Golf club head

Abstract

To provide a method of forming a device of a composite material.SOLUTION: The method includes: providing a mold having an internal space forming a cavity with an inner surface having a shape corresponding to an inner shape of a device to be formed; placing inserts at one or more predefined positions along the inner surface; holding the inserts at the one or more positions; introducing removable material into the cavity of the mold to form a pattern having the inserts fixed therein when the removable material is in a solid form; and removing the pattern having the inserts fixed therein from the mold.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present invention relates to a method for forming a composite material device, a pattern for a composite device, and a composite material device, in which inserts and / or functional components are essentially embedded in the pattern and / or the device during the method.

Background Art

[0002] Composite materials are often used to form lightweight and high-strength devices (also called composites) instead of metal devices such as vehicle panels and device housings.

[0003] Composites are further used to form panels, frames, interior parts, housings, etc., for example, in vehicles, sports equipment, electronic applications, robotics, composite equipment, tools, etc., to form lightweight and stable parts. <00​​​​​​​​​​​​​​​​​​​This objective is satisfied by a method for forming a composite material device having the configuration described in claim 1.

[0007] The method is, A step of providing a mold having an internal space that forms a cavity having an inner surface, wherein the cavity has a shape corresponding to the inner shape of the device to be formed, The steps include positioning the insert at one or more predetermined positions along the inner surface, The steps include holding the insert in one or more positions, The steps include introducing removable material into the mold, such that when the removable material is in a solid state, it forms a pattern in which the insert is fixed inside, The steps include removing the pattern in which the insert is fixed from the mold, and Includes.

[0008] The use of patterns to form part of a composite mold is well known for manufacturing composites with clearly defined internal structures. The general idea underlying this invention is to embed inserts, which form either functional components or supports for functional components, directly into a removable pattern in place, so that they can be embedded in a composite device in the same location. Complex housing structures can also be formed in this way. This makes cost-effective composite manufacturing available through the use of patterns.

[0009] In this regard, the support for the functional component can be the negative shape of the functional component and may include undercut recesses used to connect the functional component to the composite.

[0010] The holding step may include holding the insert through the application of a vacuum, the use of a slider, a functional element, and / or the use of a magnet. In this way, the insert can be held in a simple and repeatable manner.

[0011] The insert may include at least one of a magnetic material and a metal. Such an insert may be held in a suitable manner in a mold for a pattern.

[0012] The insert can be shaped to form a functional component, or can be formed by a functional component of the device, i.e., it is a functional component. In this way, either a functional component or a support for a functional component can be directly embedded in the pattern and later incorporated into the device, either directly or by a support formed by the insert.

[0013] The removable material patterns can be manufactured by injection molding or wax casting processes. Such processes enable rapid and cost-effective production of the patterns.

[0014] The removable material is introduced into the cavity in liquid form. In this way, it is possible to ensure that the entire inner surface of the mold is covered with the removable material, thereby creating a pattern with the desired outer shape.

[0015] The step of introducing the removable material into the mold may include filling 40-99% of the cavity with the liquid removable material. In this way, the effects of shrinkage on the outer surface of the pattern can be minimized.

[0016] This method may further include the step of introducing gas into the removable material present in the mold and pressurizing the removable material present in the mold with a pressure difference selected within the range of 0.02 to 20 bar between the outside of the formed pattern and the hollow space within the pattern. In this way, the effect of shrinkage on the outer surface of the pattern can be further minimized.

[0017] The method may further include the step of applying a pressure selected in the range of 0.02 to 0.95 bar, particularly 0.05 to 0.5 bar, into the cavity before introducing the removable material into the cavity. In this way, a pattern having at least a substantially defect-free outer surface can be adequately formed.

[0018] This method includes the steps of moving the mold to completely coat the inner surface of the mold with the removable material in liquid form, The process may further include a step of solidifying the removable material within the mold. By preventing shrinkage effects on the surface of the pattern due to centrifugal force or gravity acting on the removable material, a pattern can be obtained in which the insert is reliably positioned on the outer surface of the pattern to form a functional component in a predetermined position on the inner surface of the device.

[0019] This method may further include the step of covering the pattern having the insert with one or more layers of a web of fibrous material. By covering the pattern with one or more layers of a web of fibrous material, a composite device having an internal shape corresponding to the external shape of the pattern can be formed.

[0020] In this regard, it should be noted that the pattern can be used as part of a mold for the so-called resin transfer molding (RTM) process. In this case, the mold can be covered with roving and then inserted into another mold for resin to be added and heat-treated to form the final composite device in a manner known in itself.

[0021] In this regard, it should be noted that each web of the fibrous material can be a layer of fabric made of woven fibers formed by interweaving two or more tow of fibers at right angles to each other. Additionally or alternatively, the web of the fibrous material can be formed by the tow of fibers. In this regard, the tow of fibers is a bundle of fibers such as yarn.

[0022] In this regard, while the tow of fibers can be applied at the position of the insert to reinforce the insert of the finished device, it should be further noted that the woven fabric can be introduced into the area representing the inner and / or outer surface of the device.

[0023] One or more layers of the fibrous material can include carbon fibers, glass fibers, basalt fibers, natural fibers such as wood fibers, and hemp fibers, aramid fibers, polyester fibers in a dry state or as a prepreg. Such fibers can be beneficially used in the formation of composite devices. In this regard, it should be noted that a prepreg is a layer of fibers containing an adhesive.

[0024] This method may further include the step of placing the pattern having the insert and covered with one or more layers of fibrous material into another mold. In this way, one or more layers of the web of the fibrous material can be held within the other mold between the pattern and the inner surface of the other mold, and the predetermined inner and outer shapes of the device can be formed through the one or more layers of the fibrous material.

[0025] This method may further include the step of heating the other mold to a first, second, and / or third temperature within a first, second, and / or third temperature range. By selecting an appropriate heating step, the resin can be transported to the desired position within the mold, the resin can be cured around one or more layers of the fibrous material within the mold, and the removable material can be removed from the mold.

[0026] The first, second, and third temperatures can be used for at least one of heating the mold to assist in introducing the resin into the mold, heating the mold to cure the material of the device to be formed, and removing a removable material such as wax.

[0027] It should also be noted that the first temperature range is preferably a temperature range of ±3° centered around the desired first temperature. The first temperature is preferably selected between 30 and 85°C, particularly between 50 and 80°C.

[0028] It should also be noted that the second temperature range is preferably a temperature range of ±3° centered around the desired second temperature. The second temperature is preferably selected between 60 and 105°C, preferably between 70 and 95°C. It should be noted in this regard that the temperature can also be gradually adapted step by step over the entire temperature range.

[0029] It should also be noted that the third temperature range is preferably a temperature range of ±3° centered around the desired third temperature. The third temperature is preferably selected between 80 and 130°C, preferably between 95 and 120°C.

[0030] This method may further include a step of introducing the resin into the other mold before and / or during the step of heating the mold to the first temperature, wherein a vacuum is applied optionally during the step of curing the resin. By applying temperature and / or vacuum, the resin can have a viscosity more fluid than at room temperature, thereby flowing better through the voids between one or more layers of fiber material disposed between the pattern and the inner surface of the cavity. By introducing the resin into the other mold and coating one or more layers of a web of fiber material in the space between the inner surface of the other mold and the outer surface of the pattern, a composite device can be formed having functional components essentially formed in the walls of the device at the positions of the inserts present in the pattern and having the desired inner and outer shapes.

[0031] This method comprises the step of curing the resin in the other mold to form the device, wherein the curing step may further include at least one of heating and irradiation with UV light. By steps of such a method, the removable material can be beneficially cured.

[0032] The step of applying heat may include heating the other mold to the second temperature. This is a quick and efficient method for curing the resin in one or more layers of the fibrous material web.

[0033] The resin may be heated to a second temperature, for example, below the curing temperature of the resin, when introducing the resin into the other mold. In this way, the resin can be more efficiently transported around one or more layers of the fibrous material web present in the other mold, in order to avoid the inclusion of bubbles that may degrade the quality of the housing at the location of the bubbles.

[0034] The resin may be one of a one-component resin, a two-component resin including a curing agent, or a multi-component resin including one or more curing agents. The resin may include epoxy-based resins, polyurethane-based resins, cyanate esters, or other base resins suitable for injection or injection. Such resins can be beneficially used for forming composite devices.

[0035] This method may further include the step of removing the removable material from the device. In this way, the pattern can be removed without damaging the composite device. This method may further include the step of heating the other mold to a third temperature. By heating the removable material to a temperature above the melting point of the removable material, rapid removal of the removable material is possible.

[0036] In this regard, it should be noted that the third temperature step can be carried out in a further device such as an oven or furnace.

[0037] In a further embodiment, the present invention relates to a removable material pattern, which can optionally be formed by the method described herein, wherein the pattern includes one or more inserts positioned at one or more predetermined positions along the outer surface of the pattern. Such patterns can be usefully used in the manufacture of composite devices.

[0038] The pattern of the removable material may have a melting point selected in the temperature range of 80 to 130°C, preferably in the range of 95 to 120°C. The pattern of the removable material may remain shape-stable at a temperature selected in the range of 60 to 100°C, preferably in the range of 70 to 95°C. The pattern of the removable material may remain shape-stable at a temperature lower than the melting point of the removable material. These properties of the pattern make it particularly suitable for low-cost, high-precision manufacturing of composite devices.

[0039] In a further embodiment, the present invention relates to a composite material device which can optionally be formed by a method described herein and comprises one or more functional components arranged at one or more predetermined positions along the inner surface of the pattern, wherein the functional components are formed integrally with the device and one component, or are embedded within a structure formed integrally with the device and one component.

[0040] Functional components may be selected from a group of members consisting of tappets with undercuts, pockets with undercuts, internal seats (cylindrical), bearing seats with optional insertion points for circlips, T-shaped grooves (formed outward and inward), external threads such as bolts or studs with external threads, internal threads such as sleeves with internal threads or nuts, bayonet connections, open wedge sockets, eyelets, ball studs, dowels and dowel pins (both optionally with insertion points for circlips), hooks, spring elements, bearing blocks, bearing blocks with clamps, bored or unbored serrated pins / couplings, sleeves, apertures, supports for one or more of the aforementioned, and combinations thereof.

[0041] The device may have a pre-settable wall thickness with a tolerance of ±0.5 mm, particularly ±0.1 mm, particularly ±0.05 mm, with respect to a wall thickness selected in the range of 1 to 4 mm, and in particular, with respect to the length of the device material cut from the device in a width selected in the range of 0.5 to 2.5 cm, in the range of 1 to 5 cm from the device. Using conventional types, such tolerances are not possible in hollow devices.

[0042] The device may have a wall thickness tolerance of ±0.3 mm, particularly ±0.2 mm, and very preferably less than 0.05 mm, for a wall thickness selected in the range of 1 to 4 mm.

[0043] The device may have a surface profile tolerance of ±0.1 mm. In this way, devices with particularly smooth surfaces can be achieved by this teaching.

[0044] In this context, it should be noted that surface profile tolerances are a standard measurement technique used to define the surface quality of an object. The more uniform the surface, the lower the tolerance. A surface profile is defined by a uniform boundary around the surface where the surface elements must exist. Surface profiles are complex tolerances that simultaneously control the shape, size, orientation, and sometimes position of a feature. Surface profiles are three-dimensional tolerances that apply in all directions, regardless of the drawing view in which the tolerance is specified. This is typically used for parts with complex external shapes and a constant cross-section, such as extrusions.

[0045] To measure the tolerance of a surface profile, two planes are placed around the surface to which the tolerance profile is being measured, and the tolerance is defined by the distance between the planes placed around the surface.

[0046] The device may have a surface profile tolerance of ±0.05 mm, particularly ±0.03 mm, and particularly ±0.01 mm at the location of the functional component forming the second insert. Such a device has a particularly smooth surface.

[0047] Two or more inserts can be provided, and the angular tolerance for positioning between two inserts in the device can be less than 0.3°, preferably less than 0.2°, and if two or more inserts are fixed to each other in a pattern, the angular tolerance between two inserts can be less than 0.1°, preferably less than 0.05°. Two or more inserts can be provided, and the axial tolerance for positioning between inserts in the device is less than 0.2 mm, preferably less than 0.1 mm, and if two or more inserts are provided in a pattern and fixed to each other, the axial tolerance between two inserts can be less than 0.1 mm, preferably less than 0.05 mm. Two or more inserts can be provided, and the positioning tolerance between inserts in the spacing between inserts in the device can be less than 0.1 mm + 1 mm / m, preferably less than 0.05 mm + 0.5 mm / m, and if two or more inserts are fixed to each other in a pattern, the positioning tolerance between two inserts can be less than 0.05 mm + 0.5 mm / m, preferably less than 0.05 mm + 0.2 mm / m.

[0048] The device can be the head of a golf club, and one or more functional components may be selected as a weight integrated into the golf club, a shaft connector insert that forms a connector to the shaft of the golf club, and at least one of the surfaces that function as the face of the golf club. Using the above method, a golf club with a very favorable weight distribution can be made.

[0049] One or more functional components can be provided that function as one or more weights of the head, one functional component can be provided that function as a shaft connector insert, and one functional component can be provided that function as the face of the golf club head. In this way, one or more weights can be formed separately from the face, thereby obtaining a particularly favorable weight distribution within the golf club head. In this regard, it should be noted that both iron and wood heads can be formed in this manner, particularly using the method described herein. By embedding the shaft connector insert, the angular accuracy of the face relative to the shaft position can be improved compared to conventional golf clubs.

[0050] Further embodiments of the present invention are described below in the accompanying figures and the following description of the dependent claims. The present invention is described in detail below by embodiments and with reference to the illustrated drawings. [Brief explanation of the drawing]

[0051] [Figure 1] A perspective view of functional components positioned at one or more predetermined locations along the inner surface of a device. [Figure 2] A partial schematic cross-sectional side view of a mold for forming device patterns that show various inserts. [Figure 3] A partial schematic cross-sectional side view of a mold for forming a device pattern that indicates an insert present within the mold. [Figure 4] A partial schematic cross-sectional side view of a mold for forming a pattern for a device filled with removable material around the insert of the device. [Figure 5] A cross-sectional view similar to Figure 4, in which a pattern with an internally embedded insert has been removed from the mold. [Figure 6] A cross-sectional view similar to Figure 5, where the pattern is covered with a layer of fibrous material. [Figure 7] A cross-sectional view similar to Figure 6, where the covered pattern is arranged on other types. [Figure 8] A cross-sectional view similar to Figure 7, with space around the fiber layer between the pattern and the inner surface of the other mold filled with resin. [Figure 9] A cross-sectional view similar to Figure 8, where the device has been removed from other types. [Figure 10] A cross-sectional view similar to Figure 9, in which the pattern has been removed from the aforementioned device. [Figure 11] A cross-sectional view similar to Figure 10, showing the insert removed from the device. [Figure 12] A cross-sectional view similar to Figure 10, having further types of functional components that are inherently present on the inner surface of the aforementioned device. [Figure 13] A cross-sectional view similar to Figure 10, having further types of functional components that are inherently present on the inner surface of the aforementioned device. [Figure 14] A cross-sectional view similar to Figure 10, having a further type of functional component that is essentially present on the inner surface of the device, wherein the further type of functional component is an insert previously embedded in a pattern. [Figure 15] A cross-sectional view similar to Figure 14, having a further type of functional component that is essentially present on the inner surface of the device, wherein the further type of functional component is an insert previously embedded in a pattern. [Figure 16] A schematic diagram of the internal components of a device in which a bearing support is integrally formed with the device. [Figure 17] A diagram of a golf club head. [Figure 18] A diagram showing the pattern of a golf club head. [Modes for carrying out the invention]

[0052] In the following, the same reference numerals are used for parts with the same or equivalent function. Statements made considering the orientation of a part are made relative to the position shown in the drawing and may naturally change depending on the actual application location.

[0053] Figure 1 shows a perspective view of functional components 12, 12' positioned at one or more predetermined locations along the inner surface 14 of the housing 16 of the device 10. The functional component 12 can be formed by and within the housing 16 of the device 10 itself. Alternatively, the functional component 12' can be directly supported within the housing 16 of the device 10 by a support formed within the housing 16.

[0054] The functional component 12' shown in Figure 1 is a hook 12' and a bolt 12' that are located within the pattern 54 for the device and are formed by inserts embedded in the device 10 during the manufacturing of the device 10. The support for the functional component 12 shown in Figure 1 is a pocket 12 with an undercut, an internal seat 12 (cylindrical), a support 12 for the nut, a bearing seat 12, an inwardly facing T-shaped groove 12, and a sleeve 12.

[0055] Functional components or supports for functional components may be one of the following types of functional components 12, 12', selected from the group of members consisting of tappets with undercuts, bearing seats with insertion points for circlips, outward-facing T-shaped grooves, external threads such as bolts and studs with external threads, internal threads such as sleeves or nuts with internal threads, bayonet connections, open wedge sockets, eyelets, ball studs, dowels and dowel pins (both optionally with insertion points for circlips), spring elements, bearing blocks, bearing blocks with clamps, bored or unbored sawtooth pins / couplings, apertures, supports for one or more of the above, and combinations thereof.

[0056] To form the device 10, a pattern 54 (see Figure 4) of removable material M is first formed within the mold 18. Figure 2 shows a partial schematic cross-sectional side view of the mold 18 for forming the pattern 54 of the device 10. The mold includes an upper half and a lower half 18', 18'', which together define a cavity 20 having an inner surface 22.

[0057] The seal 19 is located between the upper and lower halves 18', 18'' to seal the cavity from the outside. Such a seal 19 can be formed, for example, by an O-ring.

[0058] The first and second types of inserts 24, 24' are positioned and held in the inner surface 22. The first type of insert 24 is inserted into the cavity 20, for example via a slider 26, and is thus formed by a structure that can protrude into the cavity before and during the manufacturing of the pattern 54 for the device 10, thereby forming a structure on the outer surface 56 (see Figure 4) of the pattern 54. The structure can thereby form a recess within the pattern 54, which can be filled with the material that forms the device 10.

[0059] A second type of insert 24' is an insert intended to remain within the pattern 54 after it has been formed. This second type of insert 24' can similarly form structures on the outer surface 56 of the pattern 54. These structures can form supports for the functional component 12, i.e., they can have shapes that complement the functional component 12'. Alternatively, the second type of insert 24' is the functional component 12 (see Figures 14 and 15). The functional component 12' is then bonded to the device 10 via structures present on the outer surface 56 of the pattern 54.

[0060] A second type of insert 24' can be held within the mold cavity 20 via one or more magnets 28 or through the application of a vacuum V. For this purpose, the second type of insert 24' is connected via a vacuum passage 30 to a vacuum pump 32 connected to the mold 18 via a vacuum port 36.

[0061] To form a pattern, a removable material M (see, for example, Figure 4) is introduced into the cavity 20 from a container 38 of the removable material, which can be wax W. The removable material M is introduced into the cavity 20 in liquid form via ports 40 and lines 42. In fact, the volume of the cavity 20 of the mold 18 is only filled to 40-98% with the liquid removable material M.

[0062] To pressurize pattern 54, gas G can be introduced into the removable material M via a gas supply unit 44 connected to the mold 18 through gas ports 46 and gas lines 48. Additionally or alternatively, the cavity 20 may be sealed in that manner, or sealed so that gas present in the cavity is compressed upon introduction of the removable material M to form a pressurized gas G within the cavity.

[0063] As shown in Figure 4, in each case, the gas G creates a hollow space 54' within the pattern 54. The gas fills this cavity 54' and pressurizes the removable material M present in the mold 18 so that the wax 20 covers the entire surface of the cavity 20. The pressure difference between the outside of the formed pattern 54 and the hollow space 54' within the pattern 54 is selected to be in the range of 0.02 to 19 bar, i.e., the pressure inside the hollow of the wax pattern can be selected to be in the range of 1.02 to 20 bar before the wax solidifies, i.e., when the wax is in a molten state. In this regard, it should be noted that the pressure inside the hollow of the wax pattern may be lower after the wax has solidified than before the wax has solidified, due to the shrinkage of the wax as it solidifies.

[0064] Typically, the wax is selected to melt at high temperatures in the range of 60–140°C, particularly 70–120°C, and to solidify at low temperatures in the range of 30–100°C, particularly 60–90°C. The temperature difference between the high and low temperatures is preferably selected to be less than 40°C, preferably less than 30°C, particularly less than 20°C, and particularly less than 10°C.

[0065] The wax may have a viscosity exceeding 2000 mPas at temperatures below 85°C and a viscosity of less than 800 mPas at temperatures above 105°C. Such waxes have been found to be particularly stable in shape up to their melting point, and the transition between liquid and solid states occurs over a relatively narrow temperature range, making them more cost-effective in their use.

[0066] When forming the wax pattern 54, the mold 18 can be heated to a temperature lower than the wax solidification temperature, in particular below the wax solidification temperature, and selected within the range of 1 to 40°C, especially 5 to 25°C. In this way, the wax can be solidified in a more controlled manner, and the shrinkage effect on the surface of the wax pattern can be reduced because the wax does not automatically solidify even when it comes into contact with the surface of the mold cavity.

[0067] The mold cavity can be evacuated to a pressure selected in the range of 0.02 to 0.95 bar, particularly to a pressure selected in the range of 0.05 to 0.5 bar.

[0068] Subsequently, the mold can be rotated around one or more axes of rotation. A first possible axis is shown around the vertical axis 36, in which case the mold 18 can rotate in the direction of the arrow shown around the vertical axis 36 or in the opposite direction. A second possible axis of rotation is around the horizontal axis H, in which case the mold 18 can rotate in the direction of the arrow shown around the horizontal axis H or in the opposite direction. By moving the mold 18 in this way, centrifugal force or gravity biases the pressurized removable material toward the inner surface 22 of the mold 18, as a result, which is completely coated with the removable material, and the resulting pattern has an outer surface 56 that is essentially free from shrinkage and other forms of defects (see Figure 4). During the rotation of the mold 18, it can be cooled, for example using water cooling, which leads to the solidification of the removable material M inside the mold 18.

[0069] To form a pattern 54 having functional components 12, 12' positioned at one or more predetermined locations, a vacuum can be applied to the mold 18 using a vacuum pump. Once a desired vacuum of, for example, 0.3 bar is achieved within the mold 18, a valve can be closed to maintain the pressure within the cavity. Subsequently, a liquid form of a removable material M can be introduced into the mold 18. For example, 80% of the volume of the mold 18 can be filled with a liquid material M, such as wax W. Thereafter, residual air in the mold is compressed by the addition of wax W, such that the pressure within the mold can range from 1.02 to 4 bar, depending on the initial vacuum pressure and the amount of wax added.

[0070] Next, the pressurized gas inside the mold and the rotation of the mold allow the mold 18 to rotate around the axis of rotation while the mold is cooling, so that the liquid wax first covers the entire surface of the mold and forms a wax pattern such that the outer shape resembles the inner shape of the mold and the hollow interior has a wax pattern.

[0071] Especially when forming patterns with complex external shapes, additional gas can be added to the mold before, during, and / or after the addition of the liquid removable material M. Additionally or alternatively, the mold can be filled with the removable material M to more than 80% of the volume of the cavity 20. This additional pressure within the mold guides the liquid removable material into the complex negative shape of the mold, ensuring the formation of a pattern with a substantially defect-free external surface.

[0072] Figure 3 shows a partial schematic cross-sectional side view of the mold, in which, instead of using a movable insert 12 that can move within the cavity 20, the inner surface 22 of the mold 18 includes projections 52 on its inner surface that take over the function of the insert 12 for forming a support structure for the functional component 12'. A second type of insert 24' is inserted into the mold 18. The left insert 24' is held in place by the inner surface 22 via a magnet. The right insert 24 is held in place by a vacuum V, a seal 50 in the form of an O-ring seal between the mold 18 and the insert 24'.

[0073] Figure 4 shows a partial schematic cross-sectional side view of the mold from Figure 3 in which the removable material M has been introduced. The hollow space 54' is also visible.

[0074] Figure 5 is a cross-sectional view similar to Figure 4, where the removable material has solidified and the pattern 54 has been removed from the mold 18. The insert 24' is held in place within the pattern 54 on its outer surface 56. The pattern 54 further includes a recess 58 on its outer surface 56.

[0075] The pattern 54 includes two inserts 24, 24' positioned at one or more predetermined locations along the outer surface 56. The pattern 54 of the removable material M may have a melting point selected in the temperature range of 80 to 130°C, preferably in the range of 95 to 120°C. The pattern 54 may remain shape-stable at temperatures selected in the range of 60 to 100°C, preferably in the range of 70 to 95°C. Generally speaking, the pattern 54 of the removable material M may remain shape-stable at temperatures lower than the melting point of the removable material M.

[0076] Figure 6 shows a cross-sectional view similar to Figure 5, in which pattern 54 is covered with layers 60 and 62 of fibrous material. The woven layer of fibrous material 60 is positioned directly on the outer surface 56, while the tows of the fibers 62 are inserted into the free space of recesses and inserts accessible from the outer surface 56 of pattern 54.

[0077] One or more layers of the fibrous materials 60, 62 may contain carbon fibers, glass fibers, basalt fibers, wood fibers, hemp fibers, aramid fibers, or polyester fibers, either in a dry state or as a prepreg.

[0078] Therefore, the pattern 54 of the removable material M can be used as a mold in a resin transfer molding (RTM) process to form a composite device in a manner known in itself.

[0079] Figure 7 shows a cross-sectional view similar to Figure 6, where the covered pattern 54 is placed inside another mold 64. The other mold 64 has an inner surface 64'. Thus, the layers 60, 62 of the fibrous material are placed between the inner surface 64' of the other mold 64 and the outer surface 56 of the pattern 54.

[0080] Figure 8 shows a cross-sectional view similar to Figure 7, with space around layers of fibers 60, 62 between pattern 54 and the inner surface 64' of another mold 64 filled with resin R. Resin R is introduced from container 66 via supply line 68.

[0081] Other types 64 can be heated to a first, second, and / or third temperature within a first, second, and / or third temperature range via a heating and / or cooling device 96.

[0082] In this regard, it should be noted that when other types 64 are heated to one of the first, second, and third temperatures, the heating step can be carried out gradually or continuously.

[0083] It should be noted that, especially during the RTM process, fiber-and-resin composites are typically heated stepwise to below the glass transition temperature of the resin to prevent the formed device from becoming soft and thereby obtaining a deformed outer and / or inner surface.

[0084] In this regard, it should be noted that the upper half 18' of mold 18, the lower half 18'' of mold 18, and the other molds 64 are preferably formed from a thermally conductive and nonmagnetic material such as aluminum or an aluminum alloy.

[0085] The resin R is introduced into the other mold 64 during the step of heating the other mold 64 to the first temperature. The resin R is heated to below its curing temperature when it is introduced into the other mold 64. To enhance the flow of the resin R with a fluid viscosity, a vacuum V can be simultaneously applied via a vacuum pump 74 connected to a vacuum line 78 via a port 76.

[0086] The resin R is cured in another mold 64 to form the device 10. The curing step includes heating the other mold 64 to the second temperature, which is higher than the first temperature.

[0087] The resin R may be one of a one-component resin R, a two-component resin R including a curing agent, or a multi-component resin R including one or more curing agents. The resin R may include an epoxy-based resin, a polyurethane-based resin, a cyanate ester, or another base resin suitable for injection or injection.

[0088] Therefore, in the aforementioned RTM process, at least one roving layer is provided as a first layer of fiber material 60, and optionally a second layer or several layers of fiber material 62 are also provided. Next, the pattern 54 covered with the first layer of fiber material 60 and optionally the second layer of fiber material 62 is placed in another mold 64. Next, the other mold 64 is evacuated to create a vacuum inside the other mold 64. Then, the resin R is injected into the other mold 64 at a temperature higher than room temperature, but probably lower than the ideal curing temperature of the resin R under pressure. The resin R, which can be pressurized at a high temperature, is more fluid than the unpressurized resin R at room temperature, and therefore can flow more easily through the roving and the other mold 64 to ensure that, if possible, no air pockets are formed in the composite material of the final device.

[0089] Next, the resin R can be solidified, or cured, at a temperature selected to be lower than the melting temperature of the wax pattern 54, preferably by gradually increasing the mold temperature from low to high (e.g., from 90°C to 100°C) between the boundaries of a second temperature range. If necessary, openings and / or apertures can be added to the cured composite device. Subsequently, the temperature of the other mold 64 is gradually increased, for example, from 100°C to 120°C, to dissolve and remove the wax pattern 54. The dissolution and removal of the wax pattern 54 can optionally be carried out outside the mold 64, for example, in an oven.

[0090] As is known to those skilled in the RTM process, the glass transition temperature of the resin can be temporarily raised in the mold while the temperature gradually rises stepwise above the melting point of the wax to form the device. The liquid wax can then be removed through openings and / or apertures provided in the device 10.

[0091] Furthermore, the insert 24' can be removed following the removal of the liquid wax in order to allow the functional components to be placed in the position where the support is consequently formed. For example, in Figure 16, the insert 24' forms a support for a bearing, and then the bearing 84 is placed on the bearing support 12 which is essentially formed within the device 10.

[0092] Figure 9 shows a cross-sectional view similar to Figure 8, where device 10 has been removed from another pattern 64. The removable material M of pattern 54 is still present within device 10.

[0093] Figure 10 shows a cross-sectional view similar to Figure 9, in which the pattern 54 is removed from the device 10 by applying a heating step that heats the material M, which can be removed by heating the other pattern 64 to a third temperature, above its melting point.

[0094] Figure 11 shows a cross-sectional view similar to Figure 10, with insert 24' removed from the device 10. The insert on the left in Figure 10 was used to form an aperture 80 in the housing 16 of the device 10. The insert on the right was used to form a support for the bearing, that is, the bearing race can be assembled with the functional component 12 shown on the right side of Figure 11. The functional component 12 on the left is an internal seat for a component that can cooperate with the bearing seat.

[0095] Therefore, the composite material device 10 includes two functional components 12 positioned at two predetermined locations along the inner surface 14 of the device 10. The functional components 12 are formed integrally with the device 10 as a single part.

[0096] The device 10 may have a pre-settable wall thickness with a tolerance of ±0.5 mm for a wall thickness selected in the range of 1 to 4 mm, and in particular for the length of the material of the device 10 cut from the device 10 in the range of 1 to 5 cm and with a width selected in the range of 0.5 to 2.5 cm.

[0097] Figure 12 is a cross-sectional view similar to Figure 10, showing a seat 12 for a nut, i.e., a component having an internal thread that is essentially present on the inner surface 14 of the device 10.

[0098] Figure 13 is a cross-sectional view similar to Figure 10, in which a T-shaped groove is provided as a functional component 12 that is essentially present on the inner surface 14 of the device 10.

[0099] Figure 14 shows a cross-sectional view similar to Figure 10, in which a functional component 12' in the form of a threaded bolt is embedded in the material of the device 10 on the inner surface 14 of the device 10. The threaded bolt is joined in place by providing an insert surrounding the bolt 12', which holds the bolt 12' in place within the pattern and allows for the formation of a permanent bond between the bolt 12' and the device 10 during the step of curing the resin R, thereby forming the device 10. In this way, the bolt 12' is embedded integrally with the device 10 as a single component.

[0100] Figure 15 shows a cross-sectional view similar to that of Figure 14, in which the sleeve 12' has internal threads that are essentially present on the inner surface 14 of the device 10. Similar to the bolt 12' in Figure 14, the sleeve 12' is bonded to the device during the curing step of the resin R used to form the housing 16 of the device 10.

[0101] Figure 16 shows a schematic diagram of the internal components of device 10. Device 10 includes a shaft 82 extending along the horizontal axis of the device 10, and a ball bearing 84 within the device 10 is attached to the device by a bearing support 12' formed integrally with the device 10 as a single piece. The shaft 82 is also journal-connected to the device 10 in sleeves 86 and 88. The shaft 82 is connected to an electric motor 94 via a transmission 92 and a drive shaft 90.

[0102] In Figure 16, the angular tolerance between the sleeve 86 and the ball bearing 84 is less than 0.1°, since the inserts 12 used for the two parts are fixed to each other when forming the wax pattern 45. An angular tolerance of less than 0.05° is achievable by this teaching. Furthermore, the axial positioning tolerance between the insert 12 of the sleeve 86 and the insert 12 of the ball bearing 84 is less than 0.1 mm, preferably less than 0.05 mm. Similarly, the positioning tolerance between the insert 12 of the sleeve 86 and the insert 12 of the ball bearing 84 is less than 0.05 mm + 0.5 mm / m, preferably less than 0.05 mm + 0.2 mm / m.

[0103] Figure 17 shows a device 10 which will be the head of a golf club 96. The head 96 includes a front surface 98 and a body 100. The head can be connected to a shaft (not shown) via a shaft connector 102 in a manner known in itself.

[0104] Although not shown in Figure 17, as shown in Figure 18, for example, two weights 104 formed by tungsten inserts can be provided as inserts 12' in the wax pattern 54.

[0105] As also shown in Figure 18, an additional insert 12' is embedded within the wax pattern 54. This additional insert 12' is a shaft connector insert 106 that enables precise connection of the shaft to the front and base 108 of the golf club 10' at a predetermined angle. In this way, the angle between the shaft and the front of the golf club can be reliably formed with improved alignment quality compared to the prior art. [Explanation of Symbols]

[0106] 10, 10' device, golf club 12, 12' functional parts, 12 formed by inserts 14. Inner self 16 Housing 18, 18', 18'' pattern template, upper half of 18, lower half of 18 19 stickers 20 cavities 22 Inner self 24, 24' Type 1 insert, Type 2 insert 26 Slider 28 Magnets 30 Vacuum passage 32 Vacuum pump 34 Vacuum Ports 36 Vertical axis 38W container 40 resin ports 42 Resin line 44 Gas Supply Department 46 Gasport 48 Gas lines 50 stickers 52 22 protrusions 54, 54' pattern, hollow space 56 54 outer surface 58 56 indentation 60. First layer of fibrous material 62. The second layer of the fibrous material 64 Other types Container 66 R 68 R line 70 Heating and Cooling Devices Coupling from 72 70 to 64 74. Further vacuum pumps 76 Vacuum Ports 78 Vacuum Line 80 Aperture 82 Shaft 84 Ball bearings 86 sleeves 88 sleeves 90 Drive shaft 92 Transmission 94 Electric motor 96 Golf club heads 98 Front 100 Main Unit 102 Shaft Connector 104 weight 106 Shaft Connector Insert 108 Bass G Gas H horizontal axis M Removable materials R resin V vacuum W wax

Claims

1. A golf club head (10') made of a composite material, comprising a plurality of functional components (12, 12') arranged at predetermined positions along the inner surface (14) of the golf club head (10'), wherein the functional components (12, 12') are integrally formed with the golf club head (10') as a single component, or embedded within a structure integrally formed with the golf club head (10') as a single component. The plurality of functional components (12, 12') are selected to function as two weights (104) integrated into the golf club head (10'), a shaft connector insert (106) that forms a connector to the shaft of the golf club, and a surface that functions as the face (98) of the golf club head (10'). The angular tolerance for positioning between two functional parts (12, 12') is less than 0.1°, for a golf club head (10').

2. The golf club head (10') according to claim 1, wherein the golf club head (10') has a wall thickness with a tolerance of ±0.5 mm for the material of the golf club head (10') that has been cut from the golf club head (10') to a length of 1 to 5 cm and to a width selected in the range of 0.5 to 2.5 cm, with respect to a wall thickness selected in the range of 1 to 4 mm.

3. The golf club head (10') according to claim 1 or claim 2, wherein the golf club head (10') has a wall thickness tolerance of ±0.3 mm with respect to a wall thickness selected within the range of 1 to 4 mm.

4. The golf club head (10') according to any one of claims 1 to 3, wherein the golf club head (10') has a surface profile tolerance of ±0.1 mm.

5. The golf club head (10') according to any one of claims 1 to 4, wherein the golf club head (10') has a surface profile tolerance of ±0.05 mm at the position of the functional components (12, 12').

6. The golf club head (10') according to any one of claims 1 to 5, wherein the positioning tolerance between the two functional parts (12, 12') is less than 0.05 mm + 0.5 mm / m.

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