Golf Club Head Flexure for Sweet Zone Expansion
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Solution Overview
Problem
Conventional golf club heads face challenges in achieving a larger 'sweet zone' with uniform high initial ball speed due to variations in impact location on the club face, and they struggle to maintain structural integrity while minimizing viscoelastic relaxation, which affects ball travel distance and accuracy.
Innovation Solution
The golf club head design incorporates a flexure feature with a face insert made of maraging steel, less than 2.0 mm thick, and a compliant portion that allows for controlled deformation during impact, optimizing the coefficient of restitution and energy transfer to the ball.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the club face is made thinner to reduce viscoelastic relaxation and increase ball speed, then the coefficient of restitution is improved, but the structural integrity and resistance to permanent deformation deteriorate
Solution Approach 1:
The club head employs a composite construction with a titanium alloy body (6Al-4V or 5Al-2.5V) combined with a stainless steel face (17-4 PH or 304). This composite material approach allows the face to be thinner (reducing viscoelastic relaxation) while the titanium body provides overall structural strength and energy absorption. The dissimilar metals are joined through friction stir welding or diffusion bonding, creating a structure that optimizes both energy return and structural integrity.
Solution Approach 2:
The club head features variable wall thickness throughout its structure, with the face being thinnest (0.5mm to 2.0mm) to maximize coefficient of restitution, while the crown, sole, and hosel areas have increased thickness for structural support. The titanium body provides localized strength where needed, allowing the face to be optimized for energy return without compromising overall structural integrity during impact.
2Strength
If the face thickness is increased to ensure structural integrity, then the strength and resistance to permanent deformation are improved, but the coefficient of restitution and ball speed deteriorate
Solution Approach 1:
The use of titanium alloy for the club body provides high strength-to-weight ratio, allowing the overall structure to be strong while the face can be made thinner. The stainless steel face layer (0.5mm to 2.0mm) optimizes coefficient of restitution, while the thicker titanium body (varying from 3mm to 10mm) provides the necessary structural integrity and energy absorption capability.
Solution Approach 2:
The patent specifies precise thickness parameters for different components: face thickness of 0.5mm to 2.0mm for optimal COR, crown thickness of 2mm to 5mm, sole thickness of 3mm to 8mm, and hosel thickness of 4mm to 10mm. These parameter optimizations balance structural strength requirements with energy return efficiency, allowing thin face for speed while maintaining adequate thickness in support areas for strength.
3Speed
If the club head design is optimized for maximum ball speed, then the coefficient of restitution is improved, but the manufacturing complexity and precision requirements increase
Solution Approach 1:
The club head is divided into separate components (titanium body and stainless steel face) that are manufactured independently with optimized tolerances, then joined through friction stir welding or diffusion bonding. This segmentation allows the face to be manufactured with precise thin thickness (0.5mm to 2.0mm) for optimal COR, while the body can be formed with less critical tolerances. The separate manufacturing of face and body reduces the overall manufacturing precision requirements compared to forming a monolithic thin-walled structure.
Solution Approach 2:
The patent establishes specific parameter ranges for face thickness (0.5mm to 2.0mm) and specifies tolerance controls to maintain uniformity within ±0.05mm to ±0.1mm across the face surface. These controlled parameter specifications enable consistent coefficient of restitution performance while providing clear manufacturing targets that balance precision requirements with manufacturability.
4Area of stationary object
If the club face is made thinner to increase the 'sweet zone' area, then the initial ball speed is improved, but the resistance to permanent deformation and failure deteriorates
Solution Approach 1:
The stainless steel face layer (0.5mm to 2.0mm thickness) provides high yield strength and resistance to permanent deformation, while the titanium alloy body provides overall structural support. This composite construction allows the face to be made thinner to increase the effective sweet zone area, while the high-strength stainless steel material and titanium body backing prevent permanent deformation and failure during impact.
Solution Approach 2:
The club head features localized thickening in the hosel area (4mm to 10mm thickness) and crown/sole regions to provide structural support and distribute impact stresses away from the thin face. This local quality variation allows the face to be thin for maximum sweet zone area and coefficient of restitution, while strategically placed thicker sections maintain reliability and resistance to permanent deformation under impact loads.
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 ball speed and distance by increasing the 'sweet zone' and reducing backspin, while maintaining structural integrity and minimizing viscoelastic relaxation, thereby improving the overall performance and accuracy of the golf club.
Implementation Method 1
a compliant portion configured to permit relative movement between the face and the body
Implementation Method 2
The face insert is constructed of maraging steel and has a thickness less than 2.0 mm
Implementation Method 3
a portion of energy is dissipated in club head vibration and in viscoelastic relaxation of the ball
Data Source
AI summary
A golf club head including a crown, a sole, a hosel, a face and a flexure. The flexure provides compliance during an impact between the golf club head and a golf ball, and is tuned to vibrate, immediately after impact, at a predetermined frequency. A slot is included in a portion of the golf club head and works with the flexure to further tune performance.