US20160059095A1

US20160059095A1 - Mutli-Color Golf Club and Process for Producing Same

Info

Publication number: US20160059095A1
Application number: US14/472,008
Authority: US
Inventors: David Hodgson
Original assignee: Hodgee Custom Shafts LLC
Current assignee: Hodgee Custom Shafts LLC
Priority date: 2014-08-28
Filing date: 2014-08-28
Publication date: 2016-03-03

Abstract

The present disclosure provides a process for producing a multi-color golf club shaft and the resultant multi-color golf club. The process includes providing a golf club shaft and first applying a first color powder coating material onto at least a portion of the shaft to form a first powder coated shaft. The process includes melt-adhering the first color powder coating material to at least a portion of the shaft to form a first color coated shaft. The process includes second applying a second color powder coating material onto at least a portion of the shaft. The process includes curing the shaft and forming a multi-color powder coating adhered to at least a portion of the shaft.

Description

BACKGROUND

The present disclosure is directed to a golf club with a shaft having a multi-color coating and a process for producing the multi-color coating.
Customization of golf clubs to individual users is a growing trend in the golfing industry. Many options for customization are available to today's golfer including interchangeable grips, tailored club sizing, and selection of club color. Despite the many customization options available, the options for a multi-color golf club are lacking. Conventional approaches apply a colored decal onto a mono-color shaft or apply a colored shrink wrap to the club shaft. Decals and shrink wrap lack permanence and they also detract from the appearance of a high quality golf club.
The art therefore recognizes the need for golf clubs with shafts that can be customized with multiple colors. The art further recognizes the need for multi-color shafts that can be tailored to an individual's preference.

SUMMARY

The present disclosure provides a process for producing a multi-color powder coating on a golf club shaft having at least two colors. The present disclosure is directed to aesthetic enhancement of the shaft and provides a unique way to individualize golf clubs. The present process applies at least two decorative colors to the shaft while simultaneously maintaining the physical demands of the club (flex strength, tensile strength, re-coil) without the colors cracking, peeling, chafing, flaking from the shaft.
The present disclosure provides a process. In an embodiment, a process for producing a multi-color golf club is provided and includes providing a golf club shaft and first applying a first color powder coating material onto at least a portion of the shaft to form a first powder coated shaft. The process includes melt-adhering the first color powder coating material to at least a portion of the shaft to form a first color coated shaft. The process includes second applying a second color powder coating material onto at least a portion of the shaft. The process includes curing the shaft and forming a multi-color powder coating adhered to at least a portion of the shaft.
The present disclosure provides an article. In an embodiment, a golf club is provided and includes a steel shaft. The steel shaft includes a multi-color powder coating adhered to at least a portion of the shaft.
An advantage of the present disclosure is a process for producing a multi-color golf club that is customized to an individual's desired color preferences.
An advantage of the present disclosure is a way to attract new participants to the sport of golf by enabling the new golfer to tailor her golf clubs to her personal multi-color palette.
An advantage of the present disclosure is a multi-color golf club that makes the golf experience more personable, and delivers individuality to an otherwise commoditized sporting good item.
An advantage of the present disclosure is a multi-color golf club that conforms to the United States Golf Association (USGA) rules for golf clubs and simultaneously allows a golfer to showcase individuality.
An advantage of the present disclosure is a golf club that couples artistic design and sport performance while conforming to the USGA rules for golf clubs.
An advantage of the present disclosure is a multi-colored golf club that brings enjoyment to the golf club owner.
An advantage of the present disclosure is the ability for a golfer to express herself through her golf clubs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a golf club.

FIG. 2 is a schematic representation of the application of a color powder coating material to a golf club shaft in accordance with an embodiment of the present disclosure.

FIG. 3 is schematic representation of a process of producing a 2-color fade area in accordance with an embodiment of the present disclosure.

FIG. 4 is a schematic representation of a process for producing a 2-color fade area in accordance with an embodiment of the present disclosure.

FIG. 4A is an enlarged view of area 4A of FIG. 4.

FIG. 4B is an enlarged view of area 4A of FIG. 4 after formation of a multi-color powder coating in accordance with an embodiment of the present disclosure.

FIG. 5 is a perspective view of a golf club having a multi-color powder coating adhered to the shaft in accordance with an embodiment of the present disclosure.

FIG. 5A is an enlarged view of area 5A of FIG. 5.

FIG. 6 is a perspective view of a golf club having a multi-color powder coating adhered to the shaft in accordance with an embodiment of the present disclosure.

FIG. 6A is an enlarged view of area 6A of FIG. 6.

DETAILED DESCRIPTION

The present disclosure provides a process for producing a multi-color golf club. In an embodiment, the process includes providing a golf club shaft, and applying a first color powder coating material and a second color powder coating material onto at least a portion of the shaft to form a powder coated shaft. The process may include blending the first color powder coating material with the second color powder coating material so that the two colors gradually fade together. Alternatively, the first color powder coating material and the second color powder coating material are applied to form a sharp contrast or a crisp delineation or cut-off line between the two colors. The process includes melt-adhering the color powder coating to the shaft to form a color coated shaft. The process includes curing the shaft and forming a multi-color coating on at least a portion of the shaft.
In an embodiment, the process includes providing a golf club shaft (or shaft), and first applying a first color powder coating material onto at least a portion of the shaft to form a first powder coated shaft. The process includes melt-adhering the first color powder coating to the shaft to form a first color coated shaft. The process includes applying a second color powder coating material to at least a portion of the shaft. The process includes curing the shaft and forming a multi-color powder coating on at least a portion of the shaft.
The present process includes providing a golf club shaft. A golf club 10 includes a shaft 12, a grip 14, and a head 16 as shown in FIG. 1. The shaft 12, subject to the present process, may be provided before assembly of the golf club, may be a component of the golf club, or may be disassembled from the golf club. The shaft 12 is made of a metal or a carbon material (such as graphite). The shaft is tubular in shape and is in the form of a pipe. The inside of the tube is open to the outside at each end thereof. The head 16 is fitted onto a distal end of the shaft 12, and the grip 14 is fitted onto a proximal end of the shaft 12. The shape of the shaft is formed so as to have a diameter that is increasingly tapered toward the distal end onto which is fitted the head 16. The tapered feature can be stepped or stepless. The golf club 10 can be a wood club, an iron club, a hybrid club or a putter.
The shaft 12 may be made of steel or graphite. In an embodiment, the shaft 12 is a steel shaft. Nonlimiting examples of suitable steel shafts include non-plated steel, nickel-plated steel, nickel-chrome plated steel, chrome-plated steel, stainless steel or steel that s otherwise provided with a protective, corrosion resistant, or other exterior layer, typically a metallic exterior layer.
In an embodiment, the shaft 12 is a graphite shaft. Nonlimiting examples of suitable graphite shafts include carbon shafts, carbon fiber shafts, and graphite shafts.
In an embodiment, the process includes providing a golf club, removing the grip and the head from the shaft. The process further includes providing the bare shaft for further processing.
In an embodiment, the process includes cleaning the shaft to remove oil and dirt from the shaft surface. The cleaning step may include washing the shaft with a cleanser and water, wiping the shaft with a towel, and combinations thereof.
In an embodiment, the process includes sanding the shaft with an abrasive material to roughen the shaft surface prior to the multi-color coating procedure.
In an embodiment, the process includes pre-heating, before the first applying step, the shaft to a temperature from 250° F. to 400° F. In a further embodiment, the process includes pre-heating, before the first applying step, the shaft to a temperature from 250° F., or 251° F., or 275° F., or 300° F., or 325° F. to 350° F., or 375° F., or 399° F., or 400° F.
1. First Color
The process includes first applying a first color powder coating material to at least a portion of the shaft to form a first powder coated shaft. The first color powder coating material is a polymer resin and includes curatives, pigments, leveling agents, flow modifiers, and other additives. The first color powder coating material may be a single color or a blend of two or more colors. In an embodiment, the first color powder coating material is applied to the shaft by way of electrostatic spray deposition (ESD). The first applying step includes electrically charging the first color powder coating material and spraying the electrically charged first color powder coating material onto the shaft. The first color powder coating material is an electrostatic material. The first color powder coating material is loaded to an electrostatic gun which imparts a positive electric charge to the first color powder coating material. An electrostatic gun 18 is then used to spray the electrically-charged a first color powder coating material 20 onto the surface of shaft 12 as shown in FIG. 2.
Nonlimiting examples of suitable materials for the first color powder coating material include polyurethane powder coating material, polyester powder coating material, epoxy powder coating material, epoxy-polyester (hybrid) powder coating material, and combinations thereof.
Prior to spraying the electrically-charged first color powder coating material, the shaft is grounded as shown in FIG. 2. Grounding the shaft enables electrostatic adsorption of the color powder coating particles to the shaft surface. The powder coating material particles electrostatically bind to the shaft surface to form a first powder coated shaft. In an embodiment, the shaft is grounded by hanging the shaft from a conductive material such as a metal wire.
The first applying step applies a uniform layer of the first color powder coating material onto the shaft. The first applying step coats (i) one or more portions of the bare shaft, (ii) some of the shaft, or (iii) all of the shaft with the first color powder coating material. The first applying step forms a first powder coated shaft 22 as show in FIG. 2.
2. Melt-Adhering
The process includes melt-adhering the color powder coating material(s) to the shaft to form a color coated shaft. The melt-adhering step may be performed after the first applying step (and before the second applying step), or after the first applying step and after the second applying step.
In an embodiment, the melt-adhering step is performed after the first applying step. The first powder coated shaft is composed of particles that are electrostatically bound to the shaft surface. Handling or touching the shaft at this stage can move or otherwise disrupt an even coating of the electrostatically bound particles. The process includes melt-adhering the first color powder coating material to the shaft to form a first color coated shaft. The melt-adhering includes heating the first color powder coated shaft for a duration from 1 minute to 15 minutes at a temperature from 200° F. to 400° F.
In an embodiment, the melt-adhering step includes placing the first powder coated shaft in an oven and heating for a duration from 5 minutes, or 6 minutes, or 7 minutes to 8 minutes, or 9 minutes, or 10 minutes, or 11 minutes, or 12 minutes, or 13 minutes, or 14 minutes, or 15 minutes at a temperature from 350° F., or 360° F., or 370° F., or 375° F. to 380° F., or 390° F., or 399° F., or 400° F. The melt-adhering step melts, or partially melts, the first color powder coating material so that the first color powder coating material adheres to the shaft surface.
In an embodiment, the melt-adhering step does not fully cure the first color powder coating material to the shaft. The shaft is heated to melt, or partially melt, the first color powder coating material. The melt/partial melt adheres the particles of the first color powder coating material to the shaft to the extent that the shaft can be handled and manipulated for further processing without removal or disruption of the particles from the shaft surface. The melt-adhering step is not a full cure step. The melt-adhering step as a “partial cure step” advantageously permits further color blending, contributes to a vivid 2-color fade area, and/or permits further design work to be performed on the shaft.
In an embodiment, the process includes cooling, after the melt-adhering, the first color coated shaft for a duration from 5 minutes, or 10 minutes to 15 minutes, or 20 minutes before commencement of the second applying step.
3. Second Color
The process includes second applying a second color powder coating material onto at least a portion of the shaft. The second color powder coating material is a polymer resin and includes curatives, pigments, leveling agents, flow modifiers, and other additives. The second color powder coating material may be a single color or a blend of two or more colors. The second color powder coating material has a color (or colors) that is (are) different than the color(s) of the first color powder coating material. The second applying step may be performed simultaneously, substantially simultaneously, or after the first applying step.
In an embodiment, the second applying step is performed after the melt-adhering step. The second color powder coating material is applied to the shaft by way of electrostatic spray deposition (ESD). The second applying step includes electrically charging the second color powder coating material and spraying the electrically charged second color powder coating material onto at least a portion of the shaft. The second color powder coating material is an electrostatic material. The second color powder coating material is loaded to an electrostatic gun which imparts a positive electric charge to the second color powder coating material. The electrostatic gun is then used to spray the electrically-charged second color powder coating material onto the shaft surface.
Nonlimiting examples of suitable materials for the second color powder coating material include polyurethane powder coating material, polyester powder coating material, epoxy powder coating material, epoxy-polyester (hybrid) powder coating material, and combinations thereof.
Prior to spraying the electrically-charged second color powder coating material, the shaft is grounded as previously described. Grounding the shaft contributes to the static electrical attraction and contact between the charged second color powder coating material particles and the shaft surface. The second color powder coating material particles electrostatically adsorb to the shaft surface to form the coated shaft.
In an embodiment, the process includes heating the first color coated shaft to a temperature from 250° F., or 251° F., or 275° F., or 300° F., or 325° F. to 350° F., or 375° F., or 399° F., or 400° F. before performing the second applying step.
The second applying step coats one or more: (iv) portions of the bare shaft; (v) portions of the first color coated shaft; or (vi) a combination of (iv) and (v). The second applying step forms a powder coated shaft, such as a second powder coated shaft.
It is understood that additional color powder coating materials (third, fourth, fifth, sixth color powder coating materials) may be used so that the present process may include a third applying step, a fourth applying step, a fifth applying step, a sixth applying step to form a multi-color shaft with three, four, five, six, or more different colors. The melt-adhering step may or may not be performed between any subsequent applying steps.
In an embodiment, the process includes performing the melt-adhering step after the second applying step and subsequently third applying a third color powder coating material onto the second color coated shaft. The shaft is heated to a temperature from 250° F., or 251° F., or 275° F., or 300° F., or 325° F. to 350° F., or 375° F., or 399° F., or 400° F. before the third applying step.
In an embodiment, the process includes performing the melt-adhering step after the third applying step and subsequently fourth applying a fourth color powder coating material onto the third color coated shaft. The shaft is heated to a temperature from 250° F., or 251° F., or 275° F., or 300° F., or 325° F. to 350° F., or 375° F., or 399° F., or 400° F. before the fourth applying step.
In an embodiment, the first applying step and the second applying step are performed before the melt-adhering step.
4. Optional Clear Coat
The process may include an optional clear coat step. In an embodiment, the process includes applying, before the curing, a clear coat material to the shaft. The clear coat material is a polymer resin and includes curatives, leveling agents, flow modifiers, and other additives. Pigment is absent in the clear coat material. Nonlimiting examples of suitable materials for the first color powder coating material include polyurethane powder coating material, polyester powder coating material, epoxy powder coating material, epoxy-polyester (hybrid) powder coating material, and combinations thereof.
5. Cure
The process includes curing the coated shaft (i.e., the second color coated shaft) and forming a multi-color powder coating that is adhered to at least a portion of the shaft. The cure step fully melts the first color powder coating material, the second color powder coating material, and the optional clear coat material to form a permanent, uniform and integral multi-color coating layer on the shaft. During the cure step, the color powder coating materials melt and chemically react to produce long molecular chains, resulting in high cross-link density. These molecular chains are resistant to breakdown to produce a permanent and durable multi-color powder coating on the shaft. The term “multi-color coating” is a coating having at least two different colors. The present multi-color coating adhered to the shaft is distinct from a shaft with single color. The present multi-color coating on the shaft is distinct from a shaft with single color that varies in intensity. For example, the present “multi-color coating adhered to the shaft” includes a coating with a first color such as orange and a different second color, such as blue. The present “multi-color coating” is distinct from a shaft that is colored with a single color that transitions from a deep hue (such as a deep blue) on one end of the shaft, the intensity of the deep hue diminishing to a less-intense or lighter hue of the same color (such as a light blue) as one moves to the other end of the shaft.
The curing step firmly and permanently adheres the multi-color powder coating to the shaft. The multi-color coating does not flake, does not peel from the shaft. The present multi-color coating is a multi-color powder coating and is distinct from other types of coatings such as airbrush coating and brush coating. Compared to airbrush coating and brush coating, the present multi-color powder coating is more durable, and has greater impact resistance, greater moisture resistance, greater chemical resistance, greater scratch resistance, greater abrasion resistance, greater chip resistance, greater fade resistance, greater chip resistance, greater corrosion resistance, and greater wear resistance.
In an embodiment, the process includes curing the coated shaft for a duration from 5 minutes, or 6 minutes, or 7 minutes or 8 minutes, or 9 minutes or 10 minutes to 11 minutes, or 12 minutes, or 13 minutes, or 14 minutes, or 15 minutes, or 16 minutes, or 17 minutes, or 18 minutes, or 19 minutes, or 20 minutes at a temperature from 325° F., or 330° F., or 350° F., or 375° F. to 380° F., or 385° F., or 390° F., or 395° F., or 399° F., or 400° F.
In an embodiment the process includes applying a clear coat to the shaft and curing to form a multi-color powder coating adhered to the shaft, the multi-color powder coating having a smooth and a uniform finish.
In an embodiment, the process includes forming a multi-color coating having a thickness from 0.05 mil to 0.30 mil. In a further embodiment, the process includes forming a multi-colored coating having a thickness from 0.05 mil, or 0.10 mil, or 0.15 mil to 0.20 mil to 0.25 mil, to 0.30 mil.
In an embodiment, the process includes placing a sleeve 24 around a portion of the shaft and covering a portion of a first color coated shaft 22 with the sleeve 24 as shown in FIGS. 3-4. The sleeve 24 is an annular structure. A distal end of the sleeve 24 defines a fade area 28, where a portion of the first color coated shaft 22 is exposed, as shown in FIG. 4. The process includes applying a varying amount (such as a reduced amount) of a second color powder coating material 26 to the fade area 28 and forming a 2-color fade area 30 on the shaft.
It is difficult to apply color powder coating material to an object with precision. The grounded shaft attracts the electrostatically charged particles as they leave the spray gun. Even with fine spray nozzles, the charged color powder coating material particles tend to disperse beyond the intended spray area. This phenomenon is known as overspray. The present the process includes protecting a portion of the first color coated shaft from overspray that occurs during the second applying step. Applicant discovered that utilization of the sleeve 24 advantageously enables the formation of a compact and a controlled 2-color fade area on the shaft.
A “2-color fade area” is an area on the shaft where a first color transitions to a second color and vice versa. The 2-color fade area is distinct from a mono-color fade whereby the intensity of a single color transitions from a dark hue to a lighter hue.
FIG. 4A is an enlarged view of area 4A of FIG. 4. FIG. 4A shows a 2-color fade area 30 where a varied amount of the second color powder coating material 26 forms crisp and irregular protrusions 32 of the first color 22 (into second color 26) and crisp and irregular protrusions 34 of second color 26 (into first color 22).
FIG. 4B shows the 2-color fade area 30 after the cure step. In FIG. 4B, the second color powder coating material 26 forms second color 26 that is a component of the uniform multi-color powder coating (with first color 22 and second color 26) that is permanently adhered to the shaft 12. In an embodiment, the 2-color fade area 30 has a length from 0.5 inch, or 1.0 inch, or 1.5 inches, or 2.0 inches, or 2.5 inches, or 3.0 inches, or 3.5 inches, or 4.0 inches, or 4.5 inches, or 5.0 inches, or 5.5 inches, or 6.0 inches. The length of the fade area 30 is defined by the longest extent of the protrusions 32 and 34 as shown by distance A in FIG. 4B.
It is understood that that the first applying step can include varying (i.e., reducing) the amount of the first color powder coating material 22 in the fade area 28 to further accentuate the transition between the two colors 22 and 26 in the fade area 28.
When three, four, five or more color powder coating materials are used, a further embodiment of the process includes forming two, or three, of four, or five, or more 2-color fade areas on the shaft. FIG. 5 shows a shaft 12 with a multi-color powder coating permanently adhered to the shaft. The multi-color powder coating includes a first color 36, a second color 38, and a third color 40. The multi-color coating includes a first 2-color fade area 42 and a second 2-color fade area 44. The first color 36 is formed by way of the first applying step. The second color 38 and the two-color fade area 42 are formed by varying the amount of the second color powder coating material during the second applying step. The second applying step includes reducing the amount of the second color powder coating material sprayed, onto the shaft to form the 2-color fade area 42. The third color 40 and the 2-color fade area 44 are formed by varying the amount of the third color powder coating material during a third applying step. The third applying step includes reducing the amount of the third color powder coating material sprayed onto the shaft to form the 2-color fade area 44.
In an embodiment, the process includes placing a masking material on at least one area of the shaft and applying a color powder coating material onto the shaft. The masking material may be placed in direct contact with the bare shaft (i.e., the shaft prior to any applying step). Alternatively, the masking material may be placed on the first color coated shaft after the first applying step, after the melt-adhering step and before the second applying step. The masking material covers an area of the shaft (or covers an area of the color coated shaft) preventing color powder coating material from adsorbing to the shaft surface covered by the masking material and permitting color powder coating material to electrostatically adsorb to shaft surface exposed by the masking material.
The masking material may or may not include ornamentation. In an embodiment, the masking material includes ornamentation. A nonlimiting example of masking material with ornamentation is masking tape with one or more cut-outs. The cut-out can be a profile, a shape and/or an object such as circle, square, triangle, dot(s), polka dots, rectangle, bull's eye, stripes, spirals, star, heart, moon, half-moon, mascots, logos (business logo, sports logo), letters, words, numbers, animals, and insects. A nonlimiting example of a masking material with ornamentation is a stencil-paper (with cut-out(s) described above) that can be releasably attached to the shaft. In this sense, an “ornamentation” is an embellishment formed by a masking material, the ornamentation is a component of the final multi-color powder coating, the ornamentation composed of one or more color powder coating material(s).
FIG. 5 shows a multi-color coated shaft 12 whereby a masking material is used to produce an ornamentation 46 on the multi-color powder coating. In an embodiment, the process includes placing the masking material (which may include a cut-out) on the first color 36 (first color coated shaft), and/or placing the masking material (which may include a cut-out) on the second color 38 (second color coated shaft), and/or placing the masking material (which may include a cut-out) on the third color 40 (the third color coated shaft), or any combination thereof. The ornamentation can be any shape or object as described above. FIG. 5 shows a nonlimiting example of ornamentation 46 as a star-shape. The masking material (which may include a cut-out) is placed on the first color 36 (and/or on the second color 38, and/or on the third color 408) after the melt-adhering step. The process includes applying a color powder coating material onto the area of the cut-out or around the masking material. The color powder coating material may be the first color powder coating material, the second color powder coating material, the third color powder coating material, a fourth color powder coating material, or any combination thereof. The process includes removing the masking material from the shaft and performing the curing step. The process includes forming a multi-color powder coating having an ornamentation.
In an embodiment, the process includes forming a multi-color coating on the shaft, the multi-color coating having at least one 2-color fade area and at least one ornamentation. In a further embodiment, the process includes forming a multi-colored coating on the shaft, the multi-color coating having at least two 2-color fade areas and at least one ornamentation, or at least two ornamentations.
In an embodiment, the process includes placing the masking material on the first color coated shaft. In other words, the masking material is placed on the portion of the shaft where the first color powder coating material is melt adhered to the shaft. The process includes releasably attaching the masking material to form a stripe design or a spiral design on the shaft. The process includes performing the second applying step, and the curing step. The second applying step may apply the second color powder coating material to the bare shaft, to the first color coated shaft, and combinations thereof. The process further includes removing the masking material from the shaft. The masking material may be removed from the shaft either before or after the curing step. The process includes forming a multi-color coating having a multi-color stripe design or a multi-color spiral design on the shaft.
In an embodiment, the process includes wrapping a masking material in a spiral manner (or in an otherwise helical manner) around at least a portion of the shaft and applying a color powder coating material to the shaft. In a further embodiment, a first color powder coating material is applied to at least a portion of the shaft 12. The first color powder coating material is melt-adhered to the shaft to form the first color coated shaft. A releasably attachable and heat resistant masking material is wrapped around the first color coated shaft. The masking material covers a spiral area of the first color coated shaft (spiral-covered area) and exposes a spiral area (spiral-exposed area) of the first color coated shaft. A second color powder coating material is applied to the shaft, the second color powder coating material electrostatically adsorbing to the spiral-exposed area of the shaft. The process includes curing the shaft and forming a multi-color powder coating adhered to the shaft, the multi-color powder coating having a 2-color spiral design.
FIG. 6 shows a golf club 10 with a shaft 12 having a multi-color powder coating adhered to the shaft 12. The multi-color powder coating has a 2-color design made by the foregoing process utilizing a masking material. The 2-color design is a 2-color spiral design with a first color spiral 50 prepared from applying a first color powder coating material. A second color spiral 54 is prepared by way of spirally-wrapping the masking material and subsequent application of a second color powder coating material as previously described.
It is understood that the steps of wrapping in a spiral manner and melt adhering can be repeated to form a multi-color powder coating having a 3-color spiral design, a 4-color spiral design, a 5-color spiral design, or more.
6. Multi-Color Club Head
In an embodiment, the process includes providing a club head. The club head can be a putter head, an iron head, a hybrid head, a wood head, and any combination thereof. The process includes applying an air brush design onto at least a portion of the club head. The process includes attaching the club head with airbrush design to the shaft having the multi-color powder coating.
In a further embodiment, the process includes applying a tailored or customized design to the club head based on a request by a person, such as an owner of the golf club, for example.
The present process may comprise two or more embodiments disclosed herein.
7. Golf Club
The present disclosure provides a golf club. The golf club includes a shaft and a multi-color powder coating adhered to at least a portion of the shaft. In an embodiment, the shaft is a steel shaft as previously described. The multi-color powder coating is any multi-color powder coating as previously described herein. The multi-color powder coating is adhered to at least a portion of the shaft as previously described.
In an embodiment, the multi-color powder coating includes a 2-color fade area. In a further embodiment, the multi-color powder coating includes two 2-color fade areas, or three 2-color fade areas.
In an embodiment, the multi-color powder coating includes an ornamentation. In a further embodiment, the multi-color powder coating includes at least one, or one, ornamentation.
In an embodiment, the multi-color powder coating includes at least three colors. In a further embodiment, the multi-color powder coating has three colors and at least two, or two, 2-color fade areas. The 2-color fade areas are produced as previously described.
In an embodiment, the multi-color powder coating includes a 2-color fade area and an ornamentation. In a further embodiment, the multi-color powder coating includes three colors, two 2-color fade areas, and an ornamentation.
In an embodiment, the multi-color powder coating includes a two-color spiral design. In a further embodiment, the multi-color powder coating includes a two-color spiral design and another ornamentation that is different than the spiral design.
In an embodiment, the golf club includes a club head as previously describe. The club head includes a brush design, an airbrush design, and combinations thereof. In a further embodiment, the airbrush design and/or the brush design is a multi-color design. In yet a further embodiment, the airbrush design and/or the brush design is prepared at the request of a person, such as an owner of the golf club, for example.
In an embodiment, the present golf club conforms to the USGA Rules of Golf and, in particular, conforms to the USGA rules with respect to golf equipment and/or golf clubs. In a further embodiment, the present golf club conforms to USGA Rule 14.3.
In an embodiment, the shaft with the multi-color powder coating meets a classification A surface designation. A “classification A” surface is a:

- Surface that is highly visible to the user at all times when in the club is in use.
- Surface that is viable from all sides to the user during a walk around or view from all sides of club.
- Surface that is highly visible from the front, rear and sides when viewing the club in use. A classification A surface has no surfaces with classification B, C, or D.

The present golf club may comprise two or more embodiments disclosed herein.

DEFINITIONS

The numerical ranges disclosed herein include all values from, and including, the lower value and the upper value. For ranges containing explicit values (e.g., 1 or 2, or 3 to 5, or 6, or 7) any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).
The terms “comprising,” “including,” “having,” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically delineated or listed.
Some embodiments of the present disclosure will now be described in detail in the following Examples.
It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come with the scope of the following claims.

Claims

1. A process for producing a multi-color golf club comprising:

providing a golf club shaft;

first applying a first color powder coating material onto at least a portion of the shaft to form a first powder coated shaft;

melt-adhering the first color powder coating material to at least a portion of the shaft to form a first color coated shaft;

second applying a second color powder coating material onto at least a portion of the shaft;

curing the shaft; and

forming a multi-color powder coating adhered to at least a portion of the shaft.

2. The process of claim 1 comprising pre-heating, before the first applying, the shaft to a temperature from 250° F. to 400° F.

3. The process of claim 1 comprising first applying the first color powder coating material to at least a portion of a steel shaft.

4. The process of claim 1 wherein the first applying comprises electrically charging the first color powder coating material and spraying the electrically charged first color powder coating material onto the shaft.

5. The process of claim 1 wherein the melt-adhering comprises heating the first color powder coated shaft for a duration from 5 minutes to 10 minutes at a temperature from 350° F. to 400° F.

6. The process of claim 1 wherein the second applying comprises electrically charging the second color powder coating material and spraying the electrically charged second color powder coating material onto the shaft.

7. The process of claim 1 comprising heating the first color coated shaft to a temperature from 250° F. to 400° F.; and second applying the second color powder coating material to the shaft.

8. The process of claim 1 comprising second applying the second color coating material on at least a portion of the first color coated shaft.

9. The process of claim 1 comprising placing a sleeve component around a portion of the first color coated shaft;

defining a fade area with an end of the sleeve;

applying a varying amount of the second color powder coating material at the fade area; and

forming a 2-color fade area on the shaft.

10. The process of claim 1 comprising placing a masking material on at least one area of the shaft;

performing at least one of the applying steps; and

forming an ornamentation on the shaft.

11. The process of claim 1 comprising applying, before the curing, a clear coat material to the shaft.

12. The process of claim 1 comprising forming a multi-color coating having a thickness from 0.05 mil to 0.25 mil.

13. The process of claim 1 comprising

providing a club head;

applying an airbrush design to the club head; and

attaching the club head to the shaft having the multi-color powder coating.

14. A golf club comprising:

a steel shaft comprising a multi-color powder coating adhered to at least a portion of the shaft.

15. The golf club of claim 14 wherein the multi-color powder coating comprises a 2-color fade area.

16. The golf club of claim 15 wherein the multi-color powder coating comprises an ornamentation.

17. The golf club of claim 14 wherein the multi-color powder coating comprises an ornamentation.

18. The golf club of claim 14 comprising two 2-color fade areas.

19. The golf club of claim 14 comprising a club head, the club head comprising an airbrush design.