Golf Club Head Weld Fusion Zone Relocation
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Solution Overview
Problem
Traditional golf club heads face challenges in maintaining structural integrity and consistency due to the presence of weld fusion zones within high-stress regions, which can lead to mechanical failures and affect the coefficient of restitution (COR) and mass distribution.
Innovation Solution
A golf club head design featuring a continuous weld along the contact interface between two pieces, with the fusion zone located outside the hinge region and on the iron-type face, using materials like maraging steel or PH stainless steel, and incorporating a third piece to cover the rear weld bead, optimizing the weld placement for minimal impact on the face and maximizing COR.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a continuous weld is used to attach the face plate to the club head body, then the structural integrity is improved, but the presence of fusion zones in high-stress regions can lead to mechanical failures
Solution Approach 1:
The invention extracts the weld fusion zone from the high-stress hitting area by positioning the weld bead on the rear surface of the face plate, away from the hitting surface. This separates the welding operation from the critical impact zone, maintaining structural integrity while eliminating the reliability issue of fusion zones in high-stress regions.
Solution Approach 2:
The weld is positioned in a different spatial dimension (rear surface) rather than on the front hitting surface. This dimensional relocation allows the weld to provide structural attachment without interfering with the stress distribution and ball impact mechanics on the front face.
2Strength
If the face plate is made thick to prevent mechanical failure, then the strength is improved, but the mass distribution and coefficient of restitution are adversely affected
Solution Approach 1:
The face plate employs variable thickness with different local properties: thicker at the rear surface where the weld is located to provide strength and structural integrity, and thinner at the hitting surface to maintain proper mass distribution and coefficient of restitution. This local differentiation resolves the contradiction between strength and performance.
3Ease of manufacture
If multiple pieces are welded together to form the club head, then the manufacturing flexibility is improved, but the manufacturing precision and consistency are worsened due to weld variability
Solution Approach 1:
The invention uses a precise metal stamping process to create a template or pattern on the rear surface of the face plate that guides weld placement. This copying approach ensures consistent weld positioning and dimensions across multiple club heads, improving manufacturing precision while retaining the flexibility of multi-piece construction.
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 design enhances the structural integrity and consistency of the golf club head, improves the coefficient of restitution, and allows for mass savings by strategically placing the weld in low-stress areas, reducing the likelihood of mechanical failures and maintaining high performance.
Implementation Method 1
A continuous weld extends along the contact interface attaching the first and second pieces together at the contact interface
Data Source
AI summary
An iron-type golf club head is disclosed having a first piece including a portion of an iron-type face. A second piece including a heel portion, a sole portion, a toe portion, a top-line portion, a hinge region, and a front opening for receiving the first piece is also disclosed. A first contact surface of the first piece is connected with a second contact surface of the second piece at a contact interface. A continuous weld extends along the contact interface attaching the first and second pieces together at the contact interface. The continuous weld includes a fusion zone occurring substantially on the iron-type face outside the hinge region of the club head.