Abstract: Improved methods for manufacturing a shaft for a golf club, devices useful in such methods, and golf club shafts manufactured in accordance with such methods. A plug is detachably affixed to a distal end of a mandrel. A plurality of plies pre-preg composite sheet are wrapped around the mandrel and plug and, thereafter, heated causing the resin comprising the various plies to be cured. The mandrel is then removed from the formed shaft, leaving the plug as an integral part of the distal tip of the shaft.

Abstract: An improved shaft for a golf club and methods of manufacturing the same. A plurality of layers of composite fiber bound within a thermoset resin are bonded to one or more layers of composite fiber bound within a thermoplastic resin using a high peel strength nylon epoxy adhesive. Preferably, the layer(s) of composite fiber bound within the thermoplastic resin comprise the outermost layer of a golf club shaft.In one preferred form, a plurality of plies of pre-preg composite sheet including a thermoset resin are wrapped around a mandrel and pre-cured. Thereafter, a layer of adhesive is wrapped over the pre-cured plies, at least one ply of pre-preg composite sheet including a thermoplastic resin is wrapped over the adhesive, and a cellophane or polypropylene tape is wrapped over the outermost layer of pre-preg. Thereafter, the ply wrapped mandrel is placed in a mold and heated to a predetermined temperature for a time sufficient to allow curing of all of the plies comprising the golf club shaft.

Abstract: The present invention relates to an improved apparatus and method for manufacturing shafts from composite materials, particularly shafts for golf clubs. An elongate mandrel, having a passage therein and having a plurality of holes between the passage and an outer surface of the mandrel, includes a flexible bladder, preferably latex, dipped and cured directly on the outer surface of the mandrel. A set of plies of pre-preg composite sheet is wrapped around the mandrel in a predetermined manner. The wrapped mandrel is placed in a mold, the bladder is inflated to a predetermined pressure. The pressurized wrapped mandrel is then heated for a predetermined period of time to cure the composite material to form a shaft, preferably for a golf club. While the shaft is cured in the mold, gas of a predetermined pressure is introduced through the passage in the mandrel to inflate the bladder and force the composite sheet against the walls of the mold.

Abstract: A golf club head having a face insert plate. The face insert plate is affixed to a faceplate mounting surface wherein a plurality of channels are formed. The channels preferably have a depth that is increased in a lower region of a face of the club head. An elastomeric binding material and damping agent is provided within the channels to affix the face insert plate to the face plate mounting surface and to provide a vibration damping function. In a preferred form, the faceplate mounting surface comprises a base wall of a face insert receiving cavity or recess that is formed within a main body of the club head.