METHOD FOR MANUFACTURING GRAPHITE SHAFT

Abstract

A method for producing a graphite shaft comprises the steps of: preparing a tube made of a synthetic resin into which a thermosetting resin powder is put; inserting the synthetic resin tube into the finished product graphite shaft; closing an upper end of the graphite shaft; and placing the graphite shaft in a high-temperature pressurizing apparatus and then heating the same so that the thermosetting resin powder is foamed and filled in a part of the interior of the shaft.

Claims

1. A method for producing a graphite shaft, which comprises the steps of: preparing a synthetic resin tube into which thermosetting resin powder is charged; forming micro-perforations in the distal end of the synthetic resin tube; inserting the synthetic resin tube having said micro-perforations into a hollow graphite shaft; sealing a proximal end of the graphite shaft; and heating the graphite shaft in a high-temperature pressurizing apparatus to foam the thermosetting resin powder for filling a part of the graphite shaft.

2. The method according to claim 1, wherein the graphite shaft is used as the shaft of a golf club.

3. The method according to claim 1, wherein the graphite shaft is used as the shaft of a lure fishing rod.

4. The method according to claim 2, wherein said thermosetting resin powder is foamed in all or a portion of a section from the midpoint of the grip to the midpoint of the entire graphite shaft.

5. (canceled)

6. The method according to claim 1, wherein the method further comprises a step of forming thin films on both ends of the foamed thermosetting resin by applying polymer resin adhesive after heating the shaft.

7. The method according to claim 1, wherein said high-temperature pressurizing apparatus is an autoclave.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0019] FIG. 1 shows a driver, the longest club among the golf clubs;

[0020] FIG. 2 shows a hollow graphite shaft, and

[0021] FIG. 3 is a view showing the state in which thermosetting resin powder in a synthetic resin tube is foamed in a hollow graphite shaft, for which the method of the present invention is used to produce a graphite shaft of a golf club.

BEST MODE OF THE INVENTION

[0022] A hollow graphite shaft to be used in the method of the present invention is produced through the following steps: [0023] 1) A prepreg is prepared from yam-shaped carbon fibers and epoxy resin is impregnated (deeply penetrated) to produce a graphite sheet. [0024] 2) The graphite sheet is cut to a desired length of a golf club. [0025] 3) The graphite sheet is wound on a metal bar called a mandrel. [0026] 4) Tape is put on the graphite sheet on a mandrel for preventing deformation of its shape during the next heating process. [0027] 5) The mandrel is now put into a heating furnace and hardened. The heating process is carried out at around 80 C. for 30 minutes and at 130 C. for about an hour. [0028] 6) Tape is removed from the shaft after the heating process.

[0029] The method of the present invention uses the hollow graphite shaft produced by the above process. The inventive concept of the present invention is that a part of the section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the hollow graphite shaft is filled with thermosetting resin powder, and the shaft filled with the resin powder is heated to have the resin powder foamed in a state in which equilibrium pressure is established by applying isotropic pressure from the outside of the shaft in an autoclave. By doing so, a part of the shaft from the midpoint of the grip to the vicinity of the midpoint of the entire length of the shaft can be reinforced by the foamed thermosetting resin.

[0030] The method according to the present invention comprises the steps of preparing a synthetic resin tube into which thermosetting resin powder is charged; inserting the synthetic resin tube into a hollow graphite shaft; sealing a proximal end of the graphite shaft; and heating the graphite shaft in a high-temperature pressurizing apparatus to foam the thermosetting resin powder to fill a part of the graphite shaft.

[0031] According to the present invention, a method for producing a graphite shaft to be used with other products, such as a lure fishing rod, is also provided in the same manner as described above.

DETAILED DESCRIPTIONS OF THE INVENTION

[0032] A method for producing a graphite shaft according to the present invention will be described in detail with reference to the accompanying drawings.

[0033] In the following description, a method for producing a graphite shaft of a golf club is explained for the purpose of simplicity, but it will be obvious to a person with ordinary skill in the art that the concept of the present invention should not be limited to the use with golf clubs only.

[0034] Hence, it should be understood that the method according to the present invention can be equally applied to graphite shafts that can be used with other sports equipment and daily necessities.

[0035] In the following description, the proximal end portion of a shaft means an end portion of the shaft of a golf club or a lure fishing rod where the grip is mounted, namely, an end portion near to the user. Further, the distal end portion of a shaft is the end portion located on the opposite side to the proximal end portion, which means an end portion far from the user.

[0036] FIG. 1 shows a driver which is the longest one among golf clubs. The driver includes a club head 11 hitting a golf ball, a shaft 10 for fixing the club head 11, and a grip 12.

[0037] FIG. 2 is a view showing a hollow graphite shaft for a golf club. In both end portions of the graphite shaft, the grip is mounted on the proximal end portion 22, and the club head is attached to the distal end portion 23 having a smaller diameter than that of the proximal end portion 22.

[0038] A hollow graphite shaft to be used in the method of the present invention is produced through the following steps: [0039] 1) A prepreg is prepared from yam-shaped carbon fibers and epoxy resin is impregnated (deeply penetrated) to produce a graphite sheet. [0040] 2) The graphite sheet is cut to a desired length of a golf club. [0041] 3) The graphite sheet is wound on a metal bar called a mandrel. [0042] 4) Tape is put on the graphite sheet on a mandrel for preventing deformation of its shape during the next heating process. [0043] 5) The mandrel is now put into a heating furnace and hardened. The heating process is carried out at around 80 C. for 30 minutes and at 130 C. for about an hour. [0044] 6) Tape is removed from the shaft after the heating process.

[0045] The method of the present invention uses the hollow graphite shaft produced as above. According to the present invention, the section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the hollow graphite shaft is filled with thermosetting resin powder (filler), and the shaft filled with the filler is heated in a high-temperature pressurizing apparatus to have the filler foamed, so that the section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the shaft is reinforced by the foamed thermosetting resin.

[0046] In the first step of the method of the present invention, a synthetic resin tube 30 in which thermosetting resin powder is charged is prepared. The synthetic resin tube 30 such as a nylon tube has a length corresponding to the length of a section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the shaft. The tube is then filled with thermosetting resin powder after sealing the grip-side end portion 32 of the tube 30. The grip-side end portion means the end portion near to the user, and the head-side end portion means the opposite end portion thereof.

[0047] Thermosetting resin powder has a feature of very light in weight, and is foamed at a specific temperature to expand in volume when it is heated. Therefore, in the step of charging the thermosetting resin powder into the tube, an appropriate amount should be filled in consideration of the expanded volume of the thermosetting resin powder.

[0048] It is also important that the thermosetting resin powder is placed evenly along the entire length of the tube.

[0049] In order to allow the air to get out of the tube 30 during the foaming process, it is also desirable to form micro-perforations in the head-side end portion 34 of the tube 30 before the tube is inserted into the hollow graphite shaft. The micro-perforations may be formed manually by making holes in the head-side end portion of the tube, but not limited thereto.

[0050] After charging the tube 30 with the thermosetting resin, the tube 30 is inserted into the hollow graphite shaft. Although one synthetic resin tube is shown in the drawing, a plurality of tubes may be inserted according to its thickness and diameter.

[0051] After inserting the tube 30 into the hollow graphite shaft 10 as described above, the proximal end 22 of the graphite shaft 10 is sealed by, for example, covering the proximal end portion 22 using tape or the like.

[0052] The graphite shaft 10 is then placed in a high-temperature pressurizing apparatus, for example, an autoclave, and then the graphite shaft is subjected to a heat treatment.

[0053] The autoclave generally refers to a hot-pressing sterilizer used in the microbiology field using high temperature and high pressure steam, which is used for sterilizing or disinfecting various experimental equipments, waste materials, fiber materials and media. It can also refer to a container or a system which can withstand the reactions that occur in high temperature and high pressure. An autoclave applies isotropic pressure to a material inside, and it can control the material to be formed at a certain pressure and temperature determined by a user. The autoclave is a general device known in the relevant art.

[0054] As described above, thermosetting resin powder is charged into the synthetic resin tube, the tube is inserted into the hollow graphite shaft, the graphite shaft is placed in an autoclave, and the heat treatment is performed.

[0055] The reason why the heat treatment should be performed under a pressurized condition in the present invention is as follows:

[0056] If the graphite shaft is heated without pressure, a proper foaming of the thermosetting resin powder having been charged into the synthetic resin tube inside the graphite shaft will not occur because a proper pressure is required for the thermosetting resin powder to be foamed.

[0057] That is, since the graphite shaft is made by rolling a graphite sheet to multiple layers, the graphite shaft itself cannot apply pressure on the thermosetting resin powder when the thermosetting resin powder is heated and foamed. Therefore, the shaft should be placed in an autoclave which can apply isotropic pressure to the shaft, and the resin powder is heated to be foamed.

[0058] As the length of the synthetic resin tube 30 corresponds to the length of the section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the shaft where all or a part of the section will be filled with filler, the thermosetting resin powder subjected to the heat treatment in the tube is foamed in order to completely fill all or a part of the section from the midpoint of the grip to the vicinity of the midpoint of the entire length of the shaft.

[0059] When the heat treatment of the shaft is completed, a part of the foamed thermosetting resin could be left poking out of the proximal end portion 22 of the shaft. Using proper treatment, the poking portion could be removed from the vicinity of the proximal end.

[0060] Further, after the heat treatment of the shaft is completed, end portions of the foamed resin can be exposed outside both ends of the synthetic tube, which can result in the deformation of the golf club during the future use. Hence, to protect the ends of the foamed resin, it is preferable to have thin films formed on the foamed resin by applying a polymer adhesive through the proximal end and/or the distal end of the shaft.

[0061] After the above processes, the grip and the head are attached to the shaft, and a golf club having a graphite shaft produced according to the method of the present invention is completed.

[0062] While the present invention has been shown and described with reference to the exemplary embodiments only, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. Accordingly, these changes and modifications should be construed as being included within the scope of the appended claims.

INDUSTRIAL APPLICABILITY

[0063] As the graphite shaft produced according to the present invention has an improved strength, the shaft has a wider industrial applicability to, but not limited to, golf clubs and lure fishing rods.