Composite Golf Club Face Plate with Criss-Cross Prepreg and Water-Jet Cutting
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Solution Overview
Problem
Conventional methods for manufacturing composite golf club faces suffer from high porosity, resin loss, and fiber defects, particularly when subjected to complex loads, leading to reduced performance and durability.
Innovation Solution
A composite face plate design featuring a lay-up of prepreg plies with elongated strips arranged in a criss-cross pattern to create varying thickness profiles, combined with water-jet cutting to minimize damage to reinforcing fibers and control the curing process to shift defects into a sacrificial portion, resulting in a durable and defect-free finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods are used for composite golf club faces, then production can be achieved with standard processes, but high porosity, resin loss, and fiber defects occur leading to reduced durability and performance
Solution Approach 1:
The patent applies parameter changes by modifying the curing process conditions (temperature, pressure, time) to optimize the manufacturing of composite club faces. By carefully controlling these parameters, the process achieves complete resin curing while minimizing porosity and preventing fiber defects, thereby resolving the contradiction between reliability and manufacturing precision
Solution Approach 2:
The patent replaces conventional mechanical cutting methods with water-jet cutting technology. This substitution eliminates mechanical contact that could damage reinforcing fibers, thereby reducing fiber defects and improving both durability and manufacturing precision simultaneously
2Ease of manufacture
If conventional cutting methods are used, then material removal can be achieved, but damage to reinforcing fibers occurs reducing club performance
Solution Approach 1:
The patent replaces mechanical cutting systems with a water-jet cutting system. This substitution allows for precise material removal without mechanical contact that would damage the reinforcing fibers. The water jet achieves clean cuts while preserving fiber integrity, thereby maintaining both ease of manufacture and impact resistance
Solution Approach 2:
The patent introduces water as an intermediary medium for the cutting process. Instead of direct mechanical contact between the cutting tool and the composite material, water serves as the intermediary that removes material through erosion while leaving the reinforcing fibers undamaged, thus preserving strength
3Strength
If thicker face plates are used to increase structural mass, then strength and structural support are improved, but energy transfer to the ball is reduced lowering performance
Solution Approach 1:
The patent optimizes the thickness parameter of the face plate to achieve the ideal balance between structural support and energy transfer. By carefully selecting and controlling the thickness parameter during manufacturing, the design achieves sufficient strength while maintaining the flexibility needed for effective energy transfer to the golf ball
Solution Approach 2:
The patent applies local quality by varying the thickness of the face plate in different regions. Certain areas have optimized thickness to provide structural support where needed, while other areas maintain thinner sections to maximize energy transfer and flexility, thereby resolving the contradiction between strength and energy use
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the durability and performance of golf club faces by reducing porosity and fiber defects, improving impact resistance and overall club performance under dynamic loads.
Implementation Method 1
water-jet cutting to minimize damage to reinforcing fibers
Implementation Method 2
control the curing process to shift defects into a sacrificial portion
Data Source
AI summary
The present disclosure pertains to composite articles, and in particular a composite face plate for a golf club-head, and methods for making the same. In certain embodiments, a composite face plate for a club-head is formed with a cross-sectional profile having a varying thickness. The face plate comprises a lay-up of multiple, composite prepreg plies. At least a portion of the plies comprise a plurality of elongated prepreg strips arranged in a predetermined criss-cross pattern in the lay-up. The prepreg strips create one or more areas of increased thickness where the strips overlap each other, thereby creating a desired profile for the plate. Metallic or polymer covers or cover layers can be used to define a striking surface.