Method of making an outer shell for hockey or lacrosse...

Details Method of making an outer shell for hockey or lacrosse... Method of making an outer shell for hockey or lacrosse...

2010-07-30

2011-11-22

Tucker, Philip (Department: 1745)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C156S224000, C264S257000, C264S321000

Reexamination Certificate

active

08062446

ABSTRACT:
A method of making an outer shell, the method comprising: (a) providing first and second sheets, each of the first and second sheets being made of a layer of high-density polyethylene, polypropylene, polyurethane or polycarbonate extruded with a layer of non-woven fabric; (b) providing a third sheet made of high-density polyethylene foam, polypropylene foam, polyurethane foam or polystyrene foam, the third sheet having top and bottom sides; (c) affixing a first layer of adhesive film on the top side of the third sheet; (d) affixing a second layer of adhesive film on the bottom side of the third sheet; (e) placing the third sheet between the first and second sheets such that the first layer of adhesive film of the third sheet contacts the layer of non-woven fabric of the first sheet and the second layer of adhesive film of the third sheet contacts the layer of non-woven fabric of the second sheet; (f) stitching together the first, second and third sheets in order to form a composite sheet; and (g) thermoforming the composite sheet for forming the outer shell wherein the outer shell has a shape suitable for a hockey or lacrosse leg pad, shoulder pads or elbow pad.

REFERENCES:
patent: 6070273 (2000-06-01), Sgro
patent: 2006/0080762 (2006-04-01), Kobren et al.

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