Golf Club Head Composite Face Variable Thickness Molding

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Solution Overview

Problem

The existing use of prepreg plies in golf club face construction is time-consuming, expensive, and wasteful due to the need for hand-oriented layers to create variable thickness patterns, which are not ideal for achieving the desired performance and efficiency in golf club manufacturing.

Innovation Solution

A composite material comprising prepreg plies and a variable thickness core material, such as sheet molding compound or metal, is used to create a golf club head with a face that can be custom molded or affixed with an adhesive, allowing for efficient production of structurally sound parts with continuously variable thicknesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If prepreg plies are used to create variable thickness patterns in golf club faces, then the structural integrity and performance are improved, but the manufacturing time and cost increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The face is divided into multiple thickness zones (first, second, and third thickness zones) that are formed as integrated portions during a single molding process, eliminating the need for sequential hand-laying of prepreg plies for each thickness variation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The molding process utilizes variable packing pressure and temperature parameters to create different thickness regions within the same mold cycle, allowing continuous thickness variation without additional manufacturing steps

Inventive Principle:

Principle #35Parameter changes

2Strength

If prepreg plies are used to create variable thickness patterns, then the face performance is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveface performanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The mold cavity is segmented into multiple regions with different packing pressure parameters, allowing each region to achieve optimal thickness and density for its specific performance requirements while being manufactured as a single integrated part

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process employs spatially varying pressure and temperature parameters during molding to create the variable thickness pattern, eliminating the need for expensive custom tooling for each thickness variation

Inventive Principle:

Principle #35Parameter changes

3Strength

If prepreg plies are used to create variable thickness patterns, then the face performance is improved, but material waste increases

Engineering Contradiction:

Improveface performanceVSAvoidmaterial waste

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The face structure is segmented into multiple thickness zones that are all formed from the same material charge in a single molding operation, ensuring complete utilization of the thermoplastic material without the scrap generation inherent in ply-by-ply construction

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9283447B1Golf club head with composite face

Publication Date: 2016.03.15 CALLAWAY GOLF COMPANY

AI summary

A novel material comprising collections of prepreg plies and a variable thickness core material such as sheet molding compound or metal, methods of forming said material, and golf clubs comprising said material are disclosed herein.