Golf Club Head Composite Face With Z-Axis Delamination Reinforcement
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Solution Overview
Problem
Composite laminates in golf club heads suffer from weak interlaminar shear strength and delamination due to the lack of reinforcement across resin-rich interfaces, leading to premature failure and reduced fatigue life.
Innovation Solution
Incorporating vertically aligned carbon nanotubes (VACNTs), z-axis aligned carbon fibers, low-modulus high-strain-to-failure materials, and z-stitching between composite plies to enhance interlaminar shear strength and fracture toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight composite materials are used in golf club heads, then the center of gravity is lowered and moment of inertia is increased, but the interlaminar shear strength is reduced and delamination occurs
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforced polymer plies with a specific interlaminar reinforcement layer. This reinforcement layer contains fibers oriented perpendicular to the ply surfaces (in the z-direction), creating a multi-layer composite structure that addresses the weakness at the resin-rich interfaces while maintaining the lightweight properties of the original composite components.
Solution Approach 2:
The patent applies local quality by placing reinforcement specifically at the interlaminar interfaces between composite plies, rather than uniformly throughout the entire structure. The interlaminar reinforcement layer is positioned only where needed—to strengthen the resin-rich zones that are prone to delamination—while leaving the rest of the composite structure lightweight and optimized for its original function.
2Strength
If carbon fiber reinforced polymer composites are used with resin matrix, then high specific strength and stiffness are achieved, but the resin-rich interfaces become preferential pathways for crack initiation and propagation
Solution Approach 1:
The patent applies the intermediary principle by introducing a reinforcement layer that acts as a mediator between the carbon fiber reinforced polymer plies. This intermediate layer, containing z-oriented fibers, blocks the preferential pathways that cracks would otherwise follow through the resin-rich interfaces, thereby preventing crack initiation and propagation while allowing the high-strength CFRP plies to maintain their load-bearing function.
Solution Approach 2:
The patent creates a multi-level composite structure where the interlaminar reinforcement layer is itself a composite material combining fibers oriented in the z-direction with a matrix material. This composite reinforcement layer is integrated between the CFRP plies to create a hierarchical composite structure that addresses the reliability issue at the interface level.
3Adaptability or versatility
If multiple composite plies are used to satisfy design requirements, then structural flexibility is improved, but the number of resin-rich interfaces increases and delamination risk increases
Solution Approach 1:
The patent applies segmentation by dividing the reinforcement function into discrete interlaminar reinforcement layers positioned between specific composite plies. Rather than attempting to reinforce the entire structure uniformly or treating all interfaces equally, the reinforcement is segmented and placed only at critical interfaces where delamination is most likely to occur, thereby managing complexity in a targeted manner.
Solution Approach 2:
The patent uses composite materials to create a multi-scale structure where macro-level composite plies are combined with micro-level interlaminar reinforcement. This composite approach allows the structure to maintain flexibility through multiple plies while managing the complexity of multiple interfaces by reinforcing only the critical ones with a specialized composite reinforcement layer.
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
Improves interlaminar shear strength and fatigue life of composite components in golf club heads, preventing delamination and extending their usable lifespan.
Implementation Method 1
Incorporating vertically aligned carbon nanotubes (VACNTs), z-axis aligned carbon fibers, low-modulus high-strain-to-failure materials, and z-stitching between composite plies to enhance interlaminar shear strength and fracture toughness
Implementation Method 2
a critical limitation of composite laminates lies between the region between laminated plies, or generally speaking in the z-direction... Due to the lack of reinforcement across this resin rich interface, it can serve as a preferential pathway for both crack initiation and crack propagation
Implementation Method 3
Incorporating vertically aligned carbon nanotubes (VACNTs), z-axis aligned carbon fibers, low-modulus high-strain-to-failure materials, and z-stitching between composite plies to enhance interlaminar shear strength and fracture toughness
Implementation Method 4
Incorporating vertically aligned carbon nanotubes (VACNTs), z-axis aligned carbon fibers, low-modulus high-strain-to-failure materials, and z-stitching between composite plies to enhance interlaminar shear strength and fracture toughness
Data Source
AI summary
A composite material for a component of a golf club head is disclosed herein. The composite material includes a composite layers and at least one an interlaminar layer that includes one of vertically aligned carbon nanotubes, Z-Axis aligned carbon fibers or graphene platelets. In one preferred embodiment, the golf club head component is a face component.