Abstract:
A golf club having removable components is disclosed herein. The golf club having removable components includes a club head, a shaft, and a connection assembly. The connection assembly includes a sleeve mounted on the tip end of the shaft and a screw-cap. The sleeve has an offset aperture for receiving the tip end of the shaft in order to adjust the face angle of the golf club. The screw-cap is mounted over the sleeve and includes a body having an upper area and a threaded area, the latter of which is capable of engaging the upper threaded portion of the hosel to removably secure the shaft to the club head.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     The present application is a continuation-in-part application of U.S. patent application Ser. No. 13/186,118, filed on Jul. 19, 2011, which is a continuation application of U.S. patent application Ser. No. 13/013,656, filed on Jan. 25, 2011, now U.S. Pat. No. 8,002,644, which is a divisional application of U.S. patent application Ser. No. 12/692,428, filed on Jan. 22, 2010, now abandoned, which is a divisional application of U.S. patent application Ser. No. 11/928,146, filed on Oct. 30, 2007, now abandoned, which is a continuation of U.S. patent application Ser. No. 11/461,132, filed on Jul. 31, 2006, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 10/904,581, filed on Nov. 17, 2004, now U.S. Pat. No. 7,083,529, all of which are hereby incorporated by reference in their entireties. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a golf club having an improved connection for interchanging a shaft with a golf club head, components for the golf club, and a method of manufacturing the components. 
     2. Description of the Related Art 
     In order to improve their game, golfers often customize their equipment to fit their particular swing. Golf equipment manufacturers have responded by increasing the variety of clubs available to golfers. For example, a particular model of a driver-type golf club may be offered in several different loft angles and lie angles to suit a particular golfer&#39;s needs. In addition, golfers can choose shafts, whether metal or graphite, and adjust the length of the shaft to suit their swing. Golf clubs that allow shaft and club head components to be easily interchanged facilitate this customization process. 
     One example is Wheeler, U.S. Pat. No. 3,524,646 for a Golf Club Assembly. The Wheeler patent discloses a putter having a grip and a putter head, both of which are detachable from a shaft. Fastening members, provided on the upper and lower ends of the shaft, have internal threads, which engage the external threads provided on both the lower end of the grip and the upper end of the putter head shank to secure these components to the shaft. The lower portion of the shaft further includes a flange, which contacts the upper end of the putter head shank, when the putter head is coupled to the shaft. 
     Another example is Walker, U.S. Pat. No. 5,433,442 for Golf Clubs with Quick Release Heads. The Walker patent discloses a golf club in which the club head is secured to the shaft by a coupling rod and a quick release pin. The upper end of the coupling rod has external threads that and engage the internal threads formed in the lower portion of the shaft. The lower end of the coupling rod, which is inserted into the hosel of the club head, has diametric apertures that align with diametric apertures in the hosel to receive the quick release pin. 
     Still another example is Roark, U.S. Pat. No. 6,547,673 for an Interchangeable Golf Club Head and Adjustable Handle System. The Roark patent discloses a golf club with a quick release for detaching a club head from a shaft. The quick release is a two-piece connector including a lower connector, which is secured in the hosel of the club head, and an upper connector, which is secured in the lower portion of the shaft. The upper connector has a pin and a ball catch that protrude radially outward from the lower end of the upper connector. The upper end of the lower connector has a slot formed therein for receiving the upper connector pin, and a separate hole for receiving the ball catch. When the shaft is coupled to the club head, the lower connector hole retains the ball catch to secure the shaft to the club head. 
     Two further examples are published applications to Burrows, U.S. Publication Numbers 2004/0018886 and 2004/0018887, both of which are for a Temporary Golf Club Shaft-Component Connection. The Burrows applications disclose a temporary connection that includes an adapter insert, a socket member, and a mechanical fastener. The adapter insert, which is mounted on a shaft, includes a thrust flange. The socket member, which is mounted on the other golf club component (e.g., a club head), includes a thrust seat for seated reception of the thrust flange. The mechanical fastener (e.g., a compression nut or a lock bolt) removably interconnects the adapter insert and the socket member. 
     The prior art temporary head-shaft connections have several disadvantages. First, they require that the golf club head have a conventional hosel for attachment. Second, these connections add excessive weight to the club head, thereby minimizing the amount of discretionary mass that may be distributed in the club head to optimize mass properties. Third, the prior art connections offer small, faying surfaces for centering and reacting to bending moments. 
     Currently the time required to machine the existing geometry of an interior hosel is between 10-20 minutes depending on the set-up time of the machinist. The time and resources to set up the golf club head component for machining adds to the overall costs. 
     In the current method employed to machine the interior hosel hole geometry a ball end-mill cutter is used. The ball end-mill cutter spirals down the hosel hole in a constant X, Y, and Z axis positioning method which cuts the hosel hole geometry to the finished dimensions. This descending-spiraling method is slow and consequently costly due to the time required for the process. 
     BRIEF SUMMARY OF THE INVENTION 
     One aspect of the present invention is a golf club having removable components. The golf club comprises a club head, shaft and a connection assembly. The club head has a body with a hosel. The hosel has an upper threaded portion and a lower portion. The upper threaded portion has a threaded cross-section. The lower portion has a ribbed cross-section. The shaft has a tip end and a butt end. The connection assembly comprises a sleeve and a screw-cap. The sleeve mounted on the tip end of the shaft. The sleeve has a body with a top section and a lower section. The lower section has a tapered, multi-faceted surface for engaging the lower portion of the hosel. The sleeve also comprises an aperture for receiving the tip end of the shaft, wherein the aperture is at an angle ranging from 1 to 3 degrees relative to a centerline of the body. The screw-cap has a body with a central aperture. The screw cap is mounted over the sleeve. The body of the screw-cap has an upper area and a threaded area. The threaded area engages the upper threaded portion of the hosel of the club head for removably securing the shaft to the club head. The face angle and the loft angle of the golf club are adjusted by adjusting the orientation of the shaft in the club head. 
     Another aspect of the present invention is a golf club having removable components with the golf club comprising a multi-material club head, a shaft and a connection assembly. The club head comprises a face cup and an aft-body. The face cup composed of a metal material and including a striking face, a return portion and a hosel. The hosel has an upper threaded portion, a central portion and a lower portion. The upper threaded portion having a plurality of threads thereon. The central portion has a circular cross-section. The lower portion has a tapered, ribbed cross-section. The shaft having a tip end and a butt end. The connection assembly comprises a sleeve and a screw-cap. The sleeve mounted on the tip end of the shaft. The sleeve has a body with a top section and a lower section. The lower section has a tapered, multi-faceted surface for engaging the lower portion of the hosel. The sleeve also comprises an aperture for receiving the tip end of the shaft, wherein the aperture is at an angle ranging from 1 to 3 degrees relative to a centerline of the body. The screw-cap has a body with a central aperture. The screw cap is mounted over the sleeve. The body of the screw-cap has an upper area and a threaded area. The threaded area engages the upper threaded portion of the hosel of the club head for removably securing the shaft to the club head. The face angle and the loft angle of the golf club are adjusted by adjusting the orientation of the shaft in the club head. 
     Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a front plan view of a golf club. 
         FIG. 2  is an exploded top perspective view of the golf club of  FIG. 1  illustrating the various components, including a club head, a shaft, and the connection assembly, which includes a sleeve and a screw-cap. 
         FIG. 3  is a top view of a golf club with a closed face angle. 
         FIG. 3A  is a top view of a golf club in a neutral position with a closed face angle. 
         FIG. 3B  is a top view of a golf club with an open face angle. 
         FIG. 4  is a side view of a golf club with a club head rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 17 degrees. 
         FIG. 4A  is a side view of a golf club with a club head rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 14 degrees. 
         FIG. 4B  is a side view of a golf club with a club head rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 12 degrees. 
         FIG. 5  is a cross-sectional view of a connection assembly for a golf club. 
         FIG. 6  is an isolated front view of a connection assembly for a golf club. 
         FIG. 7  is an isolated cross-sectional view of a sleeve of a connection assembly for a golf club. 
         FIG. 8  is a top view of a screw cap of a connection assembly for a golf club. 
         FIG. 8A  is a cross-sectional view along line A-A of the screw cap of  FIG. 8 . 
         FIG. 8B  is a front view of the screw cap of  FIG. 8 . 
         FIG. 9  is a front view of an embodiment of a screw cap with NYLOK on the threads. 
         FIG. 10  is a front view of an embodiment of a screw cap with NYLOK on the threads. 
         FIG. 11  is a front view of an embodiment of a screw cap with NYLOK on the threads. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in  FIGS. 1-2 , a golf club is generally designated  20 . Golf club  20  has a club head  22  and a shaft  24  that is coupled to club head  22 . Club head  22  is preferably a wood-type golf club head, such as a driver, a fairway wood, or even a hybrid iron-wood-type club, but may also be an iron-type club head. Club head  22  includes a body  26  having a striking face  30 , a crown portion  23 , a sole portion  25 , a heel end  32  and a toe end  34 . Striking face  30  generally extends along the front of club head  22  from heel end  32  to toe end  34 . 
     The club head  22  is alternatively a club head such as disclosed in U.S. Pat. No. 6,758,763 for a Multiple Material Golf Club Head, which is hereby incorporated by reference in its entirety. The club head  22  is alternatively a club head such as disclosed in U.S. Pat. No. 7,166,038 for a Golf Club Head, which is hereby incorporated by reference in its entirety. The club head  22  is alternatively a club head such as disclosed in U.S. Pat. No. 7,273,419 for a Multiple Material Golf Club Head, which is hereby incorporated by reference in its entirety. The club head  22  is alternatively a club head such as disclosed in U.S. Pat. No. 7,410,428 for a Golf Club Head With A High Moment Of Inertia, which is hereby incorporated by reference in its entirety. 
     Body  26  is preferably composed of a metallic material, such as titanium, titanium alloy, stainless steel, or the like. Alternatively, body  26  may be composed of multiple materials, such as a metal face cup attached to an aft-body composed of a different material, such as a carbon composite material, or a stainless steel body with a carbon composite crown. Body  26  preferably has a hollow interior and includes a hosel for receiving shaft. Where body  26  is comprised of a cup face and an aft-body, the hosel is provided in cup face. The hosel is preferably an internal hosel that extends into body  26  with an opening in crown portion. Alternatively, club head  22  may be provided with an external hosel (not shown) rather than an internal one. 
     The shaft  24  is preferably composed of a graphite material, however, the shaft  24  is alternatively composed of a metallic material, such as stainless steel or titanium. Alternatively, the shaft  24  is composed of a hybrid of graphite and metal. The shaft  24  is coupled to club head  22  using a connection assembly  44  that provides for easy assembly, disassembly and reassembly, thereby facilitating customization of golf club  20 . 
     The connection assembly  44  preferably comprises a sleeve  46  and a screw-cap  48 . Connection assembly  44  cooperates with a hosel of club head  22  to secure shaft  24  to club head  22 . Sleeve  46  is mounted on a tip end  50  of shaft  24 . Shaft  24  with sleeve  46  mounted thereon is then inserted in the hosel of club head  22 . Screw-cap  48  secures sleeve  46  to hosel to retain shaft  24  in connection with club head  22 . 
     The sleeve  46 , has an aperture formed in an upper end thereof for receiving tip end of shaft  24 . The sleeve  46  is fixedly secured to shaft  24  using an adhesive, such as epoxy. The sleeve  46  is preferably comprised of a metal material, such as titanium alloys and aluminum alloys. 
       FIG. 3  is a top view of a golf club  20  with a closed face angle. 
       FIG. 3A  is a top view of a golf club  20  in a neutral position with a closed face angle. 
       FIG. 3B  is a top view of a golf club  20  with an open face angle. 
       FIG. 4  is a side view of a golf club  20  with a club head rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 17 degrees. 
       FIG. 4A  is a side view of a golf club  20  with a club head  22  rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 14 degrees. 
       FIG. 4B  is a side view of a golf club  20  with a club head  22  rotated around a shaft axis to obtain a square face angle with a loft angle measured at approximately 12 degrees. 
     As shown in  FIG. 7 , the sleeve  46 , which preferably has an overall length L S  of at least 1.500 inches, includes a body having a top section and a lower splined section  46   a . The top section has an aperture formed therein. The aperture preferably has a diameter D A  that complements the outer diameter of tip end of shaft  24 . A depth L A  of aperture is preferably sufficient to receive at least 1.000 inch of tip end of shaft  24 . In one embodiment of the invention, the depth L A  is approximately 1.126 inches. 
     The lower splined section  46   a  of sleeve  46  has a length L L  preferably in the range of 0.375 inch to 0.525 inch to provided sufficient contact surface area. When the screw-cap is tightened down on the sleeve, the screw-cap forces the multi-faceted lower section of the sleeve against the mating contact surfaces of the lower portion of the hosel of the golf club head, and all rotation is mechanically prohibited. 
     Screw-cap  48 , illustrated in  FIGS. 8-8B , is preferably comprised of a lightweight metal material, such as a titanium alloy or an aluminum alloy. Screw-cap  48  includes a body  80  having a central aperture  82 . Screw-cap  48  is mounted onto shaft  24  over sleeve  46 . Screw cap  48  includes an upper area  84  and a threaded area  86 . Threaded area  86  is provided with a plurality of threads  88 , which engage threads  64  of upper threaded portion  60  of hosel to secure shaft  24  to club head  22 . 
     As illustrated in  FIGS. 5 and 6 , the connection assembly  44  includes the sieve  46 , the screw cap  48  a fastener screw  75 , and a splined tri-lobe  49 , which mates with the splined lower section  46   a  of the sleeve  46 , e  and which preferably prevents movement of the connection assembly  44  and shaft  24  within the hosel of the golf club head  22 . As shown in  FIGS. 5 and 7 , the aperture of the sleeve  46  is offset by at least two degrees relative to a centerline of the sleeve body allows for fitting enhancements by increasing (closing) or decreasing (opening) a golf club&#39;s face angle with small corresponding changes in loft by simple inserting the shaft into one of its three possible positions in the golf club head  22 . 
     Golf club  20  is preferably assembled by placing the screw-cap  48  and the sleeve  46  over the tip end of shaft  24 . The sleeve  46  is preferably secured to shaft  24  by an adhesive, such as epoxy. The tip end of the shaft  24 , with sleeve  46  affixed therein, is then inserted into hosel of club head  22 . The tapered multi-faceted surface of lower tri-lobe  49  engages with a lower portion of the hosel. Next, the screw-cap  48  is slid along the tip end of the shaft  24 , such that its threads  88  engage threads of upper threaded portion of the hosel. A special tool (not shown) may be provided to ensure that screw-cap  48  is properly tightened with the correct amount of torque. When the screw-cap  48  is fully tightened to upper threaded portion of hosel of the club head  22 , the lower end of the screw-cap  48  seats on a ledge of the sleeve  46  to prevent the sleeve  46 , and therefore shaft  24 , from separating from club head  22 . 
     In addition, a compressible polymeric material may be provided on some or all of the threads  88  of screw-cap  48 . Alternatively, the polymeric material may be applied to threads of hosel. When mating threads and  88  of hosel and the screw-cap  48 , respectively, are engaged, the polymeric material is compressed and a counterforce is created. This counterforce creates a stronger contact between the threads of the two components and creates a positive resistance to vibration and loosening. One such material is NYLOK available from Nylok Corporation.  FIGS. 9-11  show various configurations of NYLOK material on screw-cap  48 . In  FIG. 9 , a patch  100  of NYLOK material may be coated over one or more threads  88  of screw-cap  48 . Patch  100  may have a height in the range of 0.01 inch to 0.5 inch, more preferably in the range of 0.04 inch to 0.3 inch, and even more preferably in the range of 0.1 inch to 0.2 inch. Patch  100  preferably covers between one-half and ten threads  88 , and more preferably between one and five threads  88 . Patch  100  may extend completely about one or more threads  88  of screw-cap  48  or only a portion thereof. For example, patch  100  may extend anywhere between 30° and 360° about screw-cap  48 . The thickness of patch  100  is preferably between 0.005 inch to 0.050 inch. 
     In  FIG. 10  a strip  102  of NYLOK material is coated across multiple threads  88  of screw-cap  48 . Strip  102  may have a height in the range of 0.01 inch to 0.5 inch, more preferably in the range of 0.04 inch to 0.3 inch, and even more preferably in the range of 0.1 inch to 0.2 inch. The width of strip  102  may be between 0.01 inch and 0.2 inch, more preferably between 0.02 inch and 0.1 inch. Strip  102  preferably has a thickness of 0.03 to 0.15 inch. 
       FIG. 11  illustrates a pellet  104  of NYLOK material embedded in threads  88  of screw-cap  48 . Pellet  104  may have a diameter of between 0.01 inch and 0.6 inch, more preferably between 0.03 and 0.15 inch. The thickness of pellet  104  is preferably between 0.03 inch and 0.15 inch. 
     From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.