UNIQUELY PATTERNED MULTI-COLORED GOLF CLUB PARTS

Abstract

The invention generally relates to methods for making golf club parts that are multi-colored, each having a unique appearance. The invention provides methods for making golf club parts that have multiple colors so that each part will match a club that features one of the multiple colors. A pattern of multiply-colored molding pellets can be arranged in a club part compression mold. By varying the arrangement, the sizes of the pellets, or the color combinations, batches are made in which all of the parts have the same colors and each part is unique.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/764,167, field Feb. 13, 2013, the contents of which are incorporated by reference.

FIELD OF THE INVENTION

The invention generally relates to methods for making golf club parts that are multi-colored, each having a unique appearance.

BACKGROUND

Golf clubs need to come in different colors to be most useful. Some golfers require a dark-colored club to minimize bright reflections on sunny days while needing a bright colored club for visibility on dark days. Some corporate customers need clubs of a certain color in order to comply with internal branding policies. In some cases, a club manufacturer will act as a licensee providing clubs in “college colors” to campus retailers and alumni foundations.

Unfortunately, designing a good golf club and then manufacturing it in different colors is actually both quite tricky and quite expensive. For one thing, clubs are made up of a number of different parts. The parts can all be different materials and can be made in different ways by different entities. Not only does the manufacturer have to order or make a gross of red crowns, red soles, red shafts, red grips, as well as a gross of green crowns, green soles, etc.—a list that gets quite long—real-world market conditions have expensive consequences. For example, if the green clubs don't sell, then the manufacturer is left with a gross of green club heads, a gross of green shafts, and a gross of green grips, for example. Thus there are real limits to flexibility when a manufacturer tries to fill contracts for colored clubs. It is very difficult to be nimble in responding to ever-evolving market demands.

SUMMARY

The invention provides methods for making golf club parts that have multiple colors so that each part will match a club that features one of the multiple colors. A pattern of multi-colored molding pellets can be arranged in a club part compression mold. By varying the arrangement, the sizes of the pellets, or the color combinations, batches are made in which all of the parts have the same colors and each part is unique. For example, a batch of golf club grip parts or cavity inserts that include a mixture of colors can be used for clubs that are being offered each in one of those colors. If, for example, a manufacturer wants to offer a line of drivers, some of which have a blue crown, some of which have a red crown, and some of which have an orange crown, then the manufacturer can obtain a plurality of grip parts that each include blue, red, and orange. Only a single style of grip need be ordered and it will match all of the drivers. Additionally, the methods disclosed herein give each part a unique appearance, which offers a golfer additional functional benefits. It is understood that people relate to objects through their unique appearance and thus to take a portion of a golf club product that has previously not been given a distinguishing appearance and to give each part a unique appearance assists a golfer in using his clubs. A golfer may grow familiar, for example, with the particular appearance of the grip of his favorite iron. This makes picking up the correct iron out on the course easy and intuitive. Additionally, golfers show a monetary demand for customized golf clubs and a part according to the invention satisfies that requirement in that each piece can be made to have a unique appearance out of all the pieces in a set. Thus, through the use of methods of the invention, a manufacturer can offer golf clubs in different colors without all of the costs and difficulties associated with procuring the right numbers of all of the different parts in the various colors.

In certain aspects, the invention provides a method of making a part by determining a plurality of colors that will each appear on the same component of one of a plurality of golf clubs; obtaining a molding material of each of the colors; making an arrangement of the molding materials for each of the colors all together in each of a plurality of molds; and molding the molding materials with the plurality of molds to produce a plurality of parts.

In some embodiments, the part may be made to further include a customized aspect. For example, the included colors may be chosen as part of a custom order, or the part may be made with an indicia such as text or a logo. For example, a part molded according to methods described herein may be molded or post-processed to include initials, symbols, sayings, etc. A sports team may have its mascot molded into a part or a corporation may have its logo molded into a part. Patterns or indicia may be custom ordered using, for example, an on-line customization and ordering interface.

The molding may be compression molding. The materials can include a plurality of pellets, preferably rubber, of each color. Unique appearances can be augmented by varying the size of the pellets throughout the process, by uniquely arranging the pellets throughout the process, or both.

In some embodiments, the method is useful for making an end cap for a golf club grip. Preferably at least 12 or more (e.g., at least 15 or more) are made, to provide for a golfer's set. More, such as 50 or more (e.g., 144 or more) can be made as a full production run. Whatever number is made, they can all have substantially the same dimensions, and each can have a unique appearance. The unique appearance of each part can be provided by a plurality of colored areas on a surface of the part, each colored area being bounded by an irregular perimeter.

In certain embodiments, the method is useful for making an insert for a cavity-back iron or a back plate of an iron medallion. Such a part may attenuate vibration and would make for a better fit in the back cavity due to the plasticity of the material. Such a part maybe combined with other back plate materials such as, for example, metal, plastic, leather, wood, pearl, marble, etc. The molding methods described herein can be used to create areas with visibly irregular borders and it may be found that such a design is suited for integration with materials that have an otherwise irregular or organic appearance such as leather or wood, due to the fact that the irregular borders of the piece molded according to methods of the present invention may conceal otherwise poor fit between organic and inorganic materials attributable to the micro-irregularities inherent in organic materials. Thus a molding method of the present invention may provide an unexpected utilitarian benefit by creating a process that allows organic materials (leather, wood, pearl, etc.) to be included in golf products otherwise manufactured with inorganic materials (metal, molded plastics, etc.)

In related aspects, the invention provides a plurality of parts for a golf club in which all of the parts have substantially the same shape, dimensions, material, and colors appearing on a surface and each of the parts has a unique pattern of the colors. The part may be a golf club grip or a piece for a golf club grip such as an end cap. In some embodiments, each part comprises at least three colors and all of the parts comprises at least the three colors. For example, each part may have at least four colors, the four colors being in common among all of the parts. The unique pattern of each part may include a plurality of areas with irregular perimeters. The irregular perimeter of each of the plurality of areas defines a surface area unique to that area among the plurality of areas of that part.

The parts can be made of rubber, plastic, or any other moldable material. The color can appear not just on the surface, thus making the appearance of the parts more wear-resistant that prior art parts. For example, the color may extend into a material of the part. The color can in- fact extend throughout the part.

Aspects of the invention provide a set of parts for a golf club. The parts may be end caps for golf club grips, all having substantially the same shape and dimensions, and rubber material. The set can have at least 12 such part (i.e., to cover a golfer's driver, woods, hybrids, and irons) and preferably 14 or 15 to cover an entire set. At least two colors appear on an outside surface of each part. Further, the at least two colors appear on the outside surface as a unique plurality of areas with irregular perimeters. If made by the molding process disclosed, the color appearing on the outside surface will extend through the rubber material to an inside surface.

Preferably, the end caps are made by a method that includes obtaining a molding material of each of the at least three colors; making an arrangement of the molding materials for each of the colors all together in each of a plurality of molds; molding the molding materials with the plurality of molds to produce a plurality of parts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a golf club grip with an end cap according to embodiments of the invention.

FIG. 2 presents two end caps according to certain embodiments.

FIG. 3 gives a detail view of a grip.

FIG. 4 shows a golf club with an end cap.

FIG. 5 illustrates a top view of a golf club with an end cap.

FIG. 6 shows a top view of a golf club with an end cap.

FIG. 7 shows a top view of a golf club with an end cap.

FIG. 8 shows a top view of a golf club with an end cap.

FIG. 9 diagrams a method of making a part.

FIG. 10 depicts molding material.

FIG. 11 gives an arrangement of molding materials.

FIG. 12 illustrates molding material in a mold.

FIG. 13 shows an end cap resulting from an arrangement.

FIG. 14 shows an end cap resulting from an alternative arrangement.

FIG. 15 shows a plurality, or set, of end caps.

FIG. 16 shows two end caps with unique patterns.

FIG. 17 is a perspective view of an end cap.

FIG. 18 presents a side view of an end cap.

FIG. 19 illustrates installing an end cap on a golf club.

FIG. 20 reveals a side view of an alternative end cap.

FIG. 21 discloses another alternative structure for an end cap.

FIG. 22 shows a grip with end cap monolithically molded according to embodiments.

DETAILED DESCRIPTION

The invention provides systems and methods by which a single process can be used to make a plurality of parts that are all made by the same process and that are each unique. Processes and methods of the invention can be used to produce any suitable component of a golf club such as, for example, a grip, an underlisting for a grip, an outer sleeve for an underlisted grip, an end cap for a grip, or a combination thereof. The parts are particularly useful on golf clubs that have a colored surface, particularly where one line of like-styled golf clubs includes clubs with different colors on the surface. Since a part made according to the methods disclosed herein can itself have a surface that is colored, the part can match the golf club. Since each part from a plurality of such parts can have a multi-colored surface, each part will match a golf club, even where the golf clubs have different colors.

FIG. 1 shows a golf club grip 101 with an end cap 105 in which end cap 105 is made by a multi-color molding process. Grip 101 generally includes an elongated body member 109 capable of being mounted on a shaft 117 of a golf club. Additionally, grip 101 may include colored indicia 113. Grip 101 may include any feature or structure known for use in a golf club grip. Grip 101 may include any suitable material such as a rubber, leather, polymer, elastomer, plastic, vinyl, nylon, cork, wood, metal, or any other material. Grip 101 may include an additive in the material to give it color, surface tackiness, weather proofing, durability, or a combination thereof. Structural features suitable for grip 101 include a textured gripping surface, a “reminder” (e.g., a protrusion or asymmetrical portion that can be detected when the club is gripped so a golfer has an intuitive input guiding a proper grip), ridges (e.g., that appear cosmetic but that in-fact play a functional role such as guiding proper installation depth to comply with association rules), embossed or proud indicia or colored indicia (e.g., to communicate functional information about the club or grip), or other features. Golf club grips and feature suitable for them are described in U.S. Pat. No. 8,317,634 to Hachiro; U.S. Pat. No. 3,606,325 to Lamkin; U.S. Pub. 2005/0049071 to Chuang; and U.S. Pub. 2004/0248664 to Billings, the contents of each of which are incorporated by reference for all purposes.

FIG. 1 also introduces a representation of colors. Areas that are hatched in the figures represent colors that appear on the surfaces of the depicted objects. Distinct hatching patterns (e.g., angle of parallel hatching lines relative to the horizontal) represent distinct colors. For the purpose of ease of discussion, exemplary colors are given where, for example, a surface that appears red is represented by hatches of parallel lines making a 90° angle with the horizontal, blue surfaces are hatched with lines that are 0° from the horizontal, green is represented by hatch lines that are −45° from the horizontal, and white surfaces of the depicted objects are un-hatched but specified as being white in this detailed description (otherwise an un-hatched portion of a figure does not specify any color on the depicted object). However, it should be understood that the assignment of particular colors to hatching patterns is arbitrary. The depicted objects could include any colors that are desired (e.g., 90° is orange; 0° is fuchsia; and −45° is lavender).

As shown in FIG. 1, end cap 105 includes red, blue, green, and white portions. Additionally, indicia portion 113 also may include any of the colors that appear on end cap 105. Preferably, each color that appears on end cap 105 will also appear on indicia portion 113. By including this combination of colors on end cap 105, indicia portion 113, or both, grip 101 will match a club that features one of the combination of colors. Thus, if a manufacturer seeks to produce a volume of a given club, each featuring one of the combination of colors, the manufacturer need only have one style of grip produced to have grips that match every club. The inventors have discovered that multi-colored grips and their parts described herein match clubs of differing colors to commercially practicable standards.

Club parts, such as end cap 105, made according to methods of the invention provide an additional benefit in that each part has a unique appearance. In some embodiments, the colored areas on the part define different shape such as irregular, or semi-random, shapes. The irregular, unique patterns of color on each part can be provided by the methods described and disclosed herein.

FIG. 2 presents two end caps 105a and 105b of the invention. End cap 105a has areas that are blue, red, green, and white. End cap 105b also has areas that are blue, red, green, and white. However, end cap 105a does not look the same as end cap 105b. This gives a golfer the ability to make each of his clubs unique. Golfers may grow to become familiar with the unique pattern of an end cap 105 such that the unique pattern serves as a functional identifier of that golf club. Uniquely patterned surfaces serve as functional identifiers in a variety of contexts (e.g., a person can choose the correct denomination of bill from their wallet even without seeing the numeral, a person can recognize individual kittens from a litter, even constellations are known to carry distinct meaning in their unique appearances). The invention employs the insight that uniquely identifying clubs will aid a golfer out on the course. Even when looking at his clubs from the grip end, the golfer can quickly grab his favorite iron without much thought. Looking at FIG. 2, if end cap 105a and end cap 105b were on his clubs, the golfer would quickly be able to recognize which club was which. In addition to providing a unique appearance for each club, the appearance of the end caps can be integrated into the appearance of the club through the inclusion of the optional indicia portions 113.

FIG. 3 gives a detail view of end portions of grip 101. Here, the colors of end cap 105 coordinate with the colors that appear in indicia portions 113. Indicial portions 113 can have any suitable pattern and can include characters, shapes, patterns, and can be smooth or have relief. Inclusion of indicia portions 113 provide a unifying transition element between the unique appearance of end cap 105 and a colored surface of a golf club.

FIG. 4 shows a golf club 119. Golf club 119 is depicted as a wood-style golf club that includes a club head 131 attached to shaft 117 via hosel 127. Wood-style golf clubs include a crown 135 with a large area that is visible to a golfer at address. Golf club 119 may be any style of golf club including, for example, a wood-style club, a hybrid, an iron, a wedge, or a putter. Wood-style clubs include drivers and fairways woods. In certain embodiments, club 119 is a wood style club in which the large surface area of crown 135 includes one of the colors of end cap 105 of grip 109. Since drivers can have some of the larger crown areas of the club styles, the invention may have particular applicability in drivers. In certain embodiments, club 119 is a driver and crown 135 has a surface (e.g., visible to a golfer when the club is at address) that includes one of the colors of grip 109 (e.g., as may be on end cap 105). One of ordinary skill will appreciate that other parts of a club may optionally be colored instead of or as well as a crown of a driver. Other parts that may have color on a surface include shaft 117, ferrule 127, a sole of a head, a medallion of an iron, an insert in an iron, a striking face, or a combination thereof.

FIGS. 5-8 each illustrate a top view of a golf club 119 with a colored portion of crown 135 and an end cap 105. In each of the four cases, the color of crown 135 matches one of the colors of end cap 105. It will be appreciated that a multi-colored part made according to the invention can have any number of colors (e.g., 2, 3, 4, 5, 6, or more). In some embodiments, a multi-color part will have two different colors and will thus match a separate men's and women's versions of a golf club. In certain embodiments, the part will include three colors such as, for example, each of the primary colors. In certain embodiments, the part will include four colors which can be, for example, three colors plus a neutral color (e.g., a pale shade of a minimally-saturated hue). It may be found that it is preferable to include a neutral color (e.g., as the center) in each part. In cases with four colors per part, there may be three or four matching club colors (e.g., each of the four included colors may be matched, or each of the three colors other than a certain one of them may be matched). Choosing the colors and making the parts can proceed according to the methods disclosed herein. Methods of making a part are directed to solving prior art problems with applying and maintaining color designs on a golf club grip, as reported in U.S. Pub. 2012/0309557 to Su, et al., which requires a skin that is separately painted or inked, and unfortunately, still susceptible to having the color scratched off.

FIG. 9 diagrams an inventive method of making a part. Reference 151 is made to colors that will appear on a club 119. A molding material is obtained 155 that can embody those colors.

In some embodiments, the part will be molded and the molding material will include a plurality of colored pellets 175. A unique appearance of each part to be made can be made more apparent by mixing 159 different sizes of the pellets. For example, if a single part is to be molded from about seven pellets, placing a smaller blue pellet adjacent to a larger red pellet in one mold will exaggerate the differences in colored areas on the finished part, particularly where another mold may contain a larger blue pellet adjacent to a smaller red pellet.

The pellets 175 are arranged 163 and a final appearance of a product will relate back to that arrangement. Further exaggeration of the apparentness of the uniqueness of each part can be accomplished by varying 167 the arrangement of pellets from part to part or from batch to batch.

The arranged pellets are placed 171 in a mold and molded 173 to produce the final part. Molding generally employs a pre-formed mold defining the shape of the final part. A method of forming a mold for a golf club grip is discussed in U.S. Pat. No. 6,696,659 to Wallace, the contents of which are incorporated by reference. Those methods of forming a mold can be used to form a mold for an end cap of a grip. The part can be molded by a variety of molding methods that include injection molding and compression molding. The choice of molding method will depend upon factors such as the finish desired, the number of components required, or costs. In general, one or more pieces of uncured rubber is placed between two halves of a heated mold. The mold is closed in a press under a pressure of around 14 MPa and the rubber is forced into the shape of the cavity. The rubber gains heat by conduction from the mold surfaces and “cures”. When the rubber has cured, the mold can be opened and the part removed.

Direct injection molding can use a continuous strip of molding material. A variety of processes are used to produce material suitable for molding. Uncured material can be produced in sheets or materials can be extruded through a die. Extrusions may be cut to required lengths as they emerge from the die. This process can be accurately controlled to produce blanks of precise volume for compression molding. Machines can be manually fed or fed automatically. Automatically-fed multi-color molding machines are discussed in U.S. Pat. No. 4,902,214 to Min, et al. and U.S. Pat. No. 8,153,045 to Boor, the contents of which are incorporated by reference.

In certain embodiments, parts such as end cap 105 are made by compression molding. Compression molding includes applying an optimum amount of heat energy for a certain amount of time. Heating is done by an appropriate technique and force is applied so that the molding material takes the proper shape. The mold may be designed for rapid cooling after the material has been compressed into the mold. Details of the process may be referenced in Peters, S.T., Ed., 1997 HANDBOOK OF COMPOSITES (2ND EDITION), Springer-Verlag (Heidelberg) 1140 pages, and in Isayev, 1987, INJECTION AND COMPRESSION MOLDING FUNDAMENTALS (PLASTICS ENGINEERING), Marcel Dekker, Inc., New York, N.Y., 704 pages, the contents of each of which are incorporated by reference. In certain embodiments, compression molding uses a molding material such as a bulk molding compound (BMC) in the form of pellets.

FIG. 10 depicts molding material, or BMC, in the form of pellets 175. Such molding material include or are referred to as preforms or slugs. Materials that may be used in compression molding include one or a combination of: natural rubber, synthetic rubber, polyester fiberglass resin systems, polyamide-imide, a polyimide-based polymer such as those sold under the trademark VESPEL by E. I. du Pont de Nemours and Company (Wilmington, Del.), poly(p-phenylene sulfide), and many grades of polyether ether ketone. BMC pellets, preforms or slugs, are available from All-Tra Rubber Processing (Tallmadge, Ohio) or Maine Rubber Preforms LLC (Middlefield, Ohio). Molding according to methods disclosed herein may be particularly beneficial in that recycled materials can be used. Using a recycled material may decreases waste, costs, or environmental effects. Recycled materials can be obtained from a variety of source materials including, for example, soles from discarded shoes, old golf club grips, salvaged track or basketball court surfaces that included a soft material.

Pellets 175 are molded by positioning them in a mold cavity. Heated platens are closed by a hydraulic ram. Bulk molding compound (BMC) (e.g., pellets 175) or sheet molding compound (SMC), are conformed to the mold form by the applied pressure and heated until the curing reaction occurs. The mold is then cooled and the part removed. Materials may be loaded into the mold either in the form of pellets or sheet, or the mold may be loaded from a plastic extruder. Materials are heated above their melting points, formed and cooled. Preferably, the molding material and the heat are distributed evenly. Each described step is optional and may be omitted, varied, or modified to optimize the process.

To achieve desired properties, the material of pellets 175 (e.g., rubber) be combined with a range of additives. The additives in a rubber compound may vary from 2-3% to over 60% by weight and may include one or more curatives (to cross-link polymers, e.g., sulphur); accelerators (to vary the speed and timing of the curing reaction); reinforcing fillers (e.g., carbon black or a silica); fillers (to modulate the bulk of compound, e.g., clays); pigments; plasticizers; anti-oxidants; anti-ozonants; or other process aids. Rubber pellets are available from suppliers such as Windrow Inc. (Burton, Ohio). Once the pellets 175 are obtained, they are made into an arrangement for each part, such as for each end cap 105.

FIG. 11 shows an arrangement 179 of pellets 175 for molding. Making the arrangement 179 of pellets 179 in a mold relates to the appearance of the finished part.

FIG. 12 shows the arrangement 179 in a mold 177. For compression molding, pellets 175 may be preheated and are placed in an open, heated cavity of mold 177. Mold 177 is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured. Compression molding is a high-volume, high-pressure method suitable for molding complex, high-strength fiberglass reinforcements. Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. Advantages of compression molding include an ability to mold large, fairly intricate parts; low cost of among molding methods; it wastes relatively little material, giving it an advantage when working with expensive compounds. Molding is particularly good for recycled material since one benefit of the low waste is that few rounds of re-using excess material leftovers, which may be associated with material degradation, are required. Once the pellets 175 are molded in mold 177, an end cap 105 will be produced. All of the end caps from given mold 177 will be the same, but each end cap 105 will have a unique, multi-colored appearance. The appearance relates to the arrangement 179 of pellets 175 in mold 177.

FIG. 13 shows how end cap 105a includes all of the colors of pellets 175 in a unique appearance influenced by arrangement 179a. In certain embodiments, an arrangement preferably has a neutral colored pellet 175 at the center and six pellets embodying other colors distributed around the periphery, as shown in arrangement 179a. The size of the individual pellets 175 varies from arrangement 179 to arrangement 179 as shown in FIG. 13, contributing to the unique appearance of end cap 105.

FIG. 14 shows an end cap 105n with a unique appearance contributed by an arrangement 179n. It is an insight of the invention that using various arrangements 179 of pellets 175 produces a plurality of parts that all have the same colors in common but that each has a unique pattern of colors. Use of different colored molding materials is discussed in U.S. Pat. No. 5,670,228 to Kakuma, the contents of which are incorporated by reference for all purposes. Any number of end cap 105 can be produced to these standards. For example, multiples of a grosses can be produced (e.g., 144, 144×12, etc.). In certain embodiments, multi-colored parts for golf clubs are made as sets. The number of parts in a set may relate to Rule 4 of the rules of golf limiting play to a set of 14 clubs. Some golfers may want a set of parts for their clubs, and accordingly, may want 14 parts. Some golfers may have a set of more than 14 clubs (e.g., 18), of which they take 14 clubs to the course on any given day, for which they want the same number (e.g., 18) of parts. Some golfers may have one club which does not need a part for extrinsic reasons (e.g., some putters, in particular, are made and sold separately with their own requirements regarding appearance and finishes) and thus may need only 13 parts such as 13 of end cap 105.

The part made by methods described herein may be an insert for a cavity-back iron or a back-plate of an iron medallion (i.e., useful for vibration dampening). Such a part maybe combined with other materials such as, for example, metal, plastic, leather, wood, pearl, marble, or others. Parts may include visual designs with irregular shapes and it may be found that such a design is suited for integration with materials that have an otherwise irregular appearance to allow for more relaxed manufacturing tolerances when those materials are to be used. Thus a molding method of the present invention may provide an unexpected utilitarian benefit by creating a process that allows organic materials (leather, wood, pearl, etc.) to be included in golf products otherwise manufactured with inorganic materials (such as metal or molded plastics).

FIG. 15 shows a plurality, or set, of end caps, 105a, 105b, . . . 105o, here shown to include 15 of the part. Fifteen is a good number for a set because if one of the parts has a pattern that does not satisfy some standard (e.g., matches another one too closely), it can be discarded and the set can be used on one entire set of clubs. As noted with respect to FIG. 14, the appearance of the parts can be varied by varying the arrangement. Even for any given arrangement, each part will have a unique appearance due to size and placement variation that may be effectively random. However, an average size of pellets 175 may be controlled (e.g., varied) to create sets with different overall properties.

FIG. 16 shows two end caps 105n and 105p that have properties in common and in which those properties vary from the set of end caps, 105a, 105b, . . . 105o shown in FIG. 15. Here, larger pellets 175 may be used to accomplish the depicted appearance.

Where the part is an end cap, one of skill in the art will recognize that molding can be used to prepare different styles of end cap for use with different styles of grip. Any style of end cap can be made, including ones that are integrated with an overall grip as well as ones that are attached to a grip after being made.

FIG. 17 is gives a perspective view of end cap 105. This type of “plug-style” end cap 105 may be used with certain corresponding grips. In general, end cap 105 includes a head with a certain diameter and a protruding tail section with a smaller diameter.

FIG. 18 gives a side view of end cap 105.

FIG. 19 shows the installation of end cap 105 onto a grip. End cap 105 can be made to attach to grip 109 through the use of adhesives, press fit, a clasp or barb, a threading mechanism, or any other suitable mechanism. Attachment of an end cap is described in U.S. Pat. No. 8,272,973 to Lu; U.S. Pat. No. 4,195,837 to Poulin; and U.S. Pub. 2006/0172815 to Chu, the contents of each of which are incorporated by reference for all purposes.

FIG. 20 presents a side view of an end cap 106 for use with a threaded grip or club part. End cap 106 includes a head with a first diameter and a protruding tail, generally with a smaller diameter. The head may generally have disk shape. The protruding tail will generally have a cylindrical form in which an outer surface bears spiral threads for making a threaded attachment to a corresponding part such as a grip. A threaded tail end cap 106 may be most useful for a removable/ replaceable end cap (e.g., for a grip 109 that houses a component to which a golfer needs access, such as a battery).

FIG. 21 discloses an end cap 107 with a simple disk shape. End cap 107 has a bottom surface that extends continually within a plane from a center in all radial directions to an extremity of the surface. That is, the bottom is substantially flat. End cap 107 is of a design that may be suited for attaching to a grip that is designed for a flat end cap (e.g., with no recess for a protruding tail). End cap 107 may be attached with an adhesive, heat fusing, or other means. End caps are discussed in U.S. Pat. No. 3,360,264 to Lamkin; U.S. Pat. Nos. 1,931,425 and 1,931,424 to Barrett; U.S. Pub. 2008/0161123 to Han; and U.S. Pub. 2007/0219015 to Gazeley, the contents of each of which are incorporated by reference for all purposes. Additionally, methods of the invention can be used to produce entire grips or other parts for a golf club.

FIG. 22 shows a grip 108 with end cap monolithically molded according to embodiments. One of ordinary skill in the art will recognize that the methods described above can be used to mold an entire grip as a part, to provide a plurality of parts (e.g., grips). All of the plurality of parts have a combination of colors in common, appearing on a surface, and each of the plurality of parts has a unique pattern of the colors appearing on the surface.

A golf club part may include a customized aspect. For example, the included colors may be chosen as part of a custom order, or the part may be made with an indicia such as text or a logo. A part molded according to methods described herein may be molded or post-processed to include initials, symbols, sayings, or other such material. Patterns or indicia may be custom ordered using, for example, an on-line customization and ordering interface. In certain aspects, the invention provides systems and methods for providing a customized golf club part. Systems and methods include using a server computer comprising a processor coupled to a non-tangible memory to receive order information from a customer. The received order information preferably pertains to the use of certain colors or materials for a yet un-made golf club part. Materials are obtained that satisfy the order information and used in a molding process described herein. The server computer is used to receive, store, and queue customer orders. In some embodiments, the server computer will obtain a large number of customer orders (e.g., >100, possibly >500) and will organize those orders into batches according to molding materials called for by each order. Thus—for example—all of the orders that require red, white, and blue pellets of molding material will be queued for product for first. In certain embodiments, the server computer will queue the batches so that each batch has some property in common with the batch that precedes it, the batch that follows it, or both. For example, after a red, white, and blue batch, the server computer may send all through all the orders calling for red, white, and green. Then the server computer may send through all orders calling for red, green, and yellow. Then the server computer may send through all the orders calling for red, yellow, and black. The preceding example may be used, for example, where a golf company is producing a run of parts with various national colors and the represented nations may be, in order, U.S.A., France, Italy, Jamaica, Germany. Thus the server computer accomplishes significant time and effort savings on the production floor, as only one variable needs be changed between runs. Order information can be received from a customer through the customer's use of a client computer (e.g., a laptop, desktop, or tablet computer). In general, any computer will include at least processor, at least one tangible, non-transitory memory device, and at least one input/output device, all communicatively coupled by, e.g., a bus. A processor can be any chip such as one of those sold by Intel or AMD. A memory device may include RAM, ROM, or both, and can be, for example, a solid-state hard drive (SSD), flash memory, a disk drive, or other memory. Input/output devices include monitors, keyboards, pointers (e.g., a mouse), Wi-Fi cards, network interface cards, cell modems, radio antenna, or others. Computer can share information via communications networks that include the internet, cellular phone networks, local area networks, others, or a combination thereof, as will be apparent to one of skill in the art.

As used herein, the word “or” means “and or or”, sometimes seen or referred to as “and/or”, unless indicated otherwise.

Incorporation by Reference

References and citations to other documents, such as patents, patent applications, patent publications, journals, books, papers, web contents, have been made throughout this disclosure. All such documents are hereby incorporated herein by reference in their entirety for all purposes.

Equivalents

Various modifications of the invention and many further embodiments thereof, in addition to those shown and described herein, will become apparent to those skilled in the art from the full contents of this document, including references to the scientific and patent literature cited herein. The subject matter herein contains important information, exemplification and guidance that can be adapted to the practice of this invention in its various embodiments and equivalents thereof.

Claims

1. A method of making a part for a golf club, the method comprising:

determining a plurality of colors that will each appear on the same component of one of a plurality of golf clubs;

obtaining a molding material for each of the colors;

making an arrangement of the molding materials for each of the colors all together in each of a plurality of molds; and

molding the molding materials with the plurality of molds to produce a plurality of parts.

2. The method of claim 1, wherein the molding materials comprise a plurality of pellets of each color.

3. The method of claim 2, further comprising varying the size of the pellets throughout the process.

4. The method of claim 2, wherein the pellets comprise rubber.

5. The method of claim 1, wherein the molding comprises compression molding.

6. The method of claim 1, wherein each of the plurality of parts comprises an end cap for a golf club grip.

7. The method of claim 1, wherein each of the arrangements comprises a uniquely-arranged pattern of the molding materials.

8. The method of claim 1, further comprising producing at least 15 parts, all having substantially the same dimensions, and each having a unique appearance.

9. The method of claim 8, wherein the unique appearance of each part comprises a plurality of colored areas on a surface of the part, each colored area being bounded by an irregular perimeter.

10. The method of claim 6, wherein the arrangement includes a neutral colored molding material at a center of the arrangement.

11. A plurality of parts for a golf club comprising:

a plurality of a part, wherein all of the parts comprise substantially the same shape, dimensions, material, and colors appearing on a surface and each of the parts comprises a unique pattern of the colors.

12. The parts of claim 11, wherein the part is an end cap for a golf club grip.

13. The parts of claims 11, wherein, the plurality comprises at least 50 of the part.

14. The parts of claim 11, wherein each part comprises at least three colors and all of the parts comprises at least the three colors.

15. The parts of claim 11, wherein each part comprises at least four colors, the four colors being in common among all of the parts.

16. The parts of claim 11, wherein each part is attached to a golf club grip, and a surface of the golf club grip includes one or more indicia having the colors.

17. The parts of claim 11, wherein the unique pattern of each part comprises a plurality of areas with irregular perimeters.

18. The parts of claim 17, wherein the irregular perimeter of each of the plurality of areas defines a surface area unique to that area among the plurality of areas of that part.

19. The parts of claim 11, wherein each color appearing on the surface extends into a material of the part.

20. The parts of claim 19, wherein each color extends continually through the material to an opposed surface.

21. A set of parts for a golf club comprising:

at least 14 golf club grip components, all comprising: substantially the same shape and dimensions, a rubber material, and at least two colors appearing on an outside surface,

further wherein, on each of the at least 14 golf club grip components, the at least two colors appear on the outside surface as a unique plurality of areas with irregular perimeters.

22. The set of claim 21, wherein each color appearing on the outside surface extends through the rubber material to an inside surface.

23. The set of claim 21, wherein the at least 14 golf club grip components are made by a method comprising:

obtaining a molding material of each of the at least two colors;

making an arrangement of the molding materials for each of the colors all together in each of a plurality of molds;

molding the molding materials with the plurality of molds to produce a plurality of parts.

24. The set of claim 23, wherein the method further comprises varying the size of the pellets throughout the process.

25. The set of claim 23, wherein the molding materials comprise a plurality of pellets of each color and the molding comprises compression molding.

26. The set of claim 23, wherein each of the arrangements comprises a uniquely-arranged pattern of the molding materials.