Golf club head with shell and additional element(s)

Abstract

The invention relates to a club head (1) for a golf club, having an outer shell (3) and one or more additional elements (6, 7, 8) which are made of a metal. The shell (3) is made of a composite material, in particular a fiber-reinforced plastic. An attachment region (61, 71, 81) of the additional element or of each of the additional elements (6, 7, 8) is at least partly incorporated into the composite material of the shell (3). The attachment region (61, 71, 81) of the one or more additional elements (6, 7, 8) is formed by a respective surface (10, 11) which is laser-structured and / or has multiple steps. The invention additionally relates to a golf club comprising such a club head (1) and to a method for producing a club head (1).

Description

[0001] TITLE

[0002] GOLF CLUB HEAD WITH COVER AND ADDITIONAL ELEMENT(S)

[0003] TECHNICAL FIELD

[0004] The present invention relates to a club head for a golf club and a golf club with such a club head. The invention also relates to a method for producing such a club head.

[0005] STATE OF THE ART

[0006] Golf is a widespread sport in which both the performance of the golfer and the technological properties of the golf club are of key importance. From a technological perspective, it is important that the golf ball can be hit as close to the hole as possible in a wide variety of environmental situations and with as much control and precision as possible. In the field of golf club development and design, one goal is therefore to improve both directional accuracy and the achievable distance of the shots. Also important in the development of golf clubs is the forgiveness of the golf club, and in particular the club head. This means the device's ability to achieve sufficient directional accuracy and a good distance even with a less than optimal shot.

[0007] In order to achieve optimal weight distribution in the club head with regard to the above-mentioned requirements and to positively influence the dynamics of the tee shot, weighting elements are often provided on or in the club head of golf clubs.

[0008] For example, document US 2015 / 0045130 A1 discloses a club head with weighting elements arranged on the outside of the club head and within an internal damping element. Document US 9,333,390 B1 discloses a golf club head in which weighting elements can be incorporated.

[0009] The document US 10,213,665 B1 discloses hollow golf club heads which have a recess on the underside for inserting plate-shaped weighting elements.

[0010] Furthermore, the document US 2013 / 0085012 A1 discloses a golf club head with a hollow structure filled with a foam material and a metal striking plate attached to the outside.

[0011] Composite materials made from fiber-reinforced plastic have been increasingly used in the manufacture of golf club heads for some time now. The advantage of such materials over conventionally used metals lies primarily in their weight. Composite materials can be used to produce golf club heads whose structure is many times lighter than conventional metal club heads. With the help of weighting elements, the desired weight distribution can be adjusted even more precisely. By appropriately aligning the fibers in composite materials, the power transmission and transfer within the club head can be controlled and optimized. Furthermore, club heads with a wide variety of geometries can be formed using composite materials. The striking plate in club heads made of such composite materials is usually formed from a metal plate.

[0012] For example, US Pat. No. 5,193,811 A discloses a golf club head comprising a body made of a fiber-reinforced material and a metallic plate attached thereto. Inside the body is a core made of a foam material and, in some embodiments, a weighting element.

[0013] Document US 5,547,427 A discloses a golf club head with a hollow body made of a fiber-reinforced thermoplastic material and filled with a foam material. The interior space formed by the hollow body is closed at the front with a striking plate. At its rear, the hollow body has a recess into which a weighting element is inserted. Furthermore, document US 2023 / 0056990 A1 discloses a golf club head with a metal base body. The shell-like base body has an opening into which a part made of a fiber-reinforced plastic material is inserted.

[0014] A challenge for clubheads with a base made of fiber-reinforced plastic is the connection of additional metallic elements, such as the weighting elements or the striking plate, to the composite material. Very high forces typically occur in golf, as the golf ball is often struck with great force by the clubhead. When striking the golf ball, which according to the regulations takes place within a maximum of 239 microseconds, the ball is accelerated by up to 30,000 g. The golf club is decelerated by 2,000 to over 5,000 g. This places very high stress on the connection of the weighting elements to the composite material forming the clubhead structure.The high primary load of deceleration during impact is overlaid by lateral accelerations that occur in all directions as soon as the ball is struck outside the center of gravity of the clubhead, as well as further impact stresses upon contact with the ground. In addition, the connection is compromised by the strong vibrations of the structure after impact and is subject to thermally superimposed stresses due to the different thermal expansions of the connecting components. As a result, the additional elements attached to or in the golf club can detach from the composite material over time. The resulting gradual or sudden mobility of the additional elements relative to the base body can lead to undesirable changes in impact behavior, which can ultimately render the clubhead unusable. Additional elements that detach completely from the clubhead can also pose a danger to the player.

[0015] PRESENTATION OF THE INVENTION

[0016] It is an object of the invention to provide a club head for a golf club made of a composite material, in which one or more additional elements are securely held to the composite material in the long term.

[0017] This object is achieved by a club head having the features of claim 1. Claim 15 specifies a golf club with such a club head, and claim 16 specifies a method for producing a club head. Further embodiments are specified in the dependent claims.

[0018] A club head for a golf club is thus specified, comprising an outer shell made of a composite material, in particular of a fiber-reinforced plastic; and one or more additional elements made of a metal, each of which is at least partially embedded in the composite material of the shell by means of a connection region.

[0019] The connection area of ​​one or more additional elements is formed by a laser-structured and / or multi-stepped surface.

[0020] By forming the connection area of ​​the additional element(s) with a laser-structured and / or multi-stepped surface, the metal can bond particularly efficiently and permanently to the composite material of the shell. Due to the laser structuring and / or the steps, the total surface area of ​​the connection area is increased, thereby achieving a more secure connection of the respective additional element to the shell. In particular, a matrix material of the shell can engage with the structure provided in the surface of the connection area and possibly even engage behind and / or underneath it, creating a particularly strong bond between the shell and the additional element.In addition, the design of the laser structuring and / or the steps can be adapted with regard to the forces normally acting on the club head in such a way that the separation forces acting between the additional element and the shell, such as in particular shear, gravitational and tensile forces, are reduced. To this end, the steps can, for example, form undercuts with respect to the intended main striking direction or each form a surface perpendicular to the main striking direction with a deviation of a maximum of 40°, preferably a maximum of 20°, in order to optimally absorb the forces normally acting on the connection area. The surface structures created by the laser structuring can also be geometrically adapted to the normally occurring forces in such a way that the forces are transferred from the respective additional element to the shell and vice versa as efficiently as possible and while minimizing separation forces.It has been shown that, for these reasons in particular, the laser-structured and / or multi-stepped surface can sustainably improve the bonding of the additional element(s) to the shell with regard to frequent use. Thanks to the laser structuring and / or the multi-stepped surface, the number of detachments of additional elements from the shell was significantly reduced in long-term tests.

[0021] The shell typically forms the base of the clubhead. The base of the clubhead refers to the component that absorbs and transfers the forces typically exerted during golf by the golf club shaft or hosel to the faceplate, or vice versa, and generally forms the main structure of the clubhead. The faceplate is typically attached to an outer side of the base, which usually has an opening for inserting or attaching the club shaft or hosel. The base also often forms the primary shaping element of the clubhead.

[0022] The shell is a component that at least partially surrounds the interior of the club head, thus usually forming at least part of the outer shell of the club head. The shell usually has a certain curvature. Alternatively or additionally, the shell can also have corners and / or edges. The shell preferably forms a hollow body.

[0023] The shell advantageously covers at least 25%, even more advantageously at least 50%, and most advantageously at least 75% of the outer surface of the interior. It has been shown that the forces occurring during a game of golf can be distributed and transferred across the clubhead particularly advantageously when the shell covers such a large proportion of the outer surface of the interior. Even more preferably, the shell essentially completely defines the interior of the clubhead, which means that, for example, there may be a relatively small opening for attaching the club shaft or hosel, but the interior is otherwise completely surrounded by the shell. This can achieve a flow of forces across the clubhead that is particularly beneficial for playing golf.

[0024] The club head, together with the hosel, the golf club shaft and the golf club grip, usually forms the golf club. The hosel is the connecting piece on top of the club head into which the shaft is inserted. The hosel can be a separate component from the club head or formed by the club head itself. The composite material of the shell can in particular be a fibre-reinforced plastic, whereby the plastic can be a thermoplastic, but preferably a duroplastic, i.e. duromeric plastic. A composite material is understood here to be a composite material consisting of two or more materials bonded together. The composite material generally has different properties than the respective individual materials. A composite material usually consists of a base material, which is referred to as the matrix, and a reinforcing material, such as a fibre.Preferred materials for a matrix material are thermoplastic materials such as polyetheretherketone (PEEK), thermosetting materials such as resins, etc. Examples of fibers include materials such as carbon fibers, glass fibers, aramid, Kevlar fibers, etc. A variety of suitable composite materials for the shell are known to the person skilled in the art.

[0025] In order to produce a particularly light club head with good weight distribution, the weight of the composite material preferably makes up 20-50%, more preferably 20-30%, most preferably about 25% of the total club head weight.

[0026] In order to make the connection between the additional element(s) and the composite material of the shell even stronger, the composite material of the shell can contain an adhesive, particularly in the connection area. In this case, the composite material is preferably composed of a fiber-reinforced plastic, which generally forms the base material of the shell, and the adhesive. The adhesive, which is preferably an epoxy resin, is preferably present at least in those areas on the outside of the shell where the shell is connected to the additional element(s). In tests, particularly strong and durable component connections could be achieved using epoxy resins. The provision of an adhesive, such as in particular an epoxy resin, has proven particularly advantageous with regard to the engagement of the composite material in the local depressions of the laser-structured and / or multi-stepped surface of the additional element(s).of the additional elements. Especially when the recesses are very narrow, the adhesive can still ensure the mutual engagement of the materials.

[0027] Because the cover is made of a composite material, the clubhead can be manufactured with a very low weight, yet structurally very strong and durable. This low weight allows the clubhead to be more voluminous and have a larger surface area in the faceplate area, which has a particularly positive effect on the forgiveness of the clubhead. Furthermore, the composite material allows the clubhead to be manufactured with almost any geometric shape.

[0028] The additional element(s) made of metal are preferably one or more weighting elements, the striking plate and / or a base plate. In particular, if the additional element(s) relate to the striking plate or the base plate, the metal from which they are made can be iron. In particular, a light metal such as titanium can also be used for the striking plate and / or the base plate. The striking plate and / or the base plate can in particular be formed from a sheet metal. Preferably, the striking plate and / or the base plate are attached directly to the outside of the shell and in particular rest directly on it. In the case that the additional element(s) are weighting elements, the metal is preferably tungsten, lead, iron or an alloy thereof.

[0029] When the additional element(s) is / are embedded with its respective connection area at least partially into the composite material of the shell, the respective additional element lies so closely against the composite material that the composite material or a component thereof at least partially engages with the additional element and / or at least partially surrounds it. The adjoining of the additional element and shell therefore does not only occur on a purely two-dimensional surface, but there is a certain engagement of the components or their materials with one another. This engagement can also occur only on a microscopic level. Due to the mutual engagement of the additional element and the shell, the connection between the shell and the respective additional element is generally significantly strengthened. Preferably, the entire connection area is embedded in the composite material of the shell.

[0030] Preferably, the composite material of the shell is cast onto the additional element(s). This allows for a particularly tight and therefore strong connection between the components.

[0031] The plastic of the composite material forming the shell, advantageously a thermosetting plastic, is preferably cast in liquid form under vacuum during production so that it flows into the recesses formed by the multi-stepped and / or laser-structured surface. It is then preferably chemically cross-linked at preferably 70-120°C for approximately 2-20 minutes. The plastic preferably forms both a positive and a material bond with the connection area of ​​the respective additional element.

[0032] A laser-structured surface is created by treating a portion of the surface material in a targeted manner using a laser, which usually means ablating it. The surface material can be melted in a controlled manner, particularly with the help of the laser, so that it subsequently solidifies into a defined structure. The laser radiation can be applied in pulsed form. The laser structuring is detectable in the finished component due to a reproducible geometry provided in the surface. Depending on the case, this can be detected by eye or, for example, with the help of a microscope. The laser-structured surface can form only part of the connection area or the entire connection area.The provision of a laser-structured surface is particularly suitable for connecting the striking plate and / or the base plate to the shell, since these components are usually designed with very thin walls to save material and weight.

[0033] The laser-structured surface preferably has a regular geometry. For example, the laser-structured surface can have a plurality of parallel and regularly spaced grooves. A laser-structured surface with a plurality of intersecting grooves, in particular perpendicularly intersecting grooves, has proven particularly effective in achieving a strong bond.

[0034] If the connection area is formed by a multi-stepped surface, the steps on the corresponding additional element are usually easily recognizable by eye. The steps preferably run parallel to one another. Furthermore, the steps are preferably arranged at regular intervals from one another. Such a design of the multi-stepped surface with parallel and regularly arranged steps has proven particularly effective with regard to the connection of the additional element to the shell. The multi-stepped surface can form only part of the connection area or the entire connection area. The additional element(s) can in particular be cast, pressed, or sintered parts, for the production of which a cast, pressed, or sintered mold with a correspondingly multi-stepped surface is provided.In this case, the production of the multi-stepped surface generally requires no additional work steps. Providing a multi-stepped surface is particularly well-suited for attaching weighting elements to the shell, especially when the weighting elements are cast, pressed, or sintered parts.

[0035] In addition to embedding the connection area in the composite material, the additional element(s) can be secured against detachment or slippage by further measures. For example, if the additional element(s) are located in an interior space of the club head, the shell can have projections extending into the interior space, each of which forms a stop for the additional element(s) to prevent the additional element(s) from slipping relative to the shell.

[0036] In a preferred embodiment, at least some or all of the additional element(s) are one or more weighting elements, each of which is arranged entirely inside the shell. Due to their inertia associated with their high weight, weighting elements are particularly susceptible to slipping or even detaching from the composite material of the shell. Arranging them entirely inside the shell enables the club head to be manufactured in such a way that particularly efficient power transmission via the shell is achieved. The forces generated during impact can then be distributed and transmitted via the shell without being significantly influenced by the weighting element(s). Arranging the weighting elements inside the shell has the further advantage that the risk of injury is considerably reduced should they become detached.Advantageously, the shell essentially completely surrounds the weighting element(s). To achieve optimal shape with regard to weight distribution, the weighting element(s) are advantageously cast, pressed, or sintered parts.

[0037] Preferably, a first weighting element and a second weighting element are provided, which, with respect to the intended main striking direction, are each arranged laterally on the club head, in particular laterally to the striking plate. In this case, the striking plate can be arranged in particular between the first and second weighting elements. The two weighting elements can each be arranged inside or outside the shell. The weighting element(s) as a whole preferably each have an irregular geometric shape that is at least partially adapted to the inner surface of the shell. In this way, the weight distribution of the club head can be particularly well optimized.

[0038] In a further preferred embodiment, at least one of the additional elements is a striking plate, which is attached to an outer side of the shell and serves to strike a golf ball. To improve the weight distribution of the clubhead, the striking plate is often made of thin-walled sheet metal, which presents a particular challenge for permanent attachment to the shell. By laser-structuring the striking plate on the side facing the shell, a firm and permanent connection can be achieved.

[0039] Preferably, essentially all surfaces of the connection areas of the additional element(s) that are at least partially or completely projected in the intended main stroke direction are formed by a multi-stepped and / or laser-structured surface. This takes into account the fact that the main force acting on the clubhead during the tee shot is along the stroke direction.

[0040] If the connection area is formed by a multi-stepped surface, the steps of the multi-stepped surface preferably each form a surface that is perpendicular to the intended main stroke direction with a deviation of no more than 40°, preferably no more than 20°. By means of such a stepping, the connection area facing the main stroke direction can be maximized. The forces acting on the clubhead during impact are thus distributed over a larger area in the connection area, which has a positive effect on the strength and durability of the connection.

[0041] In the case of a laser-structured surface, the grooves created by the laser are preferably wider in depth than at the surface. In other words, the grooves expand from the surface into the depth of the material. When the composite material of the shell is poured, it can not only penetrate into the grooves and thus engage with them, but can even engage behind the grooves due to the widening. This can achieve a particularly strong and permanent connection of the components. As an additional measure to improve the component connection, the connection area can be formed by a roughened surface, whereby the roughening is preferably created by sandblasting, chemical etching and / or surface laser treatment.In combination with laser structuring and / or multiple surface gradations, a particularly strong and permanent connection of the components can be achieved, which will withstand long-term use even with frequent use of the club head.

[0042] It can be particularly advantageous if the additional element(s) each have an undercut relative to the intended main swing direction, preferably located in a rear area of ​​the respective additional element relative to the main swing direction. By engaging the composite material of the shell in this undercut(s), the forces generated during golf can be absorbed even better, thus further improving the connection of the respective additional element.

[0043] The club head preferably has a core made of a gaseous material, in particular air, or of a foam material, which is at least partially, preferably completely, surrounded by the shell. A foam material here means a material that is usually artificially produced and has a cellular structure with low density. Materials suitable for foaming and for the present application include, for example, many plastics in the sense of organic, polymeric solids such as thermoplastics, thermosets or elastomers, which can reduce their volume under pressure, i.e. have compressibility. If the core is made of a gaseous material, such as air, the shell preferably encloses a cavity and the gaseous material filling this cavity forms the core. The core is therefore particularly lightweight.Particularly advantageous impact behavior has been observed with club heads whose cores are foamed or gaseous. It is preferred that the core occupies a larger volume of the club head than the shell. However, it is also conceivable for the club head and shell to have a similar volume, which may be the case, for example, with a thin, delicate club head. If a weighting element is present inside the shell, it can be arranged inside or outside the core. The invention also relates to a golf club with a club head according to the above specifications. The golf club can also have a hosel, a golf club shaft, and a golf club grip.

[0044] Furthermore, the invention relates to a method for producing a club head, which is preferably designed according to the above specifications, wherein the method comprises at least the step of at least partially embedding one or more additional elements made of a metal, each with a connection region, into a composite material, in particular into a fiber-reinforced plastic, of an outer shell of the club head. The method further comprises the step of laser-structuring and / or multiply stepping the connection region of the additional element(s) before embedding them in the composite material. The laser structuring is usually carried out using a pulsed or non-pulsed laser. The multiple stepping is preferably created using a casting process.

[0045] BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Preferred embodiments of the invention are described below with reference to the drawings, which are for illustrative purposes only and are not to be construed as limiting. In the drawings:

[0047] Fig. 1 is a perspective view of a partially transparent club head according to the invention in the form of a driver;

[0048] Fig. 2 is a perspective view of a partially transparent club head according to the invention in the form of a fairway wood;

[0049] Fig. 3 is a perspective view of a partially transparent club head according to the invention in the form of an iron 7;

[0050] Fig. 4 is a perspective view of a partially transparent club head according to the invention in the form of an iron 9;

[0051] Fig. 5 is a perspective view of a partially transparent club head according to the invention in the form of a pitching wedge;

[0052] Fig. 6 is a perspective view of a partially transparent club head according to the invention in the form of a sand wedge;

[0053] Fig. 7 is a perspective view of a partially transparent club head according to the invention in the form of a putter; Fig. 8a is a perspective external view of the club head of Fig. 1;

[0054] Fig. 8b is a perspective view of the weighting elements, the striking plate and the base plate of the club head of Fig. 8a;

[0055] Fig. 8c is a perspective view of the weighting elements of the club head of Fig. 8a;

[0056] Fig. 9a is a perspective external view of the club head of Fig. 4;

[0057] Fig. 9b is a perspective view of the weighting elements, the striking plate and the base plate of the club head of Fig. 9a;

[0058] Fig. 9c is a perspective view of the weighting elements of the club head of Fig. 9a;

[0059] Fig. 10a is a perspective external view of the club head of Fig. 5;

[0060] Fig. 10b is a perspective view of the weighting elements of the club head of Fig. 10a;

[0061] Fig. 10c is a sectional view in plane AA of the club head of Fig. 10a;

[0062] Fig. 11 is a plan view of the laser-structured back of the striking plate of a club head according to the invention;

[0063] Fig. 12 a microscopic image of the laser-structured connection area of ​​the striking plate of a club head according to the invention in cross-sectional view;

[0064] Fig. 13 is a microscopic image of the laser-structured connection area of ​​the striking plate of another club head according to the invention in cross-sectional view;

[0065] Fig. 14 is a microscopic image of the laser-structured connection area of ​​the striking plate of the club head of Fig. 13 in plan view;

[0066] Fig. 15 is a schematic cross-sectional view of a laser-structured surface of a club head according to the invention in cross-sectional view;

[0067] Fig. 16a a microscopic image of the laser-structured connection area of ​​the striking plate of another club head according to the invention in cross-sectional view;

[0068] Fig. 16b is a schematic representation of the contour of the image in Fig. 16a;

[0069] Fig. 17a a microscopic image of the laser-structured connection area of ​​the striking plate of yet another club head according to the invention in cross-sectional view;

[0070] Fig. 17b is a schematic representation of the contours of the image of Fig. 17a; Fig. 18 is a schematic representation of a first, preferred variant of a laser-structured connection area of ​​a club head according to the invention in plan view;

[0071] Fig. 19 is a schematic representation of a second variant of a laser-structured connection area of ​​a club head according to the invention in plan view;

[0072] Fig. 20 is a schematic representation of a third variant of a laser-structured connection area of ​​a club head according to the invention in plan view;

[0073] Fig. 21 is a schematic representation of a fourth variant of a laser-structured connection area of ​​a club head according to the invention in plan view;

[0074] Fig. 22 is a schematic cross-sectional partial view of a club head according to the invention; and

[0075] Fig. 23 is an enlarged perspective partial view of the interior of the club head of Fig. 7.

[0076] DESCRIPTION OF PREFERRED EMBODIMENTS

[0077] Figures 1 to 22 show various preferred embodiments of golf club heads 1 according to the invention, as well as parts thereof. Elements that perform the same or a similar function are provided with the same reference numerals, regardless of whether they belong to the same or different embodiments.

[0078] Figures 1 to 7 show various types of club heads 1 according to the invention, which together form a complete golf club head set. To make the interior of the club heads 1 visible, some of them are shown transparent for illustrative purposes.

[0079] Regardless of the type of club head 1, it always has a shell 3 made of a composite material, which forms a large part of the outer surface of the club head 1 and surrounds an interior of the club head 1. The shell 3 thus forms a base body of the club head 1, which absorbs and transmits the main forces occurring during the game of golf and forms the main structure of the club head 1. The interior in each case forms a core made of a gaseous material, in particular air. The club head 1 is therefore always hollow, with the shell 3 forming a hollow body. By designing the shell 3 as a hollow body, which has a gas-filled, in particular air-filled interior, a particularly light club head with good hitting characteristics is achieved.

[0080] The composite material of the shell 3 is preferably a fiber-reinforced plastic material, in particular a carbon fiber-reinforced plastic material. Polyetheretherketone (PEEK) or epoxy resin (EP) is preferably used as the plastic material.

[0081] The club head 1 has a hosel 2, which serves to attach the club head 1 to a club shaft (not shown in the figures). The club shaft can be inserted into the hosel 2 and thus into the club head 1.

[0082] On the front side of the shell 3 of all the racket types shown in Figures 1 to 7, a striking plate 6 is attached. The striking plate 6, which forms an additional element preferably made of a thin-walled metal sheet, preferably of iron, steel, stainless steel or a light metal such as titanium, can have grooves on its front side to improve the striking properties, as can be seen in Figures 1 to 7. The back of the striking plate 6, not visible in Figures 1 to 7 but shown in Figure 11, has a laser-structured surface 10 for attachment to the shell 3. The laser-structured surface 10 forms a connection area 61 of the striking plate 6, with which the striking plate 6 rests against the outside of the shell 3.

[0083] In the interior of the club head 1, which is surrounded by the shell 3 and delimited on the outside, two weighting elements 7 are arranged in each of the types shown in Figures 1 to 7. The weighting elements 7 form further additional elements and are preferably each made of a metal, such as tungsten, lead, brass, iron or an alloy thereof. The weighting elements 7 typically have an individual weight of 20g or more. The sum of the weights of all weighting elements 7 provided in a club head 1 is preferably 60g or more, more preferably 100g or more. In the embodiments shown here, the weighting elements 7 are each arranged laterally on the club head 1. It has been found that with such an arrangement of the weighting elements 7, a particularly good weight distribution with simultaneous good power transmission within the shell 3 can be achieved.

[0084] The weighting elements 7 are each cast, pressed, or sintered parts, which as a whole have an irregular geometric shape that is at least partially adapted to the inner surface of the shell 3. The weight distribution achieved by the weighting elements 7 is thus optimally adapted to the shape of the respective racket type.

[0085] The weighting elements 7 each have a connection area 71 with a multi-stepped surface 11, which is clearly visible, for example, in Figures 9c and 10b. The weighting elements 7 are each attached to the inner surface of the shell 3 via the connection area 71.

[0086] Figures 8a to 8c, 9a to 9c and 10a and 10b each show an enlarged external view of an exemplary club head type and parts thereof.

[0087] In Figures 8a and 9a, in conjunction with Figures 8b and 9b, respectively, it can be seen that a base plate 8 is attached to the underside of the club head 1. The base plate 8, which rests on the outside of the shell 3, serves to reinforce the underside of the club head 1, which is generally particularly exposed during golf and thus susceptible to damage. The base plate 8 forms an additional element of the club head 1, preferably made of a thin-walled metal sheet. It has a connection area 81 with a laser-structured surface, which serves to permanently attach the base plate 8 to the shell 3.

[0088] The above-mentioned additional elements, each made of metal, in the form of the striking plate 6, the weighting elements 7 and the base plate 8 are each embedded in the composite material of the shell 3 with their connection areas 61, 71 and 81, respectively. There is therefore a certain engagement of the shell 3 with the respective additional element 6, 7 or 8. For this purpose, during the manufacture of the club head 1, the composite material of the shell 3 is cast onto the respective additional element 6, 7 or 8. The additional elements 6, 7, 8 are thus cast integrally with the composite material of the shell 3. In an alternative manufacturing method, it would also be conceivable to injection-mold the composite material of the shell 3 onto the additional elements 6, 7, 8.

[0089] To make the connection even stronger, the composite material of the shell 3 can each have an adhesive in the connection areas 61, 71, and 81. The base material of the shell 3 is then coated with an adhesive in the corresponding areas, whereby the adhesive can be considered a component of the composite material. The metal parts or additional elements 6, 7, 8 are then bonded to the shell 3 over a large area. This bonding is particularly advantageously carried out in situ with low-viscosity, reactive epoxy resins, and even more advantageously under vacuum and at elevated temperature, so that the adhesive can optimally wet the surface at a low viscosity (preferably between 50-10,000 mPas, in particular 100-500 mPas).

[0090] Due to the laser structuring and / or the multiple steps in the connection area, the surface area relevant for connecting the additional elements 6, 7, 8 is significantly enlarged. When the composite material is cast, it penetrates into the local recesses formed by the steps or laser structuring, so that the additional elements 6, 7, 8 are embedded in the material of the shell 3, creating a particularly tight and secure connection between the components. The strength of the connection between the additional elements 6, 7, 8 and the shell 3 is thereby significantly increased, significantly reducing the risk of the additional elements 6, 7, 8 slipping or even detaching from the shell 3.

[0091] Preferably, the connection areas 61, 71, and 81 of the impact plate 6, the weighting elements 7, and the base plate 8 are also roughened. This allows the materials of the additional elements 6, 7, 8 and the shell 3 to interlock even better, thereby making the connection even stronger. The roughening of the surfaces of the respective connection areas 61, 71, and 81 is preferably achieved by sandblasting, chemical etching, and / or surface laser treatment.

[0092] In the cross-sectional view of Figure 10c, the steps of the multi-stepped surfaces 11 of the connection areas 71 of one of the weighting elements 7 are clearly visible. The steps of the stepped surface 11 provided on the front side of the weighting element 7 each form a surface that is perpendicular to the intended main stroke direction H with a deviation of a maximum of 40°, preferably a maximum of 20°. In the embodiment shown in Figure 10c, the angle a of the deviation with which the steps of the stepped surface 11 with their respective surfaces are perpendicular to the intended main stroke direction H is approximately 14°. In this way, the forces acting on the club head 1 during the tee-off can be particularly well absorbed in the connection area 71.Tests have shown that the connection of the weighting elements 7 can be further improved by aligning the steps in such a way that they each form a surface perpendicular to the intended main impact direction H. In practice, very good results have already been achieved with a step whose respective step surfaces are perpendicular to the intended main impact direction H with a deviation of a maximum of 40°, preferably a maximum of 20°.

[0093] Preferably, all surfaces of the connection areas of the weighting elements 7 facing in the intended main impact direction in the projection form a multi-stepped and / or laser-structured surface, wherein the steps of all these surfaces are advantageously aligned such that they each have a surface perpendicular to the intended main impact direction H with a deviation of a maximum of 40°, preferably a maximum of 20°.

[0094] Slipping or even detachment of the weighting elements 7 could thus be further reduced in long-term tests.

[0095] In the rear area of ​​the respective weighting element 7, i.e., on the outer surfaces that, in projection, are at least partially directed against the intended main impact direction H, the multi-stepped surface 11 preferably forms undercuts relative to the main impact direction H. Such undercuts are provided, for example, in the weighting elements 7 shown in Figure 9c, in the areas marked by the dashed arrows. The strength of the connection of the weighting elements 7 can thereby be improved, particularly with regard to the main forces occurring during impact.

[0096] The laser-structured surface 10 of the connection area 61 of the impact plate 6, visible in Figure 11, has a regular geometry with a multitude of parallel, vertically intersecting, and regularly spaced grooves. With such a pattern, a particularly strong connection of the impact plate 6 to the shell 3 could be achieved. Due to the regular pattern, the laser structuring of the connection area 61 is also clearly visible to the naked eye. The spacing of the parallel grooves is preferably in the range between 0.1 mm and 0.3 mm, in particular approximately 0.2 mm, which has proven to be a good compromise between the strength of the connection on the one hand, and the labor required and thermal distortion of the plate during energy input on the other.

[0097] Figure 11 shows a microscopic image of the connection area between a striking plate 6 with a laser-structured surface 10 and the composite material of a shell 3. The regularly spaced grooves of the laser-structured surface 10 and the interlocking of the materials of the two components are clearly visible. Components 6 and 3 are thus connected to each other in a form-fitting and material-locking manner.

[0098] A microscopic image of the connection area between the striking plate 6 and the shell 3 of another club head 1, also according to the invention, is shown in Figure 13. The laser-structured surface 10 here has an additional structure with small local elevations and depressions in the intermediate surfaces 13 arranged between the grooves. The additional structure of the intermediate surfaces 13 can be achieved by welded metal splashes. The same laser-structured surface 10 is shown in plan view in Figure 10. Figure 15 schematically shows a corresponding contour image. The additional structure in the intermediate surfaces 13 allows the total surface area of ​​the connection area to be further enlarged, thereby further strengthening the connection between the components.

[0099] Figure 15 shows that the grooves formed by the laser-structured surface 10 partially widen downwards and / or form undercuts 12. By adjusting the parameters appropriately during the preferably pulsed laser deposition of the grooves, a downward widening of the grooves can be easily achieved and the formation of undercuts can be induced. Undercuts 12 are also formed by the local elevations in the intermediate surfaces 13. The material of the impact plate 6 can thus be gripped by the composite material of the shell 3, creating a particularly strong connection.

[0100] With regard to manufacturability and effectiveness, the grooves of the laser-structured surface 10 preferably have a width in a range between 30 and 100 μm, in particular between 30 and 50 μm. The depth of the grooves is preferably in a range between 20 and 10 μm, in particular between 30 and 10 μm. Grooves with a width less than 30 μm, for example in a range between 15 and 30 μm, and / or with a depth less than 20 μm, for example in a range between 10 and 20 μm, could prove advantageous in the future, depending on their manufacturability using a laser.

[0101] Figure 16a shows a cross-sectional view of a microscopic image of the laser-structured surface 10 of the striking plate 6 of another club head according to the invention. Figure 16b shows the contours in the area of ​​the interfaces for better visibility. Here, too, it is clearly visible how the composite material of the shell 3 engages the grooves of the laser-structured surface 10 and even engages behind them in the areas of the undercuts 12. Mutual engagement also occurs in the areas of the intermediate surfaces 13, where engagement behind the undercuts 12 also occurs.

[0102] Another variant of a laser-structured surface 10 with undercuts 12 is shown as a microscopic image in Figure 17a and as a traced contour in Figure 17b. The structuring of the intermediate surfaces 13 is considerably more pronounced here compared to the embodiment in Figures 16a and 16b, i.e., on a similar scale to the grooves arranged between them.

[0103] Figures 18 to 21 illustrate various possible geometric configurations of the laser-structured surface 10. Figure 18 shows the aforementioned preferred arrangement of vertically intersecting grooves. Figures 19 and 20 show a laser-structured surface 10 with cross-shaped depressions or elevations in a parallel or offset arrangement. In the embodiment of Figure 21, the laser-structured surface 10 has circular depressions or elevations. All of the laser-structured surfaces 10 shown in the variants of Figures 18 to 21 have a regular geometry with local elevations or depressions arranged at equal distances from one another.

[0104] In order not to negatively influence the positive properties of the composite material of the shell 3 with regard to elasticity and natural frequencies, the impact plate 6 and the base plate 8 are each designed to be as thin as possible. Preferred thicknesses of the impact plate 6 are in a range of 0.2-0.8 mm, in particular approximately 0.5 mm. Preferred thicknesses of the base plate 8 are in a range of 0.8-1.25 mm. Figure 22 shows that the impact plate 6 preferably has an edge bevel 14, i.e., the edge termination of the impact plate 6 is chamfered. The sheet thickness is tapered towards the edge by preferably 30-50%. Typically, the edge bevel 14 is 1-4 mm wide. The grooves of the laser-structured surface 10 are advantageously present up to the outer edge. The edge region of the impact plate 6, in particular the edge bevel 14, can also be laser-structured more densely to further strengthen the bond in this area.

[0105] A further measure, which is preferably used in addition to the laser-structured and / or multi-stepped and optionally roughened surfaces to prevent slipping or detachment of the weighting element 7, can be seen in Figure 23: The shell 3 has a plurality of inwardly projecting projections 15, each of which rests against an outer side of the weighting element 7 in the region of an edge and thereby hinders its mobility. Also clearly visible in Figure 23 is the core 4 of the club head 1, which is essentially completely surrounded by the shell 3 and is formed from a gaseous material, such as air in particular. The shell 3 thus forms a hollow body.

[0106] LIST OF REFERENCE SYMBOLS

[0107] 1 club head

[0108] 2 Hosel 10 Laser-structured surface

[0109] 11 Stepped surface

[0110] 3 shell 12 undercut

[0111] 4 Core 13 Intermediate surface

[0112] 6 Impact plate 14 Edge phase

[0113] 61 Connection area 15 projection

[0114] 7 Weighting element

[0115] 71 Connection area H Main direction of impact

[0116] 8 Base plate a angle

[0117] 81 connection area

Claims

PATENT CLAIMS 1. A club head (1) for a golf club, comprising an outer shell (3) made of a composite material, in particular of a fiber-reinforced plastic; and one or more additional elements (6, 7, 8) made of a metal, each of which is at least partially embedded in the composite material of the shell (3) by means of a connection region (61, 71, 81), characterized in that the connection region (61, 71, 81) of the one or more additional elements (6, 7, 8) is each formed by a laser-structured and / or multiply stepped surface (10, 11).

2. Club head (1) according to claim 1, wherein at least a part of the additional element(s) is / are one or more weighting elements (7), each of which is / are arranged entirely inside the shell (3).

3. Club head (1) according to claim 2, wherein a first and a second of the one or more weighting elements (7) are each arranged laterally on the club head (1) with respect to the intended main stroke direction (H).

4. Club head (1) according to claim 2 or 3, wherein the weighting element(s) (7) as a whole each have an irregular geometric shape which is at least partially adapted to the inner surface of the shell (3).

5. Club head (1) according to one of the preceding claims, wherein the composite material comprises an adhesive, in particular an adhesive in the form of an epoxy resin, in order to connect the additional element(s) (6, 7, 8) to the composite material of the shell (3).

6. Club head (1) according to one of the preceding claims, wherein at least one of the additional element(s) (6, 7, 8) is a striking plate (6) which is attached to an outer side of the shell (3) and serves to hit a golf ball.

7. Club head (1) according to one of the preceding claims, wherein substantially all surfaces of the connection regions (61, 71, 81) of the additional element(s) (6, 7, 8) which, in the projection, are at least partially directed in the intended main striking direction (H) are formed by a multiply stepped and / or laser-structured surface (10, 11).

8. Club head (1) according to one of the preceding claims, wherein the connection region (61, 71, 81) is formed by a multi-stepped surface (11), and wherein the steps of the multi-stepped surface (11) each form a surface which is perpendicular to the intended main striking direction (H) with a deviation of a maximum of 40°, preferably a maximum of 20°.

9. Club head (1) according to one of the preceding claims, wherein the connection region (61, 71, 81) is formed by a laser-structured surface (10), and wherein the laser-structured surface (10) has a plurality of grooves formed by means of a laser, preferably parallel to one another and / or perpendicular to one another.

10. Club head (1) according to claim 9, wherein the grooves each have a greater width in depth than at the surface.

11. Club head (1) according to one of the preceding claims, wherein the connection region (61, 71, 81) is formed by a roughened surface, and wherein the roughening is preferably produced by means of sandblasting, chemical etching and / or surface laser treatment.

12. Club head (1) according to one of the preceding claims, wherein the additional element(s) (6, 7, 8) each have an undercut (12) relative to the intended main striking direction (H), which is preferably arranged in a region of the head which is rearwardly facing the main striking direction (H). respective additional element (6, 7, 8).

13. Club head (1) according to one of the preceding claims, wherein the additional element(s) (6, 7, 8) are each arranged completely inside the shell (3), wherein the shell (3) has projections (15) projecting into the interior to prevent displacement of the additional element(s) (6, 7, 8) relative to the shell (3).

14. Club head (1) according to one of the preceding claims, further comprising a core (4) made of a gaseous material, in particular air, or of a foam material, which is at least partially, preferably completely, surrounded by the shell.

15. A golf club comprising a club head (1) according to any one of the preceding claims.

16. A method for producing a club head (1), which is preferably designed according to one of the preceding claims, wherein the method comprises at least the step of embedding one or more additional elements (6, 7, 8) made of a metal, each with a connection region (61, 71, 81), at least partially in a composite material, in particular in a fiber-reinforced plastic, of an outer shell (3) of the club head (1), characterized in that the connection region (61, 71, 81) of the additional element(s) (6, 7, 8) is laser-structured and / or multiply stepped before being embedded in the composite material.

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