Patent ID: 6352662
Filing Date: 2002-03-05
Classification: A63B

Abstract:
A method of manufacturing a light-weight shaft having a grip integrally molded thereon, the method comprising:providing a mandrel covered by a flexible bladder having a proximal end, a distal end, and a proximal region; wrapping a plurality of plies of pre-preg composite sheet defining a shaft body around the mandrel, the plurality of plies including a first plurality of plies of pre-preg and a second plurality of plies of pre-preg, the second plurality of plies of pre-preg co-molded with resin films of EPDM co-polymer and having a lower durometer than the first plurality of plies being wrapped around the proximal region of the mandrel defining an integral grip of the shaft body, placing the wrapped mandrel in a mold, the mold having a wall defining a cavity, the cavity including a grip region defining a grip geometry; introducing pressurized gas through the mandrel to inflate the bladder to a predetermined pressure forcing the plurality of plies of pre-preg against the walls of the mold and heating the wrapped mandrel for a sufficient time to allow the plurality of plies of pre-preg composite sheet to cure, and to allow the second plurality of plies to co-mold with the resin film thereby forming the grip geometry of the grip region; removing the shaft from the mold and applying a coating to the proximal plies of the grip region such that the outer surface of the grip region has a finished thickness of from about 0.005 inch to 0.030 inch; and the finished weight of the shaft is less than 70 grams.