A hurley

Abstract

A hurley or hurling stick 1 comprising a shaft 2 acting as a handle, an upper cap or knob 3 affixed to the shaft, and a bas 10, wherein the shaft comprises a tubular member 14 with a lower open end or

Description

The invention provides a hurley comprising: a shaft extending in a longitudinal direction and acting as a handle, an upper cap affixed to the shaft, and a bas, wherein: the shaft comprises a tubular member with a lower open end, and the bas is part of a head portion also comprising a tongue inserted into and adhered to the shaft tubular member. In some preferred examples, the tongue is formed by a step inwards to reduce cross sectional area, and a wall of the shaft tubular member abuts the step. In some preferred examples, the shaft tubular member wall thickness at the opening is matched to the depth of the step, to provide a continuous outer surface. In some preferred examples, the head portion is of a wood material, and the shaft is of a non-wood material. Preferably, the shaft is at least partly comprises a polymer. In some preferred examples, in the bas comprises at least two layers in a laminated structure across a short dimension. In some preferred examples, the bas comprises at least three layers in a laminated structure across a short dimension. In some preferred examples, the bas comprises a central layer on each side of which there is a ball striking outer layer. Preferably, the central layer has a cross grain, and the outer layers have a longitudinal grain. Preferably, the tongue comprises at least in part a continuation of the outer layers. In some examples, the central layer includes an insert for added weight and / or a desired weight distribution. The insert may be annular. In some preferred examples, the cap is modular and is attached to an end of the shaft during manufacture. The cap may be an integral part of the shaft. In some preferred examples, the shaft tubular member is of a composite material with a primary material and reinforcing fibres. Preferably, the primary material comprises a polymer material such as nylon, epoxy, polyester or vinyl ester material. The reinforcing fibres may be glass or carbon fibres. In some examples, the head portion comprises a bamboo wood material in at least the bas. In some preferred examples, the length of the tongue as a proportion of the overall hurley length is in the range of 2% to 35%, preferably in the range of 4% to 20%, and more preferably in the range of 6% to 12%. In some preferred examples, the position of the start of the tongue is in the range of 50% from the handle end down to 80% from the handle end, preferably in the range of 65% from the handle end down to 75% from the handle end, and more preferably in the range of 67% from the handle end down to 71% from the handle end. In some preferred examples, the length of the tongue is in the range of 10 mm to 300 mm, preferably 30 mm to 150 mm, more preferably 40 mm to 150 mm, and more preferably 60 mm to 100 mm. In some preferred examples, the maximum thickness of the tongue is in the range of 6 mm to 16 mm, preferably 9 mm to 11 mm. In some preferred examples, the area of the surface of the tongue facing an internal surface of the tubular member is in the range of 6000 mm2 to 8000 mm2. In some preferred examples, the thickness of the wall of the shaft tubular member at the lower opening is in the range of 1 mm to 3 mm. In some preferred examples, the bas comprises a central layer and two outer ball-striking layers, and the central layer includes a void or a plurality of voids located to spread a ball-striking sweet spot. In some preferred examples, the voids are formed by drilling or laser cutting through holes in the central layer. We also provide a method of manufacturing a hurley of any example described herein, the method comprising: providing the head portion or a head portion blank and the shaft, applying adhesive to the tongue and / or to an internal surface of the shaft tubular member; and inserting the tongue into the groove and allowing the adhesive to cure. In some preferred examples, the tongue a head portion blank is inserted, and the head portion blank is subsequently shaped to a desired bas shape after the adhesive has cured. We describe a hurley comprising: a shaft extending in a longitudinal direction and acting as a handle, and a has, wherein: the shaft comprises a tubular member and a cap, and the bas is part of a head portion also comprising a tongue inserted in a groove of an end of the shaft tubular member. In some preferred examples, the tongue is a formed by a step inwards to reduce cross sectional area, and an opening of the shaft tubular member abuts the step to provide a continuous outer surface. In some preferred examples, the head portion is of a wood material and the shaft is of a non-wood material. In some preferred examples, the bas comprises at least two layers in a laminated structure across the short dimension. In some preferred examples, the bas comprises at least three layers in a laminated structure In some preferred examples, the bas comprises a central layer on each side of which there is a ball striking outer layer. In some preferred examples, the central layer has a cross grain, and the outer layers have a longitudinal grain. In some preferred examples, the tongue comprises at least in part a continuation of the outer layers. In some preferred examples, the central layer includes an insert for added weight and / or a desired weight distribution. In some preferred examples, the insert is annular. In some preferred examples, the cap is modular and is attached to an end of the shaft during manufacture. In some preferred examples, the cap is an integral part of the shaft. In some preferred examples, the shaft tubular member comprises a composite material with a primary material and embedded reinforcing fibres. In some preferred examples, the primary material comprises a polymer material such as nylon, Epoxy, polyester or vinyl ester material. In some preferred examples, the reinforcing fibres are glass or carbon fibres. In some preferred examples, the head portion comprises a bamboo wood material in at least the bas. In some preferred examples, the length of the tongue as a proportion of the overall hurley length is in the range of 2% to 35%. In some preferred examples, the position of the start of the tongue is in the range of 50% from the handle end down to 80% from the handle end. In some preferred examples, the position of the start of the tongue is in the range of 67% from the handle end down to 77% from the handle end. In some preferred examples, the length of the tongue is in the range of 10 mm to 300 mm. In some preferred examples, the length of the tongue is in the range of 40 mm to 150 mm. In some preferred examples, the length of the tongue is in the range of 60 mm to 100 mm. We also describe a method of manufacturing a hurley of any example described herein, the method comprising: providing the head portion and the shaft, in which the length of the tongue and / or the position of the start of the tongue is chosen to achieve a desired weight distribution and / or overall weight of the hurley, and / or stiffness of the hurley; applying adhesive to the tongue and / or an internal surface of the groove; and inserting the tongue into the groove and allowing the adhesive to cure. Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which: Fig. lisa perspective view of a hurley of the invention; Fig. 2 is an exploded view of the hurley, showing particularly how a head portion is secured to a separate shaft at the lower end and a handle cap is secured to the shaft at the upper end during manufacture; Fig. 3(a) is a front view of the hurley, showing a sectional view direction III-III, and Fig. 3(b) is a sectional view in the direction of the arrows III-III, including grain of the laminated central layer in the head portion; Fig. 4(a) is a side view of the hurley, showing a sectional view IV-IV and Fig. 4(b) is sectional view in the direction of the arrows IV-IV across the hurley head portion, showing all three layers of the head portion and how the shaft is engaged; Fig. 5 is a sectional view equivalent to Fig. 4(b) of another hurley of the invention, in this case having two layers at the upper end of the head portion; Fig. 6 is a sectional view equivalent to Fig. 4(b) of a further hurley, in this case having only a single layer at the upper end of the head portion; Fig. 7 is an exploded perspective view of another head portion, in this case having an annular insert in the bas for tuning of weight distribution to allow customisation of the hurley during manufacture; Fig. 8 is a perspective exploded view showing a bas in which the central layer has material removed in order to spread the ball-striking sweet-spot, and Figs. 9 and 10 are equivalent views with different material removal arrangements, and Fig. 11(a) is a perspective view of a hurley before completion of manufacture, Fig. 11(b) is a view showing section lines A-A, and Fig. 11(c) is a sectional view in the direction of the arrows A-A. Referring to Figs. 1 and 2 a hurley 1 comprises a head portion 4 with a bas 10, a shaft 2 with a handle cap 3 also referred to as a “knob”. For clarity, the end with the bas is referred to as the lower end and the end with the cap is referred to as the upper or handle end. The overall configuration widens from the handle end down to the bas, the bas being much wider in side view and having rounded edges. The bas 10 provides the striking surfaces of the hurley that makes contact with the ball. The shaft 2 may also be referred to as the handle. The shaft provides the player with a comfortable holding area for ball striking by the bas. The cap is an extension of the shaft; it can be a component attached during manufacture or an integral component. The purpose of the cap is to close off the end of the shaft and provide a comfortable shape for the player’s hand to rest. It also prevents the hurley from slipping out of the player’s hand during a swing. The head portion 4 comprises the bas 10 at its lower end and at its upper end it has a tongue 11 formed from a narrowed part of the wood material of the bas. The tongue 11 begins with a step 16 which extends fully around the head portion. The tongue 11 fits with a friction fit and adhesive into the hollow shaft 2, the shaft 2 being tubular and of hollow material other than wood, such as a composite material. This composite material preferably has a primary material such as a polymer having embedded reinforcing fibres. The end of the shaft is hollow and has a mouth 15 with an end wall which abuts the step 16. The outer surface of the shaft 14 and of the head portion form a smooth external surface which are matched, the thickness of the wall of the shaft 14 (providing the end surface 15) matching the step 16. At its upper end the shaft is coupled to a cap 20 during manufacture. The adhesive is in some preferred embodiments a polyurethane or a thermoplastic adhesive. The enlarged portion of Fig. 3(b) shows in a diagrammatic manner the interfacing of the end face 15 and the internal surface of the tube 14 with the tongue internal layer 21 with its part of the step 16, with the interface occupied by adhesive exaggerated in thickness for clarity. In more detail, referring to Fig. 3(b), the shaft 2 comprises a hollow member 14 of a composite material which is in this case reinforced polymer. The polymer is in some preferred embodiments nylon, or an epoxy, polyester, or vinyl ester material. The reinforcement is preferably by way of embedded reinforcing fibres. The composition of the material, wall thickness, and second moment of area are chosen to suit the desired weight, flexibility and strength characteristics. The bas 10 has three layers, as shown in Figs. 4(b), 5, and 6. The central layer 20 is shown in Fig. 3(b), and as shown graphically the wood grain is lateral (approximately horizontal when the hurley 1 is upright). However, along this central plane the tongue 11 has a layer 21 with its grain extending longitudinally, as illustrated. Referring particularly to Fig. 4(b), the bas 10 comprises the central layer 20 with the cross grain, and an outer layer 22(a) and (b) on each side laminated to the central layer 20. These outer layers have longitudinal grain. The tongue 11 is formed from a continuation of the outer layers 22(a) and (b), but the space between them is filled by an upper central layer 21 with longitudinal grain as also shown in Fig. 3(b). The invention includes various different ways of providing in the has a central layer with cross grain to complement the outer layers with longitudinal grain. Another method for laminating the has layers is by using two ply where both outer layers have their thickness routed down prior to lamination to create a slot for an insert middle ply to be laid down with its grain in the horizontal (lateral) direction. Referring to Fig. 5, a hurley has a head portion 110 with a central cross layer 120 in the bas and a longitudinal grain outer layer 122(a) and (b) on each side. The outer layers 122(a) and (b) are stepped inwardly at the upper end of the central layer 120, so that they join to form a tongue 111 with two layers 123. Another method involves using a single solid piece of wood as the bas material. A slot is cut out of the end of the bas to allow space for a horizontal grain insert. This is shown in Fig. 6, in which the head portion 210 is formed by a body of wood forming bas outer layers 222(a) and (b) which are integral with a unitary non-laminated tongue 211. A slot across the lower end of the head portion receives a central cross-grained layer 220. The tongue is defined as that part of the head portion inserted into the tubular part of the shaft. The tongue 11 extends directly from the bas 10 in the illustrated examples. However, it is envisaged that the head portion may comprise the bas and a lower part of the shaft and the tongue extends upwardly from this lower part of the shaft. Major parameters are: (a) The length of the tongue as a proportion of the overall hurley length, preferably in the range of 2% to 35%, more preferably 4% to 20%, and more preferably 6% to 12%. (b) The position of the start of the tongue (the step location, 16 in Figs. 1 to 4(a)), preferably in the range of 50% to 80% of the overall length of the hurley from the handle end downward. A more preferred range is 60% to 80%% from the handle end. More preferably it is in the range of 65% to 75% and even more preferably 67% to 71%. (c) Absolute length of the tongue, preferably in the range of 30 mm to 150 mm, more preferably 40 mm to 100 mm. The tongue length is the extent of overlap of the head portion with the shaft hollow member, and contributes to the degree of flexibility, the weight, and the centre of gravity. (d) Tongue maximum thickness, preferably between 6 mm and 16 mm, and more preferably 9 mm to 11 mm. This dimension allows adjustment for the trade-off of durability and flexibility, and also setting of the centre of gravity and sweet spot size. It facilitates advantageous weight distribution of the hurley, which impacts striking consistency, for example. Of course, the shaft has internal dimensions at the end to correspond to the tongue geometry. The size and pattern of the bas central layer and what it contains, if anything, allows balancing of the hurley to suit the target player. The invention advantageously provides that the bas is formed from a head portion which also has a tongue for engaging a shaft having a lower end which is hollow to receive the tongue. This allows the bas to be of wood for good ball-striking characteristics. Because the tongue is a continuation of the head portion there is excellent strength with the required flexibility and the joint is spread all along the length of the tongue. This provides a transition section with the wood of the head portion surrounded by the plastics (possibly reinforced by fibres) of the shaft tube 14. This combination of layers and tightness for the engagement provides excellent resistance to breaking or separation at this joint. It is also very advantageous that, because the tongue engages in a shaft tube there is a very large surface area for engagement with a friction fit and adhesion. It is preferred that the surface areas of the tongue which faces outwardly and engages the inside surface of the shaft tube is in the range of 6000 mm2 to 8000 mm2. It is preferred that the shaft tube material thickness is in the range of 1 mm and 3 mm, and so the tongue configuration is close to a continuation of the top of the bas, with only a small step, providing a smooth transition to the shaft. Tongue Length and Step Down The shaft 2 in this embodiment is hollow throughout its entire length and at its lower end it forms an opening or mouth 15 that receives and is secured to the tongue. In other examples the shaft is solid at its upper ends and only hollow for the lower end of the shaft’s length. The tongue is an extension of the head portion material and is configured to ensure that the contact surface area between the external surfaces of the tongue 11 and the internal surfaces of the shaft tube 14 are maximized while also ensuring sufficient interference to maximize structural stability and strength. The chosen length of the tongue facilitates adjustment of the weight and balance, which is also referred to as the “swing weight”, of the hurley. In effect the internal space within the tube 14 of the handle 2 provides for excellent versatility in choice of weight and location of the center of gravity of the hurley. A step down is required between the bas and the tongue to ensure that the outer surface of the shaft 2 is flush with the outer surface of the head portion 4 (as shown in Fig. 1). This step down (thickness of the shaft tube) can range in depth from 1 mm to 3 mm and can be filleted or chamfered to increase breaking strength if necessary. The assembly process includes coating the tongue and / or inner surface of the tube 14 with an adhesive, pushing the tongue up into the shaft core until the lower end of the tube 14, at the mouth 15, butts against the step-down shoulder 16 of the bas. The outer surface of the bas is flush with the outer profile of the shaft. This same joining process can also be carried out on the laminated assembly before the head portion is shaped. Figs. 11(a), (b), and (c) show the head portion before being shaped. The bas is the main contact area between the ball and hurley in use and is made from a material with appropriate physical and mechanical properties to replicate the performance and feel of a traditional wooden hurley. The bas can be made of a single piece of wood or multiple pieces or layers laminated together as described above with adhesives such as a 3-ply laminated board. The bas can be made from any natural material such as bamboo, hardwood, softwood, indeed it can be made from any natural material with a density ranging from 400 kg / m3 to 1500 kg / m3. The optimal material hardness of the bas material, according to the Brinell Hardness test method can range from 2.0 kg / mm2 to 10.0 kg / mm2 when using a 10 mm ball indenter. In traditional hurl making, some players require a heavier bas than others which was achieved by attaching bands, also known as hoops wrapped around the perimeter of the bas. For this invention, if additional weight in the bas is desired by a player and the bas was formed from a 3-ply laminated board, the central layer of the 3-ply board can have a groove carved out to facilitate the insertion of weighted inserts inside the bas, as shown in Fig. 7. Another method to increase the swing weight is to lower the joining location closer to the bas. If desired, the bas can also be made from a synthetic material, either fully synthetic or partially synthetic with wooden inserts incorporated. The shaft 2 tubular portion can be made from a composite structure, preferably of a polymer / plastics material reinforced by fibres such as glass fibres or carbon fibres or any suitable metal or alloy including aluminum and / or graphite. Composite materials may have reinforcement fibres such as fiberglass, carbon fiber, or Kevlar fiber or natural reinforcement fibres such as bamboo fibre, flax fibre and others such as jute, ramie, hemp, sisal, and / or kenaf. How the finished hurley feels and swings in the hand of the player is key to satisfying player preference and individual performance requirements. The shaft when assembled with the has must feel similar in swing weight to a traditional ash hurley. The shaft component may be made from any material or combination of material with a density ranging from a minimum of 1000 (kg / m3) to a maximum of 3100 (kg / m3). The preferred range is 1500 (kg / m3) to 2600 (kg / m3). The fact that there is a central layer in the bas allows versatility so that each hurley can be customized in manufacture by choice of weight of the central layer. For example, it may be made to have a lower density than the other wood of the head portion by using a material with a lower density and / or by having a hollow portion. It may be made denser by being of a denser material or by inserting an insert such as an annular metal ring into a recess in this layer. An example is shown in Fig. 7 in which a head portion has outer layers 310(a) and 310(c) and a central layer 310(b) has an annular recess 350 which may be left empty for lower density or may house a metal ring 360 to make it more dense. It helps to provide the hurley bas with a larger “sweet spot” centered on the center of the recess 350. The sweet spot is the location on the hurl or any sports instrument where maximum energy transfer between the hurley and ball occurs resulting in minimal vibration and maximum striking power. The bigger the sweet spot on a sports instrument, the more consistent and high performing that instrument is; there are similarities with the term sweet spot and centre of percussion which is another technical term used to describe the impact location that minimizes reactive forces, i.e. vibration. The weighted inserts of the bas, where present, are preferably a single body component in the shape of a washer located concentric with the sweet spot of the hurl. The weight insert can be made from any metal, alloy or rubber with a density greater than 800 kg / m3. The weighted insert is attached during the lamination process. Fig. 8 shows an example in which a head portion 400 central layer 420 has material removed in a pattern of apertures 460, which are covered over by the outer layers 422(a)and (b). This view shows the central material 421 which forms part of the tongue. In this case the pattern is a central aperture and four circumferentially equally spaced apertures around it. Fig. 9 shows an example in which in a head portion 500 central layer 520 has material removed in a pattern of two facing arc-shaped apertures 560, which are covered over by the outer layers 522(a)and (b). This view shows the central material 521 which forms part of the tongue. Fig. 10 shows an example in which in a head portion 600 central layer 620 has material removed in a pattern of an array of sixteen apertures 660, which are covered over by the outer layers 622(a)and (b). This view shows the central material 621 which forms part of the tongue. The knob / cap 3 serves the same function as the knob on a traditional ash hurley, which is to prevent the hurley from slipping out of player’s hand during normal use while it also closes off the hollow core of the shaft. The cap can be modified in shape and curvature to achieve various holding preferences that players may have. The cap can be made from any 3D printing material such as PLA, PA6 or ABS in basic or glass filled form. It can also be made out of any injection moldable material of any composition such as PA66, Polycarbonate and / or Low-Density polyethylene (LDPE) or similar. The main purpose of this hurley is to at least equal the performance of a traditional wooden hurley made from ash and to replicate the overall user experience as closely as possible. The swing weight is a key property of the hurley. Traditionally the hurley has been made from the same material throughout which naturally produced a familiar weight and balance in the hands of a player. As the hurley of the invention includes two main components (head portion and shaft) made from two different materials of two different material densities, it is critical that weight and balance is quantified accurately to ensure the hurley feels and performs the same as the traditional ash hurley. Swing weight quantifies the overall weight and balance of the fully assembled hurley. In this invention, the swing weight of a fully assembled hurl of any length can vary between 1.00 Nm and 4.00 Nm. Shaft stiffness is a key performance property of the hurley. The greater the value for shaft stiffness the greater the resistance to bending is. To replicate the best performing ash hurleys, the hurley of the invention can have a shaft stiffness (K) ranging from 4 N / mm to 20 N / mm. The bending stiffness (K) of a hurl is determined by setting up a three-point bend test fixture with a span equaling 90% of the hurl length. The hurl is placed symmetrically on the three-point bend fixture and the load applicator positioned at the half way point of the hurl moves downwards until the hurl is displaced by 10 mm. The maximum force (N) and displacement (mm) values are obtained, and the bending stiffness was calculated using the relationship below: k4 Where: F = Maximum force (N) 6 = Deflection (mm) Coefficient of Restitution (COR) and Smash Factor are the key performance properties identified to control the energy transfer between ball and hurley. The hurley 1 is configured to ensure that the COR and Smash Factor equal that of a typical ash hurley. The optimal COR value is within 0.34 ± 0.08. COR is a commonly used performance metric for sports striking instruments and is defined by Alan M. Nathan in a study titled “The Physics of the Trampoline Effect in Baseball and Softball Bats. Alan M. Nathan characterizes COR as the amount of energy dissipated during a ballbat collision. COR ranges on a scale from 0 to 1 with COR =1 representing no energy loss and COR=0 representing complete energy loss. Smash Factor is a similar metric commonly used in golf to describe the energy transfer from golf club to golfball. It is calculated by dividing the ball speed after impact by the club head speed prior to impact. Both COR and Smash Factor are fundamental metrics in the performance and feel of a hurl. In addition to performance and feel, another objective for this invention is to create a hurl that is compliant with GAA (Gaelic Athletic Association) regulations. Therefore, this invention replicates the COR and Smash Factor values of the traditional ash hurl to ensure the same playing characteristics while also respecting the integrity of the game by not exceeding the performance of the traditional ash hurl. The optimal Smash Factor when struck on the sweet spot as per the test method is within 1.0 ± 0.2. The hurley breaks safely in a similar nature to the typical ash hurl with minimal debris, splinters and / or sharp edges, as is required by GAA regulations to ensure safety. For manufacturing, in one example the bas is made from a 3-ply laminated bamboo board. The board is formed by laying the first outer layer of bamboo boarding with a length required to make one bas. This is placed on a flat surface and the upward facing surface is coated with lamination adhesive. The middle layer of natural bamboo boarding is then cut into two pieces to allow the grain direction to be varied (vertical &horizontal) throughout the length of the has as described above. For the upper piece of the middle ply, where the tongue will be located, the board is laid on the first outer layer with the grain in the direction longitudinal to the primary axis of the hurl. The lower piece of the middle ply, where the heel and nose of the hurl will be located, this board is laid with the grain direction perpendicular to that of the grain direction of the upper piece. As described above with reference to Fig. 7, the lower piece middle ply may also have a recess carved out to allow the insertion of a weighted insert to embed into the board. Or, as shown in Figs. 8 to 10 there may only be removal of material and in general this is preferred to the approach of adding an insert because it is simpler. A weighted insert will increase the swing weight of the hurley internally and the groove will ensure the insert is fully embedded into the middle ply with no protruding edges or features affecting lamination. The final and third layer of the 3-ply bamboo boarding is then placed on top. All layers with interacting surfaces have lamination adhesive smoothly coated between them. The entire 3-ply bamboo assembly is then exposed to a clamping pressure for 24 hours to ensure maximum strength and adhesion quality is achieved. When the 3-ply bamboo board is fully assembled, the tongue and the outer shape of the bas style required is cut out of the board with high precision. The shaft component is made in one example using a mould and moulding machine. The fabric made from the reinforcement fibers is wrapped around a thermoplastic nylon tube. This is then placed in the cavity of a mould carved out with the desired shape and profile of the finished shaft. The mould is then placed into the moulding machine, and the ends of the nylon tubes are attached to an air pressure supply. When the mould is heated to the required temperature, the epoxy / matrix is inserted, and a pressure is applied to the nylon tube to expand both the reinforcement fabric and matrix material against the outer walls of the mould cavity. This mould is allowed time to cool, and the parts are removed from the mould. The shaft is then passed on for finishing and paintwork. The shaft of desired length and material composition is also selected. The first step is to craft the tongue out of the bas as per check fixtures. The check fixtures are convenient fixtures that can be placed on the tongue under work to give feedback on the appropriate profile and dimensions required to achieve sufficient interference between the tongue and the inner walls of the shaft. When the tongue is crafted to the correct size and profile, it is then coated in adhesive, and this adhesive is ideally also applied to the inside of the core and it is pressed into the core of the shaft. It is then left for 24 hours to solidify. The desired knob shape is also selected and attached to the end of the shaft with adhesive also. When joining is complete and glue is dry the has shape is then cut as per the customer’s request. This is shown in Figs. 11(a), (b), and (c) which show a partially completed hurley 700 with a shaft 702 with a tube 714, a cap 703 and a partially manufactured head portion 750 with a bas central ply 751 and a tongue central ply 752 within a tongue 711. At this stage the tongue 711 has been inserted and affixed within the shaft tube 714, and the manufacture only then requires shaping of the bas from the bas portion 750. This allows customisation at the final stage to suit the player. For example, a batch can be made and each one finalised on an individual customised basis by machining the bas shape from the blank 750. When the drying of the assembly is complete, the bas is then shaped and finished until the desired swing weight is achieved. The final step of the finishing process is to apply a roughened texture to the bas surface on both sides to assist with ball-bas contact quality when in use in wet conditions. It will be appreciated that the invention avoids the need to provide wood for the full length, and the wood which is provided may be of a type other than ash, such as bamboo. It also provides excellent versatility during manufacture to achieve the desired playing characteristics. The invention provides a hurley made from alternative material(s) that replicate the physical and playing characteristics of the traditional ash hurl while also achieving excellent on-field performance. It is simple to manufacture, with very few steps while facilitating agile and adaptable player personalization during the ordering process. The invention also achieves environmental advantages as it facilitates repair and / or replacement of the ball striking section when necessary. The present invention also reduces the use of artificial materials. Also, it is simple and reliable because it has few parts, and it does not require a reinforcement coating around the periphery due to the extent of surface adhesive contact between the tongue and the internal surface of the shaft tube, and matching of the shaft tube wall (15) thickness to the step (16) height at the base of the tongue. Components of embodiments can be employed in other embodiments in a manner as would be understood by a person of ordinary skill in the art. The invention is not limited to the embodiments described but may be varied in construction and detail. For example, the manufacturing process may include scoring or texturing some or all of the ball-striking surface of the bas for enhanced contact in wet weather conditions.

Claims

1. A hurley comprising:a shaft (2) extending in a longitudinal direction and acting as a handle,an upper cap (20) affixed to the shaft, in which the cap is an integral part of the shaft or the cap (3) is modular (20) and is attached to an end of the shaft during manufacture, anda bas (10), wherein:the shaft (2) comprises a tubular member (14) with a lower open end (15), andthe bas (10) is part of a head portion (4) also comprising a tongue (11) inserted into and adhered to the shaft tubular member (14),the tongue (11) is formed by a step (16) inwards to reduce cross sectional area, and a wall (15) of the shaft tubular member abuts the step,the shaft tubular member (14) wall (15) thickness at the opening is matched to the depth of the step, to provide a continuous outer surface,the head portion is of a wood material, and the shaft is of a non-wood material the shaft at least partly comprises a polymer,the bas (10) comprises at least three layers (20, 22) in a laminated structure across a short dimension, in which the bas comprises a central layer (20) on each side of which there is a ball striking outer layer (22) and the tongue (11) comprises at least in part a continuation of the outer layers (22, 122, 222),the length of the tongue is in the range of 30 mm to 150 mm, the maximum thickness of the tongue is in the range of 6 mm to 16 mm, and the length of the tongue as a proportion of the overall hurley length is in the range of 2% to 35%.

2. A hurley as claimed in claim 1, wherein the central layer (20) has a cross grain, and theouter layers (22) have a longitudinal grain.

3. A hurley as claimed in either of claims 1 or 2, wherein the central layer (310(b)) includesan insert (360) for added weight and / or a desired weight distribution.

4. A hurley as claimed in claim 3, wherein the insert is annular.

5. A hurley as claimed in any preceding claim, wherein the shaft tubular member is of acomposite material with a primary material and reinforcing fibres.

6. A hurley as claimed in claim 5, wherein the primary material comprises a polymer materialsuch as nylon, epoxy, polyester or vinyl ester material.

7. A hurley as claimed in claim 5 or claim 6, wherein the reinforcing fibres are glass or carbonfibres.

8. A hurley as claimed in any preceding claim, wherein the head portion comprises a bamboowood material in at least the bas.

9. A hurley as claimed in any preceding claim, wherein the length of the tongue as aproportion of the overall hurley length is in the range of 4% to 20%.

10. A hurley as claimed in any preceding claim, wherein the length of the tongue as a proportion of the overall hurley length is in the range of 6% to 12%.

11. A hurley as claimed in any preceding claim, wherein the position of the start of the tongue (16) is in the range of 50% from the handle end down to 80% from the handle end.

12. A hurley as claimed in any preceding claim, wherein the position of the start of the tongue (16) is in the range of 65% from the handle end down to 75% from the handle end.

13. A hurley as claimed in any preceding claim, wherein the position of the start of the tongue (16) is in the range of 67% from the handle end down to 71% from the handle end.

14. A hurley as claimed in any preceding claim, wherein the length of the tongue is in the range of 40 mm to 150 mm.

15. A hurley as claimed in any preceding claim, wherein the length of the tongue is in the range of 60 mm to 100 mm.

16. A hurley as claimed in any preceding claim, wherein the maximum thickness of the tongue is in the range of 9 mm to 11 mm.

17. A hurley as claimed in any preceding claim, wherein the thickness of the wall of the shaft tubular member at the lower opening is in the range of 1 mm to 3 mm.

18. A hurley as claimed in any preceding claim, wherein the central layer includes a void or a plurality of voids (460, 560, 660) located to spread a ball-striking sweet spot.

19. A hurley as claimed in claim 18, wherein the voids are formed by drilling or laser cutting through holes in the central layer.

20. A method of manufacturing a hurley of any preceding claim, the method comprising: providing the head portion (4) or a head portion blank (750) and the shaft (2, 702), applying adhesive to the tongue and / or to an internal surface of the shaft tubular member (14); andinserting the tongue into the groove and allowing the adhesive to cure.

21. A method as claimed in claim 20, wherein the tongue (711) of a head portion blank (750) is inserted, and the head portion blank is subsequently shaped to a desired bas shape after the adhesive has cured.A

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