Multi-Material Golf Club Face for Variable Thickness Strength
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Solution Overview
Problem
Forming a golf club head with a carbon fiber composite striking face having variable thickness is challenging due to the risk of breaking carbon fibers and compromising interlaminar sheer strength during machining.
Innovation Solution
A multi-material striking face design using a base layer of variable thickness and two carbon fiber composite layers of uniform thickness, which are easily fabricated and attached to a golf club head, allowing for a variable thickness without sacrificing strength or increasing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If carbon fiber composite material is machined to produce variable thickness sheet, then the striking face can be formed with variable thickness to spread out the sweet spot, but the carbon fibers break and interlaminar sheer strength is destroyed
Solution Approach 1:
The striking face is segmented into multiple layers: a base layer with variable thickness and carbon fiber composite layers with uniform thickness. This segmentation allows the base layer to provide the variable thickness profile while the uniform carbon fiber layers maintain structural integrity and strength, avoiding the need to machine the carbon fiber layers themselves.
Solution Approach 2:
The striking face uses a composite structure combining a base layer (which can be machined to variable thickness) with carbon fiber composite layers (which maintain uniform thickness for strength). This composite approach allows each layer to fulfill its specific function: the base layer provides the thickness variation for performance, while the carbon fiber layers provide structural strength without being machined.
2Weight of moving object
If carbon fiber composite material is used to reduce mass of golf club head, then weight reduction is achieved, but manufacturing complexity increases due to difficulty in forming variable thickness sheets
Solution Approach 1:
The manufacturing process is segmented into two independent steps: first, the base layer is formed with the desired variable thickness profile using conventional methods; second, uniform thickness carbon fiber composite layers are attached to the base layer. This segmentation avoids the complex and expensive process of machining variable thickness directly from carbon fiber, while still achieving weight reduction through the use of carbon fiber.
Solution Approach 2:
The base layer is prepared in advance with the variable thickness profile before the carbon fiber layers are applied. This preliminary action allows the carbon fiber layers to be attached in their uniform, high-strength state without requiring subsequent machining that would compromise their integrity.
3Strength
If uniform thickness carbon fiber composite layers are used instead of variable thickness, then structural integrity is maintained, but the sweet spot spreading effect is reduced
Solution Approach 1:
The composite structure combines a variable thickness base layer with uniform thickness carbon fiber layers. The base layer's variable thickness provides the sweet spot spreading effect, while the uniform carbon fiber layers maintain structural integrity. This composite approach allows both requirements to be satisfied simultaneously by assigning different functions to different layers.
Data Source
AI summary
A golf club head, includes a toe; a heel; a hosel disposed at the heel and configured to couple to a shaft; a multi-material striking face, including a first carbon fiber composite layer, a second carbon fiber composite layer, and a base layer between the first and second carbon fiber composite layers and including a different material than the first and second carbon fiber composite layers; and a sole forming a bottom portion of the golf club head.