Golf Club Head Casting with Oxidation-Resistant Weight Block Isolation

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Solution Overview

Problem

Conventional methods for integrating a weight block into a golf club head, such as soldering, lock fitting, and adhesive binding, face issues like gaps, space occupation, and insufficient structural strength, while casting methods risk oxidation of the weight block during high-temperature processes, affecting the quality of the golf club head.

Innovation Solution

A casting method involving a weight block covered with a high-temperature and oxidation-resistant isolation layer, embedded in a wax pattern within a shell mold, and then encased in a molten metal to form the golf club head, ensuring the weight block is securely embedded without oxidation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the weight block is disposed during the casting process to mold the club head main body, then the structural strength between the weight block and the club head main body is increased, but the weight block is oxidized during the high-temperature casting process

Engineering Contradiction:

Improvestructural strengthVSAvoidoxidation of weight block

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A coating layer is applied to the surface of the weight block to act as an intermediary barrier between the weight block and the molten metal material during the casting process. This coating layer prevents direct contact and chemical reaction between the weight block and the molten metal, thereby preventing oxidation of the weight block while still allowing the weight block to be embedded in the club head main body for strong structural connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional soldering, lock fitting, or adhesive binding methods are used to connect the weight block to the club head main body, then the manufacturing process is simpler, but the structural strength and connection quality are insufficient

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidconnection strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The connection process is merged with the casting process itself. Instead of separately connecting the weight block to the club head main body using soldering, lock fitting, or adhesive binding, the weight block is disposed during the casting process and becomes embedded in the club head main body as the molten metal solidifies, achieving a strong integral connection in one step.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If the weight block is disposed during the casting process, then space utilization is improved and molding flexibility is enhanced, but the weight block reacts with the molten metal material causing oxidation

Engineering Contradiction:

Improvemolding flexibilityVSAvoidoxidation of weight block

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This method enhances the structural strength and flexibility of the golf club head by preventing oxidation and ensuring a strong, efficient connection between the weight block and the club head main body, improving the overall quality and stability of the manufactured golf club head.

Implementation Method 1

disposing on the weight block an isolation layer that is resistant to high temperature and oxidation

Methodology Applied

Scientific EffectOxidation resistance: Oxidation

Implementation Method 2

casting a molten metal material in the mold cavity of the shell mold to form a club head main body

Methodology Applied

Scientific EffectCasting: Melting

Data Source

PatentUS10821332B1Casting method for manufacturing golf club head having weight member and golf club head manufactured thereby

Publication Date: 2020.11.03 ADVANCED INT MULTITECH CO LTD

AI summary

A method for manufacturing a golf club head having a weight member includes: providing a weight block made of a metal material; disposing an isolation layer on the weight block to form the weight member; delivering a wax material to form a wax pattern covering a portion of the weight member; coating the weight member and the wax pattern with a shell mold plaster to form a shell mold covering the same; performing a de-waxing process which leaves a mold cavity in the shell mold; and casting a molten metal material in the mold cavity to form a club head main body, and removing the shell mold to form the golf club head having the weight member embedded in the club head main body. A golf club head manufactured by the method is also disclosed.