Patent ID: 6767422
Filing Date: 2004-07-27
Classification: A63B,Y10T

Abstract:
A method for forming a golf club shaft around a mandrel having a length along a longitudinal axis, the steps comprising:forming a first reinforcement layer from a first fiber material, said first fiber material having fibers aligned along a single direction and said fibers only extending alone an entire length of said first reinforcement layer; forming a first angled layer by bonding second and third fiber materials, such that the fibers of said second material form a first angle with the fibers of said third material, said second and third materials having fibers aligned along a single direction and said second and said third fibers only extending along an entire length of said first angled layer; forming a first straight layer from a fourth fiber material, said fourth fiber material having fibers aligned along a single direction and said fibers only extending along an entire length of said first straight layer; forming a second angled layer from fifth and sixth fiber material, said fifth and sixth materials having fibers aligned along a single direction and said fifth and said sixth fibers only extending along an entire length of said second angled layer; bonding said fifth and sixth fiber materials together to form said second angled layer, such that said fibers of said fifth and sixth material form a second angle in the range of from 70-150 degrees and said second angled layer has a thickness in the range of from 0.04 to 0.1 mm; forming a second straight layer from a seventh fiber material, said seventh fiber material having fibers aligned along a single direction and said fibers only extending along an entire length of said second straight layer; forming a second reinforcement layer from an eighth fiber material, said fiber material having fibers aligned along a single direction and said fibers only extending along an entire length of said second reinforcement layer; wrapping said first reinforcement layer around said mandrel such that said fibers of said first reinforcement layer are aligned 90 degrees with respect to said longitudinal axis; wrapping said first angled layer around said first reinforcement layer such that said first angle of said fiber material of said first angled layer is bisected by said longitudinal axis; wrapping said first straight layer around said first angled layer such that said fibers of said first straight layer are aligned with said longitudinal axis; wrapping said second angled layer around said first straight layer such that said second angle of said fiber material of said second angled layer is bisected by said longitudinal axis; wrapping said second straight layer around said second angled layer such that said fibers of said second straight layer are aligned with said longitudinal axis; wrapping second reinforcement layer around said second straight layer to form a layered wrap, such that said fibers of said second reinforcement layer are aligned with said longitudinal axis; curing said layered wrap in an oven to form a cured shaft; removing said mandrel from said cured shaft; and trimming ends said cured shaft to produce said golf club shaft having a weight of 30 to 40 grams.