Field

The present disclosure relates to sporting equipment, in particular, lacrosse equipment. The present disclosure further relates to mesh for creating a pocket in the head of a lacrosse stick, as well as heads or sticks incorporating such a pocket.

2. Description of Related Art

Lacrosse mesh is an open net structure that is typically an open warp knit structure. Currently, used to string a lacrosse pocket is constructed from a single material. Often, the material used is nylon, polyester or polypropylene. Many issues exist with such conventional mesh, including undesirable stretching (especially when wet) and breakage. Thus, a need exists for improved or alternative mesh constructions.

SUMMARY

The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized.

An aspect of the present disclosure involves using hybrid yarn strands to control mechanical properties of lacrosse mesh. Such yarn strands can comprise multiple yarns per strand. In some configurations, one yarn type is used as a reinforcement of another yarn type. In some configurations, the yarn strands are twisted in opposite directions. In some configurations, the yarn strands are provided with a high level of twist, such as above 100 TPM, 100-600 TPM or any value or sub-range within these values. In some configurations, the level of twist can be greater than 600 TPM.

In some configurations, at least two different material types are used. In some configurations, one material has a higher modulus than the other material(s). In some configurations, one material has better absorption or adhesion properties than the other material(s).

In some configurations, the yarn types used have different levels of thermal shrinkage. Such an arrangement allows some yarns or portions of the mesh (warp or weft) to be more tightly knitted and other yarns or portions of the mesh to be more loosely knitted. In some configurations, the more loosely knitted yarns or portions have a higher level of thermal shrinkage and tighten in response to heating of the mesh.

In some configurations, a lacrosse mesh for stringing to a head of a lacrosse stick includes a first outside edge extending between a first end and a second end of the lacrosse mesh and a second outside edge opposite the first outside edge. The second outside edge also extends between the first end and the second end of the lacrosse mesh. A plurality of pillars are positioned between the first outside edge and the second outside edge and extend between the first end and the second end of the lacrosse mesh. One or more of the plurality of pillars comprise connected portions and unconnected portions. The lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands, each of the plurality of warp strands and the plurality of weft strands comprising one or more yarns or filaments. At least a portion of the yarns or filaments of the warp strands or the weft strands have an individual twist of greater than or equal to 250 TPM.

In some configurations, at least a portion of the warp strands or the weft strands comprise a plurality of yarns or filaments, wherein the individual twist of each of the plurality of filaments is in a first direction, and wherein the plurality of yarns or filaments are twisted together to have a combined twist in a second direction opposite the first direction.

In some configurations, the combined twist is less than the individual twist.

In some configurations, the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

In some configurations, one or both of the warp strands and the weft strand have a first yarn that has a first physical property and at least a second yarn that has a second physical property that is different from the first physical property.

In some configurations, the first physical property and the second physical property are selected from the following: material, material grade, modulus, length, shape, orientation, ability to coat, heat treatment, elongation, shrinkage, size, and strength.

In some configurations, the warp strands have a first yarn that has a first physical property and the weft strand have a second yarn that has a second physical property that is different from the first physical property.

In some configurations, the first physical property and the second physical property are selected from the following: material, material grade, modulus, length, shape, orientation, ability to coat, heat treatment, elongation, shrinkage, size, and strength.

In some configurations, a lacrosse mesh for stringing to a head of a lacrosse stick includes a first outside edge extending between a first end and a second end of the lacrosse mesh and a second outside edge opposite the first outside edge. The second outside edge also extends between the first end and the second end of the lacrosse mesh. A plurality of pillars are positioned between the first outside edge and the second outside edge and extend between the first end and the second end of the lacrosse mesh. One or more of the plurality of pillars comprise connected portions and unconnected portions. The lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands. The plurality of warp strands have a first elongation and the plurality of weft strands have a second elongation that is different than the first elongation.

In some configurations, the first elongation is less than the second elongation.

In some configurations, the warp strands are woven tighter than the weft strands.

In some configurations, the first elongation is greater than the second elongation.

In some configurations, the weft strands are woven tighter than the warp strands.

In some configurations, the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

In some configurations, a method of manufacturing a lacrosse mesh for stringing to a head of a lacrosse stick includes constructing a lacrosse mesh comprising a first outside edge extending between a first end and a second end of the lacrosse mesh, a second outside edge opposite the first outside edge, the second outside edge extending between the first end and the second end of the lacrosse mesh, a plurality of pillars positioned between the first outside edge and the second outside edge and extending between the first end and the second end of the lacrosse mesh, wherein one or more of the plurality of pillars comprise connected portions and unconnected portions, wherein the lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands. The method also includes selecting the plurality of warp strands to have a first elongation and selecting the plurality of weft strands to have a second elongation that is different than the first elongation. The method also includes heating the lacrosse mesh such that one or both of the warp strands and the weft strands shrink, wherein the one of the warp strands and the weft strands shrink a greater amount than the other of the warp strands and the weft strands as a result of the difference in the first elongation and the second elongation.

In some configurations, the warp strands are knitted tighter than the weft strands.

In some configurations, the first elongation is less than the second elongation.

In some configurations, a lacrosse mesh for stringing to a head of a lacrosse stick includes a first outside edge extending between a first end and a second end of the lacrosse mesh and a second outside edge opposite the first outside edge. The second outside edge also extends between the first end and the second end of the lacrosse mesh. A plurality of pillars are positioned between the first outside edge and the second outside edge and extend between the first end and the second end of the lacrosse mesh. One or more of the plurality of pillars comprise connected portions and unconnected portions. The lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands. The lacrosse mesh comprises a hybrid construction having a first material and a different second material within one or both of the warp strands and the weft strands.

In some configurations, the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

In some configurations, at least a portion of yarns or filaments of the warp strands or the weft strands have an individual twist of greater than or equal to 250 TPM.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through the use of the accompanying drawings.

FIG. 1 is a plan view of a lacrosse mesh having certain features, aspects and advantages of the present disclosure.

FIG. 2 is a plan view of a portion of the lacrosse mesh of FIG. 1.

FIG. 3 is a plan view of several columns of the lacrosse mesh of FIG. 1.

FIG. 4 is a plan view of one side portion of the lacrosse mesh of FIG. 1 illustrating an edge pillar or selvedge of the mesh.

FIG. 5 is a plan view similar to FIG. 4 illustrating a mesh pillar of the lacrosse mesh.

FIG. 6 is a plan view similar to FIG. 4 illustrating a pillar connection of the lacrosse mesh.

FIG. 7 is a plan view similar to FIG. 4 illustrating an unconnected portion of a mesh pillar.

FIG. 8 is a plan view similar to FIG. 4 illustrating a warp strand of the lacrosse mesh.

FIG. 9 is a plan view similar to FIG. 4 illustrating a weft strand of the lacrosse mesh.

FIG. 10 is a plan view similar to FIG. 4 illustrating a warp loop and a weft loop of the lacrosse mesh.

FIG. 11 is a plan view of an alternative knitting pattern of a lacrosse mesh in which the warp strands are asymmetrical.

FIG. 12 is a plan view of another alternative knitting pattern of a lacrosse mesh in which the warp strands are oriented in the opposite direction compared to FIGS. 1-10.

FIG. 13 is a view of individual twisted yarns and combinations or strands of the twisted yarns that are also twisted, one in the same direction as the individual twist and one in the opposite direction of the individual twist.

FIG. 14 is a sectional view of a hybrid strand or yarn.

FIG. 15A is a side view of the hybrid strand or yarn of FIG. 14 in a first stretch position.

FIG. 15B is a side view of the hybrid strand or yarn of FIG. 14 in a second stretch position.

FIG. 15C is a side view of the hybrid strand or yarn of FIG. 14 in a third stretch position.

FIG. 16 is a block diagram of a process for creating a lacrosse mesh.

FIG. 17 is block diagram of another process for creating a lacrosse mesh.

FIG. 18 is a partial plan view of an alternative lacrosse mesh having multiple weft strands in each mesh pillar and a different number of connected loops and unconnected loops in comparison to the mesh of FIGS. 1-10.

 DETAILED DESCRIPTION

Embodiments of systems, components and methods of assembly and manufacture will now be described with reference to the accompanying figures, wherein like numerals refer to like or similar elements throughout. Although several embodiments, examples and illustrations are disclosed below, it will be understood by those of ordinary skill in the art that the inventions described herein extends beyond the specifically disclosed embodiments, examples and illustrations, and can include other uses of the inventions and obvious modifications and equivalents thereof. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner simply because it is being used in conjunction with a detailed description of certain specific embodiments of the inventions. In addition, embodiments of the inventions can comprise several novel features and no single feature is solely responsible for its desirable attributes or is essential to practicing the inventions herein described.

Certain terminology may be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “above” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “left,” “right,” “rear,” and “side” describe the orientation and/or location of portions of the components or elements within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the components or elements under discussion. Moreover, terms such as “first,” “second,” “third,” and so on may be used to describe separate components. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.

Typically, lacrosse mesh is an open net structure that is often an open warp knit structure. While most of the examples in the present application refer to mesh made out of warp knit fabric, it is contemplated that the features, aspects and advantages of the present disclosure can be applied to any open structured lacrosse mesh. Other methods for creating open structured lacrosse mesh include but are not limited to fabrics made from weft knitting, weaving, braiding, etc.

To facilitate the description of certain features, aspects and advantages of the lacrosse mesh disclosed herein, certain terms used to describe lacrosse mesh are identified below. These terms are to be interpreted in accordance with their ordinary meaning, which can include the definitions provided below.

Mesh Pillars—a mesh pillar generally is an elongate structure that extends in a lengthwise (or a widthwise) direction of the lacrosse mesh. Typically, the lacrosse mesh contains multiple mesh pillars oriented in columns (or rows). The individual mesh pillars can extend in a nonlinear path, such as a wave-like or oscillating path, such that adjacent pillars move toward and away from one another along their length. The nonlinear orientation of the mesh pillars creates an open mesh construction in which the mesh defines a plurality of open spaces between adjacent mesh pillars. One of the mesh pillars of the lacrosse mesh is highlighted in FIG. 5. The mesh pillars are constructed at least in part from the warp yarns. The warp yarns make a series of knitted loops that create a foundation of the mesh pillars. In the illustrated arrangement, the mesh pillars travel or extend in the vertical direction between first and second ends of the lacrosse mesh. However, in other arrangements, the mesh pillars can travel in the horizontal direction of the lacrosse mesh. The mesh pillars can also include weft yarns. For example, weft yarns can connect two or more mesh pillars and can also extend in a lengthwise (or widthwise) direction along one or more mesh pillars. A single weft yarn can form a portion of one or more mesh pillars, as described in greater detail hereinafter.

Pillar Connections or Connected Portions—a pillar connection or a connected portion of a pillar can be any place that, or portion along which, two or more mesh pillars are connected to each other. In some configurations, the pillar connections are created or defined by one or more of the weft yarns, which can connect a portion of two (or more) mesh pillars. A pillar connection is highlighted in FIG. 6.

Pillar Unconnected Portions—a pillar unconnected portion is a portion or section of a mesh pillar that is located between pillar connections or that is not connected to another mesh pillar. A pillar unconnected portion is highlighted in FIG. 7.

Warp Strand—a warp strand is an elongate structure that extends in a longitudinal or lengthwise (or widthwise direction) of the lacrosse mesh and creates a portion of a mesh pillar. In some configurations, the warp strand is a knitted structure comprising a plurality of interconnected loops. However, the warp strands can have other constructions or construction methods, such as woven or braided constructions. The warp strands can be constructed of one or more constituent parts (e.g., yarns or filaments). A warp strand is highlighted in FIG. 8.

Weft Strand—a weft strand is an elongate structure that extends in a longitudinal or lengthwise (or widthwise) direction of the lacrosse mesh and connects two or more warp strands to define a connected portion of a mesh pillar. The weft strand can also extend along the warp strands in an unconnected portion of one or more mesh pillars. In some configurations, the weft strand travels back and forth through the mesh pillars (e.g., through the warp strands). In some configurations, the weft strand travels from one mesh pillar to another mesh pillar. The weft strands can be constructed of one or more constituent parts (e.g., yarns or filaments). A weft strand is highlighted in FIG. 9. In some configurations, there can be multiple weft strands within the same mesh pillar—even within the unconnected portion of the pillar. Each weft strand can have a unique knitting pattern within its mesh pillar.

Warp Yarn—a warp yarn or filament is an elongate yarn or filament that is oriented in a longitudinal or lengthwise direction (or widthwise direction) of the lacrosse mesh and makes up at least a portion of a warp strand. As described above, the warp strand can include one or more constituent yarns or filaments. As used herein, yarns are typically made up of multiple interlocked fibers, which can be interlocked by spinning or twisting, for example. A filament can be constructed of one or more long, continuous fibers. Some yarns are multiple fiber yarns, in which the fibers can be twisted or grouped together. Other yarns are single fiber or monofilament yarns, which can be constructed by, for example, an extrusion process. As used herein, the term yarn can refer to spun yarn, filament yarn, monofilament yarn or any other suitable structure that can create a constituent part of a strand.

Weft Yarn—a weft yarn is an elongate yarn or filament that is oriented in a longitudinal or lengthwise direction (or widthwise direction) of the lacrosse mesh and makes up at least a portion of a weft strand. As described above, the weft strand can include one or more constituent yarns or filaments. As used herein, yarns are typically made up of multiple interlocked fibers, which can be interlocked by spinning or twisting, for example. A filament can be constructed of one or more long, continuous fibers. Some yarns are multiple fiber yarns, in which the fibers can be twisted or grouped together. Other yarns are single fiber or monofilament yarns, which can be constructed by, for example, an extrusion process. As used herein, the term yarn can refer to spun yarn, filament yarn, monofilament yarn or any other suitable structure that can create a constituent part of a strand, unless otherwise indicated.

Warp Loop—a warp loop is a single loop of a warp strand. A warp loop is highlighted in FIG. 8. The warp loops create the warp strands, which, in turn, create at least a portion of the mesh pillars. The warp yarns in the warp knitted lacrosse mesh construct the warp loops. However, as described above, one could construct the lacrosse mesh with weft knitting techniques.

Weft Loop—a weft loop is a single pass or loop of a weft strand. In some configurations, the weft strand passes back and forth through the warp loops one or more warp strands in a non-overlapping fashion. Thus, a weft loop can refer to a portion of a weft strand that passes across a single warp strand (e.g., in an unconnected portion of a mesh pillar) or across a combination of warp strands (e.g., in a connected portion of a mesh pillar) from one side of the warp strand(s) toward or to the other side of the warp strand(s). Thus, a new weft loop can begin and end each time the weft strand changes direction. Alternatively, a weft loop can refer to a portion of a weft strand that passes twice (back and forth) across a single warp strand or a combination of warp strands. Thus, a new weft loop can begin and end each time the weft strand begins a new back-and-forth cycle.

Connected Loop—a connected loop can be defined as a loop that is located within a pillar connection or a connected portion of a mesh pillar. Thus, a connected loop can comprise a warp loop that is connected by one or more weft strands and/or a weft loop that connects the warp strands. Accordingly, the individual loops located in the connected portion of the mesh pillars in FIG. 6 can be referred to as connected loops. Typically, the mesh pillars are connected together by the weft strands. However, the mesh pillars can be connected together by warp strands. This can happen, for example, when warp loops from one mesh pillar cross over into and/or interlock with warp loops of another mesh pillar. In such arrangements, connected warp loops from different mesh pillars can also be considered connected loops.

Unconnected Loop—an unconnected loop can be defined as a loop that is not directly or indirectly connected to another mesh pillar. Thus, unconnected loops can be warp loops or weft loops. Accordingly, the individual loops located in the unconnected portion of the mesh pillars in FIG. 7 can be referred to as unconnected loops.

Mesh Selvedge—the mesh selvedge is a mesh pillar that lies on the very outside of the lacrosse mesh. In some configurations, the mesh selvedge is an extra, outermost mesh pillar that is fully connected to the directly adjacent mesh pillar on an inward side of the selvedge. However, in other configurations, the mesh selvedge may be defined by the outermost mesh pillar, and the lacrosse mesh may not include a specific or an additional mesh pillar that defines the selvedge. Thus, the mesh selvedge can refer to an edge pillar or other outer edge structure of the lacrosse mesh.

Loop Length—the loop length can be defined as a length of one loop, which can be a warp loop or a weft loop. The loop length can be a length of a loop in a longitudinal or lengthwise direction of the lacrosse mesh or can be a length of the loop as measured in the direction of the relevant loop (e.g., the direction of the portion of the mesh pillar containing the relevant loop). As used herein, loop length can refer to either measurement unless otherwise indicated, either explicitly or by context.

Mesh Diamond Length—the mesh diamond length can be defined as a distance of a single cycle of a mesh pillar in a lengthwise direction of the lacrosse mesh. As described above, in many configurations, the mesh pillars are arranged in a wave-like or oscillating shape. In some configurations, adjacent mesh pillars create open spaces therebetween, which can be somewhat diamond-like in shape and are often referred to as diamonds. The mesh diamond length can be measured between any two points that define a full cycle of the mesh pillar shape, such as between centers of adjacent connected portions of a mesh pillar. Similar to the loop length, the mesh diamond length can be measured in a lengthwise direction of the lacrosse mesh or can be an actual length of the mesh pillar between the two points, including the curvature of the mesh pillar. As used herein, mesh diamond length can refer to either measurement unless otherwise indicated, either explicitly or by context.

Moreover, lacrosse mesh is often manufactured with a width that is less than a width in use. The lacrosse mesh is often stretched in a widthwise direction to increase the width prior to use or during the process of stringing the mesh to the head of a lacrosse stick. Thus, as manufactured, the lacrosse mesh can define longer and narrower mesh diamonds compared to lacrosse mesh in use or lacrosse mesh that has been stretched for use. Accordingly, loop length or mesh diamond length can be measured in a non-stretched or manufactured condition of the lacrosse mesh or can be measured in a stretch, ready-for-use or use condition of the lacrosse mesh. Loop length or mesh diamond length can refer to the measurement in any condition of the lacrosse mesh unless otherwise indicated, either explicitly or by context.

Mesh Structure

One example of a lacrosse mesh 100 is illustrated in FIGS. 1-10. The lacrosse mesh 100 defines a length or lengthwise direction 102 and a width or widthwise direction 104. The lacrosse mesh 100 has a first edge 106 that extends in the lengthwise direction 102 and a second edge 108 on an opposite side of the lacrosse mesh 100 that also extends in the lengthwise direction 102. The lacrosse mesh 100 has a first end 110 extending between the edges 106, 108 and a second end 112 extending between the edges 106, 108 at an opposite end of the lacrosse mesh 100 from the first end 110.

Between the edges 106, 108 and extending in the lengthwise direction 102 between the ends 110, 112, the lacrosse mesh 100 comprises a plurality of columnar structures, which in some configurations can be mesh pillars 114. However, as described above, in other configurations, the pillars or similar structures can extend in the widthwise direction 104 and could form or be referred to as rows. The illustrated mesh pillars 114 extend in a nonlinear path, which can define a repetitive pattern, such as a generally oscillating or wave-like path. In some configurations, the frequency or cycle-length (wave-length) of some or all of the mesh pillars 114 can be consistent within or between pillars 114. In other configurations, the frequency or cycle-length (wave-length) of some or all of the mesh pillars 114 can vary within or between pillars 114.

In the illustrated arrangement, the mesh pillars 114 cooperate to form a plurality of open spaces 116. The open spaces 116 and/or the portions of the one or more mesh pillars 114 that define the open spaces 116 are often referred to and can be referred to herein as diamonds. The open spaces 116 and/or portions of the mesh pillar(s) 114 that define the open spaces 116 can be diamond-shaped or generally diamond-shaped, but can have other shapes, as well. For example, the open spaces 116 and/or portions of the mesh pillar(s) 114 that define the open spaces 116 can be generally polygonal with any number of sides (e.g., octagonal) or generally circular.

The open spaces 116 can be organized into rows and/or columns. The open spaces 116 of adjacent rows and/or columns can be offset from one another. For example, one row and/or column can be defined entirely by whole open spaces 116, while the adjacent row(s) and/or column(s) can include divided or partial open spaces 116. In the illustrated arrangement, every other row and/or every other column includes a partial (e.g., half or more) open space 116 on each end in contrast to the whole open spaces 116 between the ends. In the illustrated arrangement, every other row includes nine (9) complete open spaces 116 or diamonds and the intervening rows include ten (10) complete or partial open spaces 116 or diamonds. In particular, the rows of ten (10) open spaces comprise eight (8) complete open spaces 116 or diamonds and two (2) partial open spaces 116 or diamonds (one partial space 116 or partial diamond on each end). However, in other configurations, each row can include some partial diamonds or each row can include only full diamonds.

The lacrosse mesh 100 can be characterized by the number of open spaces 116 or diamonds present in the rows. For example, the illustrated lacrosse mesh 100 can be referred to as a 9/10 diamond lacrosse mesh 100 as a result of the alternating nine (9) and ten (10) diamond or open space 116 rows. In the portion shown in FIG. 1, the mesh 100 has eight (8) rows of ten (10) open diamonds and nine (9) rows of nine (9) open diamonds. Typically, however, the lacrosse mesh 100 will have more rows. For example, the lacrosse mesh 100 can have 14 rows of 10 open diamonds and 14 rows of 9 open diamonds. Typical player mesh that has a width of 10/9 diamonds will have at least 11 rows of 10 open diamonds and 11 rows of 9 open diamonds. In addition, in some cases, the mesh 100 can have more than 14 rows of 10 open diamonds and/or 14 rows of 9 open diamonds.

The number of open spaces 116 per row and/or column can vary and the lacrosse mesh 100 can be identified by the number of diamonds or open spaces 116 in adjacent rows. For example, an 8/9 lacrosse mesh 100 has alternating rows of eight (8) and nine (9) diamonds and a 7/8 lacrosse mesh 100 has alternating rows of seven (7) and eight (8) diamonds. In general, lacrosse mesh 100 intended for use by field players includes between about 5-12 or 6-10 diamonds or open spaces 116 per row. In general, lacrosse mesh 100 intended for use by goalies includes between about 10-22 diamonds or opens spaces 116 per row. However, other numbers of diamonds per row can be used, if desired. Although a 9/10 diamond lacrosse mesh 100 is illustrated herein, the aspects, features and advantages of the present disclosure can be applied to lacrosse mesh arrangements having other numbers of diamonds per row.

With particular reference to FIGS. 2 and 4, in some configurations, the first edge 106 and/or the second edge 108 can be defined by a selvedge 120. The selvedge 120 is a mesh pillar 114 that lies on the very outside of the lacrosse mesh 100. In the illustrated configuration, the selvedge 120 is an extra, outermost mesh pillar 114 that is fully connected to the directly adjacent mesh pillar 114 on an inward side of the selvedge. However, in other arrangements, the extra, outermost mesh pillar 114 can be omitted and the first edge 106 and/or the second edge 108 can be defined by the next inward mesh pillar 114, which is a linear pillar 114 in the illustrated arrangement. However, one or both of the first edge 106 and the second edge 108 can be defined by a nonlinear mesh pillar 114. While a selvedge 120 is often defined by an extra mesh pillar 114, unless otherwise indicated, the outermost mesh pillar 114 one either side of the lacrosse mesh 100 that defines one of the first edge 106 and the second edge 108 can be referred to as a selvedge.

In the illustrated arrangement, each mesh pillar 114, including the pillars 114 that define the selvedges 120, comprises a warp strand 122. The warp strand 122 is an elongate structure that is knitted into a plurality of interconnected loops 124 (FIG. 10). However, the warp strand 122 can be constructed from other methods or can be of other suitable constructions. As described herein, the warp strand 122 can be constructed from one or more constituent parts, which can be yarns, for example.

In the illustrated arrangement, each mesh pillar 114 also comprises a weft strand 126. The weft strands 126 extend in a back-and-forth fashion through the loops 124 of the warp strands 122, while also extending in the lengthwise direction 102 of the lacrosse mesh 100. The weft strands 126 can define weft loops 128, which can refer to a single pass of a weft strand 126 in one direction (e.g., the width direction 104). Thus, a single weft loop 128 can begin and end at each change in direction of the weft strand 126. Alternatively, a weft loop can refer to a portion of a weft strand 126 that passes twice (back and forth) across a single warp strand 122 or a combination of warp strands 122.

In some configurations, the weft strands 126 connect two or more mesh pillars 114 to one another. The weft strands 126 can connect mesh pillars 114 at several discrete locations, which can create the open mesh structure of the lacrosse mesh 100. Portions of a mesh pillar 114 connected to another mesh pillar 114 or to another structure by a weft strand 126 can be referred to as a connected portion or a pillar connection 130 (FIG. 6). Portions of a mesh pillar 114 that is not connected to another mesh pillar 114 or another structure can be referred to as an unconnected portion 132 (FIG. 7). In other configurations, the connected portions can be defined or created by other arrangements. For example, a warp strand 122 can interlock with another warp strand 122 to create a connection portion. In such an arrangement, the connected portion can be created solely by the interlocking of the warp strands 122 or by the interlocking of the warp strands 122 in combination with connection by one or more weft strands 126.

The weft strands 126 can travel along a single warp strand 122 or can move between warp strands 122 or mesh pillars 114 along the length of the lacrosse mesh 100. In the illustrated arrangement, each weft strand 126 travels along a single warp strand 122 or mesh pillar 114 in the length direction 102 of the lacrosse mesh 100. At the connected portions 130, the weft strand 126 of a first warp strand 122 or mesh pillar 114 extends into an adjacent warp strand 122 or mesh pillar 114 and connects the two warp strands 122 or mesh pillars 114 to create the connected portion 130. Similarly, the weft strand 126 of the adjacent warp strand 122 or mesh pillar 114 extends into the first warp strand 122 or mesh pillar 114 with the connected portion 130. Thus, in the illustrated arrangement, each connected portion 130 includes two separate weft strands 126. Each unconnected portion 132 includes only the single weft strand 126 associated with that particular warp strand 122 or mesh pillar 114. However, in other configurations, this arrangement could differ. For example, multiple weft strands 126a, 126b can be associated with a single warp strand 122 or mesh pillar 114. An example of such an arrangement is shown in FIG. 18. Alternatively or in addition, as described above, the weft strands 126 can move from one particular warp strand 122 or mesh pillar 114 to another warp strand 122 or mesh pillar 114, such as at the connected portions 130, for example. In such an arrangement, a particular weft strand 126 can be associated with a first warp strand 122 or mesh pillar 114 prior to a particular connected portion 130 and can be associated with a different warp strand 122 or mesh pillar 114 after the particular connected portion 130.

The connected portions 130 and unconnected portions 132 can be characterized by the number of warp loops 124 or weft loops 128 present within the portion 130, 132. For example, in the illustrated arrangement of FIGS. 1-10, the connected portions 130 include four (4) warp loops 124 and four (4) weft loops 128. The unconnected portions 132 include three (3) warp loops 124 and three (3) weft loops 128. However, these numbers can vary, which can vary the shape of the mesh pillars 114 and/or the open spaces 116. In some configurations, the connected portions 130 can include 2-6 or 2-4 warp loops 124 and/or weft loops 128. In some configurations, the unconnected portions 132 can include 2-10, 2-6 or 3-5 warp loops 124 and/or weft loops 128. However, in other configurations, these numbers can vary depending on relevant factors, such as the desired shape of the mesh pillars 114 and open spaces 116 of the lacrosse mesh 100. For example, in FIG. 18, the connected portions 130 include three (3) warp loops 124 and three (3) weft loops 128. The unconnected portions 132 include six (6) warp loops 124 and three (3) weft loops 128.

The lacrosse mesh 100 can also be characterized by measurements of certain features or between certain features or landmarks of the mesh 100. For example, the lacrosse mesh 100 can be characterized by a length of the warp loops 124 and/or weft loops 128, which can be consistent throughout the length of the mesh 100 or can vary throughout the length. The loop length can be a distance along the length direction 102 between a first end and a second end of a loop 124 or 128 (or between two corresponding points on adjacent loops). The loop length can alternatively be measured as the actual length of the particular loop 124 or 128 taking into account the direction of the particular loop 124 or 128. Knowing the loop length in combination with the number of loops within any portion of the mesh 100, such as the connected portions 130 and the unconnected portion 132, can permit the calculation of the actual length of that portion of the mesh 100 such that comparisons can be made between different lacrosse mesh 100 arrangements.

Similarly, with reference to FIG. 2, the lacrosse mesh 100 can be characterized by mesh diamond length 140. The mesh diamond length 140 can be measured between a first end and a second end of a portion of the mesh pillar(s) 114 that define an open space 116 or diamond, or between any two corresponding points on two adjacent diamonds. In FIG. 2, the mesh diamond length 140 is measured between the centers of two adjacent connected portions 130 of a mesh pillar 114 or the adjacent mesh pillars 114 that define the open space 116 or diamond. The mesh diamond length 140 can be measured as a linear distance along the length direction 102 of the lacrosse mesh 100. This can be referred to as a linear mesh diamond length 140. As described above, however, the mesh 100 can be manufactured with a certain width and length and can be stretched to a different width and/or length prior to or during use. Thus, the mesh diamond length 140 can vary depending on whether and how much the mesh 100 has been stretched prior to measurement. The mesh diamond length 140 can be useful when measuring lacrosse mesh 100 in its manufactured state before stretching and/or when stretched toward or to a use position.

In other cases, it can be helpful to have alternative measurements of the mesh diamond length. For example, in FIG. 2 a point-to-point mesh diamond length 142 is illustrated. The point-to-point mesh diamond length 142 can be determined by measuring the two straight lines connecting center points 144 of three consecutive connected portions 130. Still another way to determine mesh diamond length 146 is to measure the actual curve of the portion of the mesh pillar 114 that defines a row of the lacrosse mesh 100, such as between first end and a second end of a portion of the mesh pillar(s) 114 that define an open space 116 or diamond, or between any two corresponding points on two adjacent diamonds. These two methods can provide more precise results in the measurement of the mesh diamond length despite the stretch condition of the mesh 100. The use of mesh diamond length herein can refer to any suitable measurement of the mesh diamond length of a lacrosse mesh 100, including those described above, unless indicated otherwise either explicitly or by context. Mesh diamond length can also be calculated by adding all the loop lengths within that diamond of the mesh pillar. For example, the mesh 100 in FIG. 1 has 6 unconnected loops and 8 connected loops for a total of 14 loops per diamond of mesh 100. Thus, the diamond length can be referred to in number of loops or the number of loops can be multiplied by the loop length to arrive at a diamond length.

Each of the warp strands 122 and the weft strands 126 can be constructed from one or more constituent parts. Each constituent part can be referred to herein as a yarn. The yarn can be any suitable type of yarn made from any suitable material. The yarn itself can be constructed of multiple fibers or it can be a single fiber or filament (monofilament). If multiple yarns (a ply) are provided for any of the warp strands 122 or the weft strands 126, the multiple yarns can be arranged in any suitable manner. For example, the yarns can simply be grouped together or alongside one another and follow substantially the same path. In other arrangements, the yarns can be twisted, braided or otherwise engaged or connected with one another. Each individual warp strand 122 or the weft strand 126 can contain any desired number of yarns, and the number of yarns can be the same or can vary between the warp strands 122 and the weft strands 126 within a particular lacrosse mesh 100.

The warp strands 122 and/or the weft strands 126 can have any desired construction. In the arrangements of FIGS. 1-10, for example, the warp strands 122 in adjacent mesh pillars 114 are symmetrical about a line that extends in the lengthwise direction 102 between the mesh pillars 114. However, other suitable arrangements are possible. For example, FIG. 11 illustrates an arrangement in which adjacent warp strands 122 are asymmetrical. In the illustrated arrangement, the warp strands 122 are constructed the same in each mesh pillar 114. In the arrangement of FIG. 12, the direction of the warp strands 122 is opposite the direction shown in FIGS. 1-10. These and other suitable arrangements can be used with any of the concepts, arrangements or methods disclosed herein.

Mesh Materials and Construction

Currently, lacrosse mesh is typically constructed of a single material, which can be nylon, polyester, or polypropylene. However, the Applicant of the present application utilizes more advanced materials to lacrosse mesh. These new materials include, for example, ultra-high molecular weight polyethylene (UHMWPE), high-modulus polypropylenes, high-modulus polyesters and nylons typically used for race car tires, aramids, carbon fibers, and even materials such as a thermoset liquid crystalline polyoxazole (PBO), which is sold under the trademark ZYLON. These more advanced high strength and high modulus yarns are very advantageous to use because they can increase the durability of the mesh. Also, by utilizing these materials we are able to reduce the weight of the mesh. This is very desirable because lacrosse players are able to shoot harder with lighter equipment.

However, there are also some challenges presented by the use of these HS-HM (High Strength and High Modulus) materials. For example, the HM material can reduce the stretch of at least portions of the mesh too much. Some stretch in the mesh is desirable because it makes catching easier for players and reduces rebounds for goalies. This attribute is often referred to as “give.” In order to increase this give, it is desirable to use materials with a lower modulus. However, use of lower modulus materials can be problematic because often times the lower modulus materials will have lower breaking strength and lower breaking energy. This means that the resulting mesh will be less durable than mesh made from higher modulus materials.

Another challenge presented by the use of some of the HS-HM materials, such as UHMWPE, is that resins, rubbers, or waxes do not adhere well to the HS-HM materials. Often, it is desirable to coat or impregnate the lacrosse mesh with resins, rubbers, or waxes in order to fine tune the final attributes of the mesh. Some reasons to coat or impregnate the mesh with resins, rubbers, or waxes include, but are not limited to, it increases the hardness of mesh, increases grip between the mesh and the ball, reduces rebounds and increases catching ability, improves a players “feel” for the ball.

Currently, lacrosse mesh is constructed of the same one material used throughout the entire piece of netting. As discussed above, typically, warp knit lacrosse mesh consists of warp strands and weft strands. Each strand can consist of one or multiple yarns. Currently, lacrosse mesh is constructed with only one material in each strand. Also, current lacrosse mesh is made with that same one material in all of the warp strands and all of the weft strands.

There are an unlimited number of pockets that one can create for the lacrosse stick. There are many different types of mesh pockets for which different types of meshes may be desirable. For example, some types of pockets may have a very tight channel. It may be desirable for the meshes in these pockets to have more elasticity. With such an arrangement, when the ball travels through the tight channel, the ball will actually stretch the channel and allow the ball to travel through relatively freely or with reduced resistance through the channel in comparison to a mesh having less elasticity. Another challenge of the HS-HM yarns is that they generally have low elasticity. This means that these yarns may not be good for the tight channel pocket described above.

One of the issues with some current lacrosse mesh discovered by the present inventors is that lacrosse mesh can become too flimsy when made with thinner and/or lighter materials. It can be desirable to make lacrosse meshes that are thinner and lighter. A thinner mesh will have less air resistance than a thicker mesh when throwing and shooting. This means that lacrosse players should be able to shoot faster with the thinner meshes. Also, with lighter mesh, lacrosse players will typically shoot faster and generally be able to move his or her stick faster. By moving the stick faster, the lacrosse player will be better able to throw stick checks or move the stick away from incoming stick checks.

An issue with making meshes thinner and lighter is that, as the meshes get thinner and lighter, the mesh tends to get flimsier and weaker. The mesh becoming weaker is not a serious problem to overcome, as there are many high strength materials that can make a very thin and very durable mesh. This can typically be done with materials with a tenacity of 20 grams/denier or higher. The more difficult problem to overcome is that the mesh gets flimsier when it is made from a thinner material.

Accordingly, when using a single material for each warp and/or weft strand is that the designer might have to make a choice between two options: 1) that the mesh has some stretch (has some “give”), but lacks durability and/or is too heavy, or 2) that the mesh is light and/or durable, but doesn't have stretch or “give.” In addition, when using a single material for each warp and/or weft strand is that the designer might have to make a choice between two options: 1) using UHMWPE or other HS-HM yarns, but not being able to have a resin, rubber, or wax attach to the mesh, or 2) facilitating the attachment of resin, rubber, or wax to the mesh, but not utilizing the benefits of UHMWPE or other HS-HM yarns high strength to weight ratio. Another issue with using a single material for each warp and/or weft strand is that the designer might have to make a choice between durability, strength, stretch, etc., but the mesh is too hard or too soft.

In some configurations, the lacrosse mesh of the present disclosure utilizes hybrid arrangements of two or more materials or the same material with different arrangements or characteristics (e.g., twisted and non-twisted, as described below), which allows precise control of desirable attributes of the mesh. In addition, or in the alternative, the high strength or high modulus (HS-HM) yarns can be modified to increase give, stretch, durability, or other characteristics. In some configurations, crimps or texture are added to the HS-HM yarns.

In some configurations, a high level of twist is added to the yarns. A high level of twist can refer to a twist equal to or above 100 twists per meter (TPM). The yarn or yarns that make up the strand can be individually twisted or can be twisted together. Alternatively, the yarn or yarns can be individually twisted and then some or all twisted together. One reason to twist the yarns that go into a strand of the mesh is to increase the rigidity of the mesh. In many cases, it is preferable to have a lightweight mesh that is thin. However, as described above, when the mesh gets lighter and thinner, the mesh tends to get flimsier and doesn't hold its shape well. This can cause inconsistent performance of the mesh. There is a desirable level of stiffness to any mesh. A mesh can be made thin and lightweight with acceptable durability, but it is more difficult to have a thin and light weight mesh that has the desired level of stiffness. By twisting the yarns at high levels, some rigidity and stiffness can be added to the yarns. The rigidity and stiffness of the yarns makes the mesh more rigid and stiff, which can be desirable. In addition, when combining and twisting two or more yarns together, the resulting mesh can be have a relatively rough texture, which can also add some grip to the ball.

One potential issue with adding high twist to yarns is that it can add a skew to the final knitted mesh. In order to address this issue, with reference to FIG. 13, the yarns 150 can first be twisted individually in a first direction (e.g., either the left-handed or “S” direction or the right-handed or “Z” direction). Two or more of the individually twisted yarns can then be combined or plied and twisted together in the opposite direction to create a yarn ply 152. For example, if all of the individual yarns are twisted in the “S” direction, then the collection of two or more yarns are twisted together in the “Z” direction. Such an arrangement can reduce torque on the resulting combined yarns. In other configurations, the yarns 150 can be individually twisted in a first direction and two or more individually twisted yarns can be combined (plied) and twisted in the same first direction to create a yarn ply 154. This arrangement can create a more lively yarn. The resulting mesh can also be livelier.

The twisting of a combination of individually twisted yarns can result in a change in the twist of the individual yarns. For example, if two or more individual yarns are twisted in a first direction to a first level of twist (in TPM) and then combined and twisted together in a second direction opposite the first direction, the twist of the individual yarns can be reduced to a second level of twist (in TPM) that is less than the first level of twist prior to the combining and twisting in the second direction. Similarly, if two or more individual yarns are twisted in a first direction to a first level of twist (in TPM) and then combined and twisted together in the first direction, the twist of the individual yarns can be increased to a second level of twist (in TPM) that is greater than the first level of twist. The initial twist of a yarn prior to being combined and twisted with other yarn(s) can be referred to herein as the individual twist. The twist of a combination of two or more yarns can be referred to herein as combined twist. The twist of the individual yarns that results from the twisting of a combination of two or more individually twisted yarns can be referred to herein as the effective twist. That is, the effective twist takes into account the decrease or increase in the individual twist that results from untwisting or additional twisting of the individual yarns that may occur as a result of the twisting of the combination of yarns.

In some configurations, the individual twist of constituent yarns can be equal to or greater than 100 TPM or 200 TPM. In some configurations, the individual twist of constituent yarns is greater 250 TPM, greater than 500 TPM, greater than 600 TPM or greater than 700 TPM. In some configurations, the individual twist of constituent yarns is between 100-700 TPM, between 100-600 TPM or between 250-500 TPM. In addition, the individual twist can be any value or subrange within the above-recited ranges.

The combined twist of two or more (twisted or untwisted) constituent yarns can be greater than 100 TPM. In some configurations, the combined twist of constituent yarns is greater 250 TPM, greater than 500 TPM, greater than 600 TPM or greater than 700 TPM. In some configurations, the combined twist of constituent yarns is between 100-700 TPM, between 100-600 TPM or between 250-500 TPM. In addition, the combined twist can be any value or subrange within the above-recited ranges. In some configurations, such as those in which the constituent yarns are twisted, the combined twist can be less than the individual twist of at least one of the constituent yarns, such as the constituent yarn with the lowest individual twist. Accordingly, substantially complete or complete untwisting of the constituent yarns can be reduced or avoided. In some configurations, the combined twist is between about 20-80% of the individual twist. In some configurations, the combined twist is between about 40-60% or is about 50% of the individual twist. The combined twist can be any value or subrange within the above-recited ranges. For example, if the constituent yarns are twisted to 500 TPM in a first direction, the combined constituent yarns can be twisted to 250-300 TPM in a second direction opposite the first direction.

In at least some configurations, twisting of individual yarns and then plying and twisting the multiple yarns can increase the abrasion resistance of the resulting mesh. Adding the high levels of twist can also add more texture to the strands to increase the grip the mesh has on the lacrosse ball. Such an arrangement is especially advantageous when using UHMWPE or other HS-HM yarns because UHMWPE and certain other HS-HM yarns can be slippery.

It has been discovered by the present inventors that a benefit of twisting the yarns as disclosed herein is that it adds rigidity to the yarns and, thus, adds rigidity to the resulting mesh structure. Typically, it is desirable to make the mesh thinner, but, as described above, when you make the mesh thinner it gets more flimsy. When the mesh is flimsy it can be more difficult to shoot and throw accurately. Thus, the increased rigidity allows for a thinner and more consistent performing mesh. Twisted yarns 150, 152, 154 can be utilized in any portion or portions of the lacrosse mesh, including some or all of the warp strands and/or the weft strands.

In other configurations, the (twisted or untwisted) constituent yarns can be braided, twisted, woven, or knitted together to create a strand. The specific modulus of the braided, twisted, woven, or knit structure will be lower than that of the specific modulus of the yarns by themselves. The benefits of using these structures for the strand of mesh include, but not limited to decreased modulus for more give and feel for the ball, decreased modulus and potential higher breaking strength, which increases the breaking energy (durability), increased abrasion resistance of mesh, and/or added texture to the strands to increase the grip the mesh has on the lacrosse ball.

There are generally two types of meshes—player meshes and goalie meshes. Goalie meshes are designed for the goalie player who has a larger stick. Player meshes are designed for all of the lacrosse players that are not the goalie. For the player position, it is typically desirable to have a thin and lightweight mesh that also has a good rigidity. As described above, the present inventors have discovered that, in general, as you decrease the thickness and/or weight of the mesh you also decrease the rigidity of the mesh. In fact, the present inventors have found that, in at least some configurations, the thickness and/or the weight of the mesh is directly related to the rigidity of the mesh. By twisting the yarns, the rigidity of the yarns and thus the rigidity of the mesh can be increased in comparison to untwisted yarns of the same material. It is thus advantageous to use highly twisted yarns when making thinner and lighter mesh.

In some configurations, the player mesh utilizes a construction of 7 diamonds to 12 diamonds per row. In some configurations, the warp loop denier can be between about 1200-5500, 2200-4200 or 2500-3900 denier or any value or subrange within these ranges. As described above, in some configurations, the mesh will have two weft strands or yarns associated with a single mesh pillar, wherein the weft strands or yarns travel in opposite directions. “Combined Weft Yarns per Mesh Pillar” as used herein means the total of all weft strands or yarns within the unconnected region of a mesh pillar or piece of mesh. In some configurations, the combined weft strands or yarns per mesh pillar denier can be between about 1200-5500, 2200-4200 or 2500-3900 denier, or can be of any value or subrange within these ranges. The denier can be measured before or after any coating or resin is applied to the mesh. Another way to describe the warp and weft deniers in a more specific way is in accordance with the definition of the “Average Warp/Weft Denier” or “AWWD.” Typically, the warp strands or yarns make up about 75% of the mesh while the weft strands or yarns make up about 25% of the mesh. So, the “AWWD” is equal to 75%*Warp Denier+25%*Weft Denier. In some configurations, the preferred “AWWD” of a mesh or portion thereof is between about 2000-4500, 2500-4000 or 2800-3600 denier.

It can be difficult to determine the best arrangements of mesh based on denier alone. This is because denier is the linear density of a yarn and does not take into account the volumetric density of a yarn. The present inventors have discovered that, to achieve a desirable level of rigidity of player mesh, the thickness of a piece or portion of the mesh (e.g., yarn, strand, pillar or pillar connection) can be an important characteristic. However, it can be difficult to accurately measure the thickness or diameter of a piece of mesh. This is because the mesh typically is not a perfect tube or cylinder or other simple geometric shape. The mesh often has many different bumps and ridges, which makes measuring the thickness or diameter difficult.

The present inventors have developed a “Theoretical Diameter” for a piece of mesh (e.g., a single mesh pillar) that can be utilized to achieve a desired level of the rigidity of the mesh. The “Theoretical Diameter” can be defined as:


Theoretical Diameter=2*(ML/(π*ρL*LL))̂0.5

Where:

    • LL—Loop length (cm)
    • ML=Loop mass (grams)
    • ρL=Loop density (g/cm̂3)

The theoretical diameter is not necessarily the true diameter of the mesh even if the mesh were a perfect cylinder. The above equation does not take into account things like yarn packing density, etc. The present inventors have discovered that for player meshes the ratio of the theoretical diameter to loop length (L—FIG. 10) can be selected to achieve a desired level of the final rigidity of the mesh. This ratio can be referred to as “TD/LL.” Assuming the theoretical diameter and loop length ratio are both in the same units, in some configurations it is preferred that the TD/LL is between about 0.3618-0.9223, 0.4670-0.8738, 0.5526-0.8089, 0.6090-0.7531 or 0.6438-0.7235. The TD/LL can be any value or subrange within the above-recited ranges. A thickness or diameter of the mesh (e.g., of a single mesh pillar) can be measured by other methods, as well, such as by the thickness or diameter of the outermost edges or maximum “diameter” or cross-sectional dimension of the portion of mesh or by the minimum “diameter” or cross-sectional dimension of the portion of mesh.

As described above, in some configurations, a strand (e.g., warp strand 122 or weft strand 126) of the mesh can be a hybrid strand. That is, the strand can comprise two or more different materials or two or more materials having different relevant properties. In some configurations, relatively high modulus (HM) yarns can be combined with relatively low modulus (LM) yarns to control the final strand modulus, stretch, durability, feel, etc. In other configurations, a yarn to which resins, rubbers, waxes or other typical coatings adhere can be combined with another yarn that has other desirable properties. For example, UHMWPE yarn can be combined with PET yarn. The UHMWPE has many desirable properties for lacrosse mesh, such as high tensile strength. However, resins, rubbers, waxes and other coatings don't adhere to it well. Resins, rubbers, waxes and other typical coatings do adhere well to PET. As a result, the UHMWPE material can provide desirable physical (e.g., strength) properties and the PET material can allow the mesh to be coated.

The different yarns of the hybrid strand can be combined in any suitable manner. In some configurations, the individual yarns are plied together. FIGS. 14 and 15 illustrate a strand 160 (which can be any strand, such as a warp strand or a weft strand or could be a constituent part of a strand) having individual yarns plied together. The illustrated yarns comprise at least a first yarn 162 having a first physical property and at least a second yarn 164 having a second physical property that is different from the first physical property. The physical property can be any property that contributes to the performance of the yarn or strand 160 or a mesh made therefrom. For example, the physical property can be material, material grade, modulus, length, shape or orientation (e.g., linear/non-linear, twisted/untwisted), ability to coat, heat treated or not, elongation, shrinkage, size (e.g., diameter or cross-sectional dimension), strength (e.g., tensile strength), among others, many of which are discussed below.

FIGS. 15A, 15B and 15C illustrate the strand 160 at three different lengths. For example, FIG. 15A can be an unstretched or relaxed length of the strand 160. FIG. 15B can be a stretched position of the strand 160, in which the strand 160 is elongated to a greater length than the position of FIG. 15A. FIG. 15C can be a further stretched position of the strand 160 relative to 15B. FIG. 15C can be a maximum elastic stretch length of the strand 160, which can be determined by the elastic stretch properties of one or more of the yarns 162, 164 (which can be the yarn 162, 164 with the lowest elastic stretch, for example). Due to a difference in physical properties, as described above, the different yarns 162, 164 can have different resistances to stretching, as described below.

The yarns can be plied together at the about the same length or can be plied together at different lengths. For example, a relatively lower modulus yarn (“LM” yarn) can have a shorter length and a relatively higher modulus yarn (“HM” yarn) can have a longer length. With such an arrangement, upon elongation, the low modulus takes some of the initial force and allows the initial give. After the low modulus stretches a certain amount, the high modulus will take on some of the force and limit the total stretch. High modulus yarn can be made longer than the relatively lower modulus yarn in a number of different ways. For example, the high modulus yarn can we crimped, textured or twisted. It is also possible to just ply the LM yarn and HM yarn together at different lengths. In some configurations, the LM yarn can be selected to have a higher thermal shrinkage than the HM yarn. After knitting, the mesh can be heat treated so that the LM yarn shrinks more than the HM yarn. Alternatively, the different yarns can be twisted together or the different yarns can be twisted individually and then twisted together, as described above.

In other arrangements, the HM yarn can be wrapped around the LM yarn. For example, the HM yarn can be twisted around the LM yarn. With such an arrangement, the total length of the HM yarn is longer than the total length of the LM yarn. In one embodiment, an HM yarn (e.g., UHMWPE yarn) is twisted around a LM yarn (e.g., polypropylene “PP” yarn). Both yarns may or may not be individually twisted before being combined together. In addition, the yarns may or may not be twisted together.

In some configurations, yarns of a strand (which can be the same or different, e.g., a hybrid strand) can be braided, knitted or woven together to create the strand. With these structures and twisted structures, not only can the fibers stretch and compress, but the structures themselves can stretch and compress. This means that the entire structure can stretch more than the yarns would by themselves.

In some configurations of a hybrid strand, PP material can be used in our hybrid strands. PP can be combined with other materials, such as a higher strength material with a tensile strength equal to equal to or above about 15 g/denier. In some such configurations, the amount of PP can be between about 30%-90%, 40%-85%, or 50%-80%.

PP can also be used as a filler to give the mesh added rigidity, bulk, and/or elongation. If PP is mixed with PET or another material with a strength equal to or below about 15 g/denier, then in some arrangements the amount of PP can be between about 10%-70%, 15%-65%, or 20%-60%.

In some configurations, a hybrid lacrosse mesh can have different yarns in the warp 122 strands relative to the yarns in the weft strands 126. For example, in some configurations, a first yarn or material can have a relatively low thermal shrinkage and can be used in one of the warp and the weft and a second yarn or material can have a relatively high thermal shrinkage and can be used in the other of the warp and the weft. As described above, it can be desirable to use high strength yarns to make lacrosse mesh. One problem with many high strength yarns such as carbon fibers, aramids (e.g., aramids sold under the trademark TECHNORA), high strength PET's, PBO (e.g., PBO sold under the trademark ZYLON), para-aramids (e.g., para-aramids sold under the trademark TWARON), etc. is that these fibers or yarns often have very low thermal shrinkage. A sufficient level of thermal shrinkage can be useful for creating tightly constructed mesh. Tightly constructed mesh is typically more dimensionally stable than loosely constructed mesh. If lacrosse mesh is made out of fibers or yarns with sufficient thermal shrinkage, the mesh can be heated to relatively high temperatures, which will shrink the fibers within the mesh and increase the tightness of the mesh. This process does not work for yarns that have too little or substantially no thermal shrinkage.

Using typical construction methods, lacrosse mesh cannot be knit tight enough to not require thermal treatment at least in order to provide a desirable level of performance. However, it is possible to knit one of the warp strands and the weft strands sufficiently tight enough in order to not need the thermal treatment for that strand; however, it is typically necessary to knit the other strand somewhat loosely. For example, as illustrated in block 170 of FIG. 16, it is possible to tightly knit the weft strand(s), but the warp strand(s) will need to be a little loose in order for the knitting machine to operate. Or, it is possible to tightly knit the warp strand(s), but in return the weft strand(s) will need to be a little loose in order for the knitting machine to operate.

Accordingly, a relatively low shrinkage yarn can be used for the warp strand(s) and a relatively high shrinkage yarn can be used for the weft strand(s). With such an arrangement, the warp strand(s) can be tightly knitted. The mesh can be thermally treated (heated), which will result in shrinkage of the relatively high shrinkage yarn used in the weft strand(s) as illustrated in block 172 of FIG. 16. As a result, the mesh can have a sufficiently tight knit in both the warp strands (due to the tight knitting) and the weft strands (due to the shrinkage of the weft yarns). Alternatively, a relatively low shrinkage yarn can be used in the weft strands and a relatively high shrinkage yarn can be used in the warp strands. The weft strands can be tightly knit and the warp strands can be more loosely knit. The mesh can be thermally treated (heated) to shrink the warp yarn to achieve a desirable or acceptable level of tightness of both the warp strands and the weft strands.

By using materials that can be heat set and then heat setting them, the mesh construction can be made tighter and more stable. This will create a more consistent pocket shape. In other words, it will increase the dimensional stability of the meshes. There are many materials that are advantageous to use, but that are relatively unaffected by heat treatment. These materials can be referred to herein as “NOHS materials.” Examples of these materials include aramids and Liquid Crystal Polymers (LCP), such as those sold under the trademark VECTRAN. A mesh that utilizes these materials may not be very dimensionally stable because these materials are relatively unaffected by heat treatment and, thus, are not very amenable to tightening as a result of shrinkage during heat treatment.

To address this situation, in some configurations, NOHS materials are combined with materials that can be effectively heat set. These materials can be combined in a number of ways. One approach is to just lay the yarns next to each other when knitting. Another approach is to ply these yarns together before knitting and warping. In one preferred arrangement, these materials are combined by twisting them together. This can be done by first twisting the individual yarns in the “S” or “Z” direction and then combining the individual yarns together and then twisting the combined ply yarn in the opposite direction, as described above. This can be done with two or more individual yarns. Other suitable ways to combine the NOHS materials with the heat settable materials can also be used. For example, another method is to braid or weave these materials together.

In some configurations, the meshes can be stretched after knitting. This can be done in a continuous fashion by putting the mesh strips through spinning rollers that stretch the mesh to different levels. Stretching can also be accomplished by putting a pipe or other support through two opposite ends of a strip of mesh and then applying a force tending to move the pipes apart. In some configurations, the meshes are stretched and heated at the same time. Even the NOHS materials may experience relatively small levels of shrinkage or heat setting so adding heat can tighten the construction to some extent. Also, pulling the mesh apart tightens the construction and gives the final product increased dimensional stability.

Other methods of heat setting while stretching the mesh can also be used, which can increase one or more of the strength, durability, rigidity and dimensional stability of the mesh. High strength yarns are typically manufactured to have the majority of the strength in the length direction of the yarn. In woven and braided fabrics, this is advantageous because the strength of the yarn will be generally parallel to the directions that the woven fabric or braided rope is being pulled. Warp knit fabrics have complex internal geometries. The yarns within the material lie in different directions. For example, lacrosse mesh, which can be a warp knit product, is generally stretched along the length of the pillars and horizontally against the weft yarns. When the mesh is subjected to forces along the length of the pillars, the yarns will typically break near one of the curved loop sections of the mesh. The type of strength required to break curved yarns is generally called “loop strength” or, similarly, there is also “knot strength” that is often discussed in connection with ropes. Knots weaken the rope in which they are made. When a knotted rope is strained to its breaking point, it tends to fail at or near the knot. The bending, crushing, and chafing forces that hold a knot in place also unevenly stress rope fibers and ultimately lead to a reduction in strength. Relative knot strength (also called knot efficiency) is the breaking strength of a knotted rope in proportion to the breaking strength of the rope without the knot. Determining a precise value for a particular knot is difficult because many factors can affect a knot efficiency test, such as the type of fiber, the style of rope, the size of rope, whether it is wet or dry, how the knot is dressed before loading, how rapidly it is loaded, whether the knot is repeatedly loaded, and so on. The efficiency of common knots can range between 40-80% of the rope's original strength.

To improve or achieve a desirable level of durability of lacrosse mesh (which will allow the mesh to be made thinner and lighter), it is advantageous to have high tenacity, high knot strength and high loop strength. Typically, materials have tradeoffs. For example, one material may have high tenacity but lower knot and loop strength. In some configurations, the disclosed method increases some or all of these strengths in the areas of the mesh in which they are desirable or required. In some configurations, the disclosed method is done in a static condition, but it could also be done with a continuous tenter system.

The method can include taking a relatively long piece of the netting, which can be typically about 2-3 meters in length. A pole or other support is passed through the diamonds on one end and another pole or support is passed through the diamonds on the opposite end. Other suitable methods for holding the mesh in place could also be used. With the mesh held on both ends, the mesh is put into an oven and heated until the oven or mesh is somewhere between the lower glass transition temperature of one or more (e.g., all) of the materials in the mesh, but under the melting temperature of one or more (e.g., all) of the material in the mesh, as illustrated in block 180 of FIG. 17. It is preferable that the temperature is controlled precisely between these two points. The relatively high temperature allows the polymers within the mesh to recrystallize and form a new structure. The high temperature can also be used to aid in tightening the construction of the mesh by shrinking the fibers.

In some configurations, the mesh can also be stretched, as illustrated in block 182 of FIG. 17. In some cases, the amount the mesh is stretched is between about 1%-30% from the original mesh size before stretching and/or heating. The stretching of the mesh can be done before, during or after the heat treatment. It is presently preferred to stretch the mesh before or during the heat treatment. Thus, in some arrangements, the mesh is both stretched and heated at the same time. However, in other arrangements, the meshes are first stretched and then heating after stretching. In other arrangements, the meshes are first heated and subsequently are stretched while cooling. While all of these methods work, it is presently preferred to both heat and stretch the mesh at the same time.

After heating, with at least some materials, it is desirable to let the mesh cool quickly while with others it is desirable to let the mesh cool over a longer period of time. The present inventors have discovered that, for some materials, controlling this cooling temperature can be significant. For example, it may be preferable to quickly quench UHMWPE after heat setting. Block 184 of FIG. 17 illustrates an optional quenching step. When taking UHMWPE meshes out of the oven, the meshes quickly start to sag while cooling. However, if the meshes are quenched with water or another cool liquid, the mesh sag can be reduced or at least substantially eliminated. In some cases, the meshes are quickly quenched after the heat treatment by submerging or spraying the meshes with a cold liquid directly after the heat treatment. By doing this, it has been discovered by the present inventors that significant increases in the elongation properties of the mesh can be achieved in the length direction, the width direction, or both. It has been specifically discovered that this process appears to work unexpectedly well for meshes that include PET and/or PP.

It is believed that this process increases the strength of the yarns in the directions in which the most stress/strain is happening to the yarns during the stretching and heat setting. In other words, the mesh yarns are being recrystallized while in a state of stress that the mesh will typically experience during use or play. The present inventors have also discovered that this method can be used to make the meshes more dimensionally stable. Stretching the meshes increases the length of the meshes. As the mesh length increases, the spaces and gaps between fibers in the meshes close. Thus, the construction of the meshes gets tighter.

In some configurations, a HM material is used in one of the warp strands and the weft strands and a LM material is used in the other of the warp strands and the weft strands. As described above, it can be desirable for the mesh to have some “give” or stretch. This can be accomplished by using a HM material in the warp or weft and a LM material in the opposite. In particular, it has been discovered by the present inventors that a substantial portion or the majority of the stretch in the mesh comes from the weft strands. The warp strands tend to have less effect on the stretch of the mesh. Thus, the material or a combination of materials of the weft strands can be selected to provide the weft strands with a desirable amount of give or stretch when considered in combination of the material or materials of the warp strands. Other arrangements of a mesh in which the modulus of elasticity varies between the warp strands or yarns and weft strands or yarns can also be used.

Similarly, other hybrid combination of materials between the warp and the weft can be used. For example, a material or materials having desirable resin adhesion properties can be used in the warp or weft and a material or materials having other desirable properties, such as high strength or high breaking energy, can be used in the opposite. A material or materials having desirable stiffness properties (e.g., high bending stiffness) can be used in the warp or weft and a material or materials having different stiffness properties (e.g, a relatively flexible material) can be used in the opposite. A cheap material or materials can be used in the warp or weft and a more expensive material or materials (e.g., a high strength and/or durability material) can be used in the opposite. A material or materials that are not very stiff (e.g., soft, low bending stiffness materials) can be used in the warp or weft and a material or materials having other desirable properties (e.g., high strength or high breaking energy) can be used in the opposite.

The above examples and others can be achieved by using totally different materials in the warp and the weft. Alternatively, this can be done by using different variations of the same base material in the warp and the weft. For example, a twisted material can be used in the warp, and an untwisted or different level of twist in the weft. Or, a high filament count material or strand can be used in the warp or weft and a low filament count material or strand can be used in the other. Other suitable combinations, including other possible combinations of any of the above examples, can also be used.

In one arrangement, a player mesh 100 has a width of 9/10 diamonds. The mesh 100 also has a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds. The connected portions 130 include four (4) warp loops 124 and the unconnected portions 132 include three (3) warp loops 124. The diamond length is between about 2.80 cm-3.10 cm, 2.86 cm-3.04 cm, or 2.88 cm-3.02 cm. The AWWD is between about 2000-4500, 2500-4000, 2800-3600 denier. The warp and/or weft yarns contain at least one of or the combination of PET and PP in the following amounts: greater than or equal to 50%, greater than or equal to 60%, or greater than or equal to 70%.

CONCLUSION

It should be emphasized that many variations and modifications may be made to the herein-described embodiments, the elements of which are to be understood as being among other acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. Moreover, any of the steps described herein can be performed simultaneously or in an order different from the steps as ordered herein. Moreover, as should be apparent, the features and attributes of the specific embodiments disclosed herein may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.

Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

Moreover, the following terminology may have been used herein. The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to an item includes reference to one or more items. The term “ones” refers to one, two, or more, and generally applies to the selection of some or all of a quantity. The term “plurality” refers to two or more of an item. The term “about” or “approximately” means that quantities, dimensions, sizes, formulations, parameters, shapes and other characteristics need not be exact, but may be approximated and/or larger or smaller, as desired, reflecting acceptable tolerances, conversion factors, rounding off, measurement error and the like and other factors known to those of skill in the art. The term “substantially” means that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also interpreted to include all of the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but should also be interpreted to also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3 and 4 and sub-ranges such as “about 1 to about 3,” “about 2 to about 4” and “about 3 to about 5,” “1 to 3,” “2 to 4,” “3 to 5,” etc. This same principle applies to ranges reciting only one numerical value (e.g., “greater than about 1”) and should apply regardless of the breadth of the range or the characteristics being described. A plurality of items may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. Furthermore, where the terms “and” and “or” are used in conjunction with a list of items, they are to be interpreted broadly, in that any one or more of the listed items may be used alone or in combination with other listed items. The term “alternatively” refers to selection of one of two or more alternatives, and is not intended to limit the selection to only those listed alternatives or to only one of the listed alternatives at a time, unless the context clearly indicates otherwise.

Claims

1. A lacrosse mesh for stringing to a head of a lacrosse stick, the lacrosse mesh comprising:

a first outside edge extending between a first end and a second end of the lacrosse mesh;
a second outside edge opposite the first outside edge, the second outside edge extending between the first end and the second end of the lacrosse mesh;
a plurality of pillars positioned between the first outside edge and the second outside edge and extending between the first end and the second end of the lacrosse mesh;
wherein one or more of the plurality of pillars comprise connected portions and unconnected portions;
wherein the lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands, each of the plurality of warp strands and the plurality of weft strands comprising one or more yarns or filaments, wherein at least a portion of the yarns or filaments of the warp strands or the weft strands have an individual twist of greater than or equal to 250 TPM.

2. The lacrosse mesh of claim 1, wherein at least a portion of the warp strands or the weft strands comprise a plurality of yarns or filaments, wherein the individual twist of each of the plurality of filaments is in a first direction, and wherein the plurality of yarns or filaments are twisted together to have a combined twist in a second direction opposite the first direction.

3. The lacrosse mesh of claim 2, wherein the combined twist is less than the individual twist.

4. The lacrosse mesh of claim 1, wherein the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

5. The lacrosse mesh of claim 1, wherein one or both of the warp strands and the weft strand have a first yarn that has a first physical property and at least a second yarn that has a second physical property that is different from the first physical property.

6. The lacrosse mesh of claim 5, wherein the first physical property and the second physical property are selected from the following: material, material grade, modulus, length, shape, orientation, ability to coat, heat treatment, elongation, shrinkage, size, and strength.

7. The lacrosse mesh of claim 1, wherein the warp strands have a first yarn that has a first physical property and the weft strand have a second yarn that has a second physical property that is different from the first physical property.

8. The lacrosse mesh of claim 7, wherein the first physical property and the second physical property are selected from the following: material, material grade, modulus, length, shape, orientation, ability to coat, heat treatment, elongation, shrinkage, size, and strength.

9. A lacrosse mesh for stringing to a head of a lacrosse stick, the lacrosse mesh comprising:

a first outside edge extending between a first end and a second end of the lacrosse mesh;
a second outside edge opposite the first outside edge, the second outside edge extending between the first end and the second end of the lacrosse mesh;
a plurality of pillars positioned between the first outside edge and the second outside edge and extending between the first end and the second end of the lacrosse mesh;
wherein one or more of the plurality of pillars comprise connected portions and unconnected portions;
wherein the lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands, wherein the plurality of warp strands have a first elongation and the plurality of weft strands have a second elongation that is different than the first elongation.

10. The lacrosse mesh of claim 9, wherein the first elongation is less than the second elongation.

11. The lacrosse mesh of claim 10, wherein the warp strands are woven tighter than the weft strands.

12. The lacrosse mesh of claim 9, wherein the first elongation is greater than the second elongation.

13. The lacrosse mesh of claim 12, wherein the weft strands are woven tighter than the warp strands.

14. The lacrosse mesh of claim 9, wherein the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

15-17. (canceled)

18. A lacrosse mesh for stringing to a head of a lacrosse stick, the lacrosse mesh comprising:

a first outside edge extending between a first end and a second end of the lacrosse mesh;
a second outside edge opposite the first outside edge, the second outside edge extending between the first end and the second end of the lacrosse mesh;
a plurality of pillars positioned between the first outside edge and the second outside edge and extending between the first end and the second end of the lacrosse mesh;
wherein one or more of the plurality of pillars comprise connected portions and unconnected portions;
wherein the lacrosse mesh comprises a plurality of warp strands and a plurality of weft strands, wherein the lacrosse mesh comprises a hybrid construction having a first material and a different second material within one or both of the warp strands and the weft strands.

19. The lacrosse mesh of claim 18, wherein the lacrosse mesh has a width of 9/10 diamonds, a length of at least 10 rows of 9 diamonds and 10 rows of 10 diamonds, wherein the connected portions have four warp loops and the unconnected portions have three warp loops, wherein a diamond length is between about 2.80 cm-3.10 cm, wherein an average warp/weft denier is between about 2000-4500, wherein the warp and/or weft yarns contain at least one of or the combination of PET and PP in an amount greater than or equal to 50%.

20. The lacrosse mesh of claim 18, wherein at least a portion of yarns or filaments of the warp strands or the weft strands have an individual twist of greater than or equal to 250 TPM.

Patent History
Publication number: 20160101333
Type: Application
Filed: Oct 8, 2015
Publication Date: Apr 14, 2016
Inventor: Jake McCampbell (Gardena, CA)
Application Number: 14/878,977
Classifications
International Classification: A63B 59/20 (20060101); A63B 60/50 (20060101); D04B 21/20 (20060101); D04B 21/12 (20060101); D04B 21/14 (20060101);