High performance nano-structured metalwood golf club heads and iron heads and components thereof

Abstract

A metalwood coated at least partially with a nanostructure material offer improved performance over existing golf club heads made from a combination of steel and titanium alloys or composite club heads made in part or wholly from fiber-reinforced plastics (FRPs) and metallic sub-components. The components of the metalwood may be coated with variable thicknesses of electro-deposited nanostructure metals and alloys.

Description

[0001]The present application claims priority to U.S. Ser. No. 60 / 891,471, filed Feb. 23, 2007 and U.S. Ser. No. 60 / 910,781, filed Apr. 9, 2007, the disclosures of which are incorporated herein.BACKGROUND[0002]The invention generally relates to metalwood golf clubs including drivers, fairway woods, hybrid irons, irons, wedges, putters and utility clubs. More particularly, this invention relates to the design, manufacturing and construction of metalwood golf club heads, hybrid iron heads, iron heads, wedge heads and putter heads and the components that make the heads, using nanostructured materials in a composite design to improve performance and durability. The invention also relates to golf iron heads having face inserts and in particular to the face inserts having nano crystalline materials as one component of a multi-material component system.BRIEF DESCRIPTION[0003]Due to the competitive nature of many sports, designers and manufacturers often seek ways to improve the performance...

AI Technical Summary

Benefits of technology

[0047]Manufacturers and designers who have used carbon-fiber reinforced plastics, commonly known as “carbon composites” for the crown or body of metalwoods have since explored the concept of using just thermoplastic or thermoset polymers without fiber reinforcement, due to their low density and moldability into complex shapes at a relatively low cost. However, the structural strength, fatigue life and maximum deflection limits of these plastic crowns have not been within acceptable performance and durability limits. In particular, the strength of neat plastics alone does not allow for the replacement of the thin-walled titanium and steel crowns common to many designs available on the market today. However, by adding a thin structural layer of nanostructured metal onto the surface of certain polymers in a metalwood crown or body design, or fully encapsulating these polymers, the resulting density of the nanostructured metal+polymer composite structure can be reduced from 4.5 g / cc for titanium alloys to less than 1.5 g / cc. This allows for the designer to shift center-of-gravity (c.g.) down toward the sole and back, improving the MOI and even COR characteristics of the entire head. These new mass properties and flex characteristics have positive effects on the performance, sound, and durability of metalwoods for the golfer.

[0048]Driver heads made with fiber-reinforced or neat resin polymer crowns, skirts, and bodies, also suffer from a low or poor-dampening response after impact with the golf ball, thus producing a less pronounced sound at impact which is less pleasing to the golfer. Low modulus polymers and / or thermoset polymer systems can reduce the performance of a club due to energy loss in the system at impact with golf ball. Titanium and steel metalwoods with their larger cavities and thinner walls produce a different and often times louder or higher-pitched sound at impact that many golfers prefer. By combining a polymer substrate with a nanostructured metal, the overall strength, strength-to weight, and sound at impact of metalwoods are improved.

Problems solved by technology

However, the structural strength, fatigue life and maximum deflection limits of these plastic crowns have not been within acceptable performance and durability limits.

In particular, the strength of neat plastics alone does not allow for the replacement of the thin-walled titanium and steel crowns common to many designs available on the market today.

Driver heads made with fiber-reinforced or neat resin polymer crowns, skirts, and bodies, also suffer from a low or poor-dampening response after impact with the golf ball, thus producing a less pronounced sound at impact which is less pleasing to the golfer.

Low modulus polymers and / or thermoset polymer systems can reduce the performance of a club due to energy loss in the system at impact with golf ball.

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