WO2003037448A1

WO2003037448A1 - Moldable golf club grip and method of manufacturing the same

Info

Publication number: WO2003037448A1
Application number: PCT/US2002/033884
Authority: WO
Inventors: Jeffrey Tocci
Original assignee: Jeffrey Tocci
Priority date: 2001-10-30
Filing date: 2002-10-24
Publication date: 2003-05-08

Abstract

A method of forming a custom-fit grip (12) for an apparatus. The method includes the steps of: (a) forming a thermokork material in a general shape of a grip (12) utilized with the apparatus; (b) placing the thermokork material on the apparatus; (c) heating the thermokork material disposed on the apparatus such that the thermokork material becomes moldable; (d) forming the custom-fit grip (12) by deforming the thermokork material when said thermokork material is moldable; and (e) determining whether the custom-fit grip is satisfactory; wherein if said custom-fit grip is unsatisfactory, repeating steps(c)-(e) utilizing the same thermokork material until the custom-fit grip (12) is satisfactory.

Description

MOLDABLE GOLFCLUB GRIPAND METHOD OFMANUFACTURINGTHE SAME

Field Of The Invention

The present invention relates to custom-fit grips for use with golf clubs and a method of manufacturing the same. Background Of The Invention

The use and manufacture of custom-fit articles is well known in the art. For example, it has long been known to form custom-fit footbeds for use in footwear. The custom-fit footbeds result in making the footwear more comfortable to wear because the weight and pressure of the person utilizing the footbeds is distributed more evenly.

Indeed, many different approaches have been developed for forming such custom-fit footbeds. h one such approach, a chemical reaction is utilized to soften a defonnable material, which is placed in the footwear (e.g., shoe). Next, the person (to whom the footbed is to be fitted) steps into the footwear and forms an impression in the footbed. Then, the person removes his/her foot from the footwear and the footbed is allowed time to harden/cure. Once the footbed has hardened, the footwear containing the now custom-fit footbed is ready for use. Examples of such systems are set forth in USP Nos. 4,520,581 and 4,128,951. It has also been known to utilize custom-fit articles for hand grips for items, such as, golf clubs, tennis, squash and racquetball rackets, ski poles, etc.

While such custom-fit articles are known, the known methods of forming such articles suffer from a number of deficiencies. More specifically, many of the deformable materials utilized to form custom-fit articles include a catalyst for activating the deformability of, for example, a thermoplastic material. Once activated, the reaction maybe irreversible, thereby requiring that the impression be made rather quickly such that the impression is obtained prior to the material setting (i.e., hardening in its final state), h such instances, if the initial mold is made incorrectly, a new moldable article must be utilized. Of course, this can lead to increased costs as it may be necessary to make several attempts prior to obtaining the desired custom-fit article.

In addition, many of the methods for forming custom-fit articles utilize various chemical compounds contained inside a sealed container. Such methods are typically rather expensive due to the costs associated with manufacturing the sealed container having the various chemical compounds, and the cost of the chemical compounds themselves, hi addition, increased care must be exhibited in handling the containers so as to avoid puncturing the container and unwanted leakage of the chemicals, thereby further complicating the overall process.

Finally, it is also noted that the known methods of forming custom-fit articles are often very time consuming. For example, as described in USP No. 5,555,584, the method disclosed therein, which utilizes a gel-pad (comprising various chemical compounds) as the moldable article, requires fitting the gel-pad to the person to form the desired mold and then heating the gel-pad for a period of approximately 30 minutes and thereafter allowing the gel-pad to cool. As such, the over-all time associated with forming the custom-fit article is substantial. While such time requirements may be acceptable for persons obtaining a custom-fit article for medical reasons, it is often unacceptable to those desirous of obtaining, for example custom-fit hand grips for sports related equipment (e.g., golf clubs).

Accordingly, there exists the need for a method of forming a custom-fit article that provides for the moldable material to be reusable so as to allow multiple impressions to be made on the same moldable material, thereby negating the requirement of disposing the moldable material if the initial mold is performed incorrectly, hi addition, there is a need to provide a custom-fit article utilizing a moldable material that does not comprise chemical compounds contained in a sealed container so as to allow for easy handling of the moldable material without risk of contacting such chemical compounds during the molding process. Finally, there is also a need for a method of forming a custom-fit article that is exceedingly fast so as to eliminate a significant deterrent of obtaining custom-fit articles for non-medical type applications.

SUMMARY OF THE INVENTION

Accordingly, the present invention relates to a method of forming a custom-fit article which addresses all of the foregoing problems of the known prior art methods. In particular, the method of the present invention provides for the moldable material to be reusable so as to allow multiple impressions to be made on the same moldable material, thereby negating the requirement of disposing the moldable material if the initial mold is performed incorrectly. In addition, the method of the present invention utilizes a moldable material that does not comprise chemical compounds contained in a sealed container, thereby allowing for easy handling of the moldable material without risk of contacting such chemical compounds during the molding process. Finally, the method of the present invention provides for generation of the custom-fit article in a relatively short time, thereby increasing the likelihood of persons purchasing such custom-fit articles for non-medical applications (e.g., custom-fit golf grips).

More specifically, the present invention relates to a method of forming a custom-fit grip for an apparatus comprising the steps of: (1) forming a thermokork material in a general shape of a grip utilized with the apparatus; (2) placing the thermokork material on the apparatus; (3) heating the thermokork material disposed on the apparatus such that the thermokork material becomes moldable; and (4) forming the custom-fit grip by deforming the thermokork material when the thermokork material is moldable. h another embodiment, the present invention relates to a method of forming a custom-fit grip for an apparatus comprising the steps of: (a) forming a thermokork material in a general shape of a grip utilized with the apparatus; (b) placing the thermokork material on the apparatus; (c) heating the thermokork material disposed on the apparatus such that the thermokork material becomes moldable; (d) forming the custom- fit grip by deforming the thermokork material when said thermokork material is moldable; and (e) determining whether the custom-fit grip is satisfactory; wherein if said custom-fit grip is unsatisfactory, repeating steps (c)-(e) utilizing the same thermokork material until the custom-fit grip is satisfactory.

The present invention also relates to a custom-fit grip for an apparatus comprising a thermokork material in a general shape of a grip utilized with the apparatus, and which is positioned on the apparatus. Importantly, the thermokork material is remoldable. Similar to above, the thermokork material is disposed on the apparatus and heated such that the thermokork material becomes moldable, and the custom-fit grip is formed by deforming the thermokork material when the thermokork material is moldable.

As described below, the method of forming a custom-fit article of the present invention provides important advantages over prior art devices. For example, the method of the present invention provides for the moldable material to be reusable so as to allow multiple impressions to be made on the same moldable material, thereby negating the requirement of disposing the moldable material if the initial mold is performed incorrectly. In addition, the method of the present invention utilizes a moldable material that does not comprise chemical compounds contained in sealed container, thereby allowing for easy handling of the moldable material without risk of contacting such chemical compounds during the molding process. Finally, the method of the present invention provides for the generation of the custom-fit article in a relatively short time, thereby increasing the likelihood of persons purchasing such custom-fit articles for non-medical applications (e.g., custom-fit golf grips).

Additional advantages of the present invention will become apparent to those skilled in the art from the following detailed description of exemplary embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a flow-chart illustrating an exemplary embodiment of the present invention.

Figs. 2a-2f illustrate exemplary embodiments of thermokork material formed in the configuration of a golf club grip.

Figs. 3a-3d illustrate a first variation of the exemplary embodiment of thermokork material formed in the configuration of a golf club grip illustrated in Figs. 2a-2d.

Figs. 4a-4d illustrate a second variation of the exemplary embodiment of thermokork material formed in the configuration of a golf club grip illustrated in Figs. 2a-2d.

The invention itself, together with further objects and attendant advantages, will best be understood by reference to the following detailed description, taken in conjunction with the accompanying drawings. DETAILED DESCRIPTION OF THE DRAWINGS

The following detailed description of a method of forming a custom-fit article in accordance with the present invention illustrates the present invention in conjunction with the formation of a custom-fit grip for a golf club. It is noted, however, that the present invention as claimed herein is not intended to be limited to the specific embodiments disclosed in the following discussion. Clearly, the method of the present invention can be utilized to form custom-fit grips for any other type of handle (e.g., tennis racket, hockey stick, etc.).

As stated, the method of the present invention will be described in conjunction with the formation of a custom- fit grip for a golf club. Fig. 1 is a flow-chart illustrating the steps associated with practicing the method of the present invention. Referring to Fig. 1, the first step (Step 1) entails forming a grip 12 comprising thermokork material, for example, Black Cork Composite 740 produced by the Monarch Rubber Company. In other words, forming the thermokork material into the shape of the desired grip and placing the thermokork material into position on the apparatus/item to have the custom grip. Typically, a master cast mold of the desired shape of the grip is formed and utilized to form each grip to be placed on the golf clubs. However, any acceptable method of forming the thermokork material into the desired shape is acceptable.

Referring to Figs. 2a-2f, illustrated therein is thermokork material 12 formed in the configuration of a golf club grip. As shown, the thermokork material 12 has substantially the same configuration as a normal cylindrical or tapered golf grip. Specifically, the grip has a circular longitudinal opening 14 extending substantially the length of the grip 12. As with any other golf grip, this opening allows the grip 12 to be placed on a golf club. Figs. 2b-2d illustrate the varying thickness of the thermokork material 12 from one end of the grip to the other end of the grip. Again, similar to conventional golf club grips, the grip becomes thicker approaching the end to be held by the user. As shown in Figs. 2e and 2f, it is also possible to form a non- tapered grip. It is noted that, as shown in Figs. 3a-4d, the actual thickness of the thermokork material utilized to form the golf club grip can vary in accordance with the type of grip/feel desired by the user, and more importantly, by the size of the hands of the user (i.e., the bigger the hand, the bigger the grip).

Returning to Fig. 1, once the thermokork material is formed in the desired shape of the grip, the thermokork material is placed on the apparatus. In the instant example, the thermokork material is placed on the shaft of the golf club. Next, the thermokork material is placed in an infrared ceramic heat oven, for example, the model FG-1 manufactured by the Intec Group, LLC, and heated for approximately 4-10 minutes at a temperature of approximately 68°C (Step 2). Heating the thermokork material for the prescribed time period causes the thermokork material to become moldable. It is noted that the desired temperature and the duration of heating can vary from the example set forth herein. Indeed, the criteria is that the heating process renders the thermokork material moldable. As will be understood, the required duration of the heating step at a given temperature may very depending on the thickness of the desired grip. However, the duration of the heating step may be reduced by increasing the temperature of the oven. In one embodiment, the oven utilized has variable heating and timing controls so as to allow the temperature and duration of heating to be adjusted on a case by case basis. The exemplary FG-1 infrared ceramic heat oven utilizes two infra-red heating elements, which are controlled by a microprocessor controller. The power rating of each element is 220/230 vac, 650 watts. Of course, any other comparable heating instrument (other than an infrared ceramic heat oven) suitable for heating thermokork material can be utilized. Once the thermokork material has become moldable (after the prescribed time in the oven), the thermokork material is removed from the infrared ceramic oven, and the thermokork material is molded into the desired position (Step 3). In the current example, this entails the user grasping the thermokork grip disposed on the golf club utilizing the desired hand positioning. This results in the thermokork material being deformed in the desired manner, thereby creating the custom grip. It is noted that the user must supply sufficient pressure such that the thermokork material is deformed into the desired position. Typically, the user needs to hold the thermokork grip for approximately 20-30 seconds in order to establish the desired mold. Once the desired mold is formed, the thermokork material is allowed to cool completely, thereby stabilizing the desired mold (Step 4).

It is noted that the thermokork material typically cools in approximately 2-3 minutes. Accordingly, it is necessary to deform the thermokork material into the desired shape in a timely manner upon removing the thennokork material from the ceramic oven. Moreover, in the given example, it is recommended that the user should utilize gloves without ventilating holes prior to placing his/her hands on the thermokork material. hi the event the resulting grip is unsatisfactory to the user, the foregoing process can be repeated utilizing the same thermokork material so as to allow the user to obtain the desired grip without having to discard the thermokork material disposed on the golf club. Specifically, assuming the grip is unsatisfactory for any reason, the thermokork material (and golf club shaft) are placed back in the infrared ceramic oven and reheated in the same manner as detailed above, which once again results in the thermokork material becoming moldable. The process then continues in the same manner as discussed above, where the user places his/her hands on the thermokork grip in the desired position and applies pressure so as to deform the thermokork material in the desired position. This process can be continually repeated so as to allow the user to obtain the desired grip.

As described above, the method of forming a custom-fit article of the present invention provides important advantages over prior art devices. Most importantly, the method of the present invention provides for the moldable material to be reusable so as to allow multiple impressions to be made on the same moldable material, thereby negating the requirement of disposing of the moldable material if the initial mold is performed incorrectly. In addition, the method of the present invention utilizes a moldable material that does not comprise chemical compounds contained in sealed container, thereby allowing for easy handling of the moldable material without risk of contacting such chemical compounds during the molding process. Finally, the method of the present invention provides for generation of the custom-fit article in a relatively short time, thereby increasing the likelihood of persons purchasing such custom-fit articles for non-medical applications (e.g., custom-fit golf grips).

Variations of the embodiment of the present invention discussed above are also possible. For example, the method of the present invention could be utilized to form custom-fit grips for any other type of handle, such as tennis rackets, hockey stick, ski poles, etc. Indeed, the method of the present invention can be utilized to form grips for any other apparatus for which a custom fit grip is desirable

Of course, it should be understood that a wide range of other changes and modifications can be made to the preferred embodiment described above. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it be understood that it is the following claims including all equivalents, which are intended to define the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A method of forming a custom-fit grip for an apparatus, said method comprising the steps of: forming a thermokork material in a general shape of a grip utilized with said apparatus; placing said thermokork material on said apparatus; heating said thermokork material disposed on said apparatus such that said thermokork material becomes moldable; and forming said custom-fit grip by deforming said thermokork material when said thermokork material is moldable.

2. The method of forming a custom-fit grip for an apparatus according to claim 1, wherein said thermokork material is allowed to cool after said deformation step so as to allow said thermokork material to hardened in the desired position.

3. A method of forming a custom-fit grip for an apparatus according to claim 1, wherein said deformation step comprises an operator holding said thermokork material in a desired position and applying pressure to said thermokork material.

4. A method of forming a custom-fit grip for an apparatus according to claim 1, wherein said apparatus comprises a golf club.

5. A method of forming a custom-fit grip for an apparatus according to claim 1, wherein said heating step comprises heating said thermokork material at a temperature of at least 68°C.

6. A method of forming a custom-fit grip for an apparatus according to claim 5, wherein said heating step is conducted for at least four minutes.

7. A method of forming a custom-fit grip for an apparatus according to claim 1, wherein said heating of said thermokork material is performed utilizing an infrared ceramic heat oven.

8. A method of forming a custom-fit grip for an apparatus according to claim 1, wherein said thermokork material can be remolded.

9. A method of forming a custom-fit grip for an apparatus, said method comprising the steps of:

(a) forming a thermokork material in a general shape of a grip utilized with said apparatus;

(b) placing said thermokork material on said apparatus;

(c) heating said thermokork material disposed on said apparatus such that said thermokork material becomes moldable;

(d) forming said custom-fit grip by deforming said thermokork material when said thermokork material is moldable; and

(e) determining whether said custom-fit grip is satisfactory; wherein if said custom-fit grip is unsatisfactory, repeating steps (c)-(e) until said custom- fit grip is satisfactory.

10. The method of forming a custom-fit grip for an apparatus according to claim 8, wherein said thermokork material is allowed to cool after step (d) so as to allow said thermokork material to hardened in the desired position.

11. A method of forming a custom-fit grip for an apparatus according to claim 8, wherein said deformation step comprises an operator holding said thermokork material in a desired position and applying pressure to said thermokork material.

12. A method of forming a custom-fit grip for an apparatus according to claim 11, wherein said apparatus comprises a golf club.

13. A method of forming a custom-fit grip for an apparatus according to claim 8, wherein said heating step comprises heating said thermokork material at a temperature of at least 68°C.

14. A method of forming a custom-fit grip for an apparatus according to claim 13, wherein said heating step is conducted for at least four minutes.

15. A method of forming a custom-fit grip for an apparatus according to claim 8, wherein said heating of said thermokork material is performed utilizing an infrared ceramic heat oven.

16 A custom-fit grip for an apparatus comprising: a thermokork material in a general shape of a grip utilized with said apparatus, said thermokork material positioned on said apparatus, said thermokork material being remoldable; wherein said thermokork material disposed on said apparatus is heated such that said thermokork material becomes moldable; and the custom-fit grip is formed by deforming said thermokork material when said thermokork material is moldable.

17. The apparatus of claim 16, wherein said thermokork material is deformed by an operator holding said thermokork material in a desired position and applying pressure to said thermokork material.

18. The apparatus of claim 17, wherein said apparatus comprises a golf club.

19. A system for forming a custom-fit grip for an apparatus, said system comprising: means for forming a thermokork material in a general shape of a grip utilized with said apparatus; means for placing said thermokork material on said apparatus; means for heating said thermokork material disposed on said apparatus such that said thermokork material becomes moldable; and means for forming said custom-fit grip by deforming said thermokork material when said thermokork material is moldable.

20. The system for forming a custom-fit grip for an apparatus according to claim 19, wherein said apparatus comprises a golf club.

21. The system for forming a custom-fit grip for an apparatus according to claim 19, wherein said means for heating said thermokork material is an infrared ceramic heat oven.

22. The system for forming a custom-fit grip for an apparatus according to claim 19, wherein said thermokork material can be remolded.