FAST Golf Club Faceplate With Isotropic Grain Structure
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Solution Overview
Problem
Existing golf club faceplates made from materials like titanium and steel have anisotropic properties, leading to inconsistent mechanical performance in different directions, and require multiple processing steps that increase manufacturing time and cost, while also generating significant waste.
Innovation Solution
The use of Field Assisted Sintering Technology (FAST) to form golf club faceplates with an isotropic equiaxed grain structure, allowing for near-net shape production, reduced waste, and improved material uniformity, which enhances durability and energy transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rolling and heat treatment processes are used to form faceplates, then strength and durability requirements are met, but manufacturing time and cost increase due to multiple processing steps
Solution Approach 1:
The patent combines multiple traditional processing steps (rolling, heat treatment, curing) into a single forming process. The faceplate is formed in one operation from a pre-formed body, eliminating the need for separate rolling and heat treatment steps while still achieving the required strength and durability through the integrated forming process.
Solution Approach 2:
The faceplate is pre-formed into the desired shape and configuration before final assembly. This preliminary forming action establishes the basic structure and properties in advance, reducing the need for subsequent processing steps and minimizing manufacturing time while maintaining strength requirements.
2Strength
If traditional rolling processes are used to form faceplates, then strength requirements are met, but manufacturing precision is reduced due to anisotropic grain structures that limit mechanical properties in different directions
Solution Approach 1:
The patent changes the fundamental forming parameters by using a pre-formed body approach instead of traditional rolling. This parameter change allows for controlled formation of the faceplate with uniform grain structure and consistent mechanical properties in all directions, achieving both strength requirements and manufacturing precision.
3Shape
If multiple processing steps are used to form faceplates, then material can be shaped, but waste increases due to material removal and rework
Solution Approach 1:
The faceplate is pre-formed into the final desired shape before assembly, establishing the correct geometry in advance. This preliminary action eliminates the need for subsequent material removal and rework steps, significantly reducing material waste while achieving the required shape.
Solution Approach 2:
The patent converts the potential harm of material waste into a benefit by using a forming process that creates the final shape directly from the pre-formed body. This approach transforms what would normally be wasteful material removal into a precise forming operation that minimizes or eliminates waste while achieving the desired shape.
4Force
If anisotropic metal crystal structures are used in faceplates, then kinetic properties can be achieved in certain directions, but durability decreases in other directions due to faceplate failure
Solution Approach 1:
The patent changes the structural parameters by forming the faceplate from a pre-formed body with controlled grain structure. This parameter change creates a more uniform, isotropic structure that maintains consistent mechanical properties and durability in all directions while still providing the necessary kinetic energy transfer capabilities.
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
FAST produces faceplates with consistent mechanical properties in all directions, reducing manufacturing time and waste, while improving energy transfer and durability, thus enhancing golf ball performance.
Implementation Method 1
Field Assisted Sintering Technology (FAST) to form golf club faceplates
Implementation Method 2
Field Assisted Sintering Technology (FAST) to form golf club faceplates
Data Source
AI summary
A golf club head, comprising: a body having a front defining a front opening, a crown, a sole opposite the crown, a toe, a heel opposite the toes, and a skirt located between the crown and the sole and extending proximate the toe to proximate the heel. A faceplate secured to the front of the body and covering the front opening to form a hollow interior cavity. The faceplate comprises a rear surface, facing the hollow interior cavity, and a striking surface opposite the rear surface. The faceplates further comprise a plurality of grains having a grain structure that is substantially equiaxed and isotropic.