Golf Club Head Miter Joint for Dissimilar-Metal Brazing
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Solution Overview
Problem
Existing brazing methods for joining dissimilar materials in golf club heads, such as titanium and steel, are inefficient, costly, and prone to stress concentration, limiting their application in smaller cross-sectional regions and compromising durability.
Innovation Solution
A miter joint using a nickel-based or copper-based filler material is employed in a vacuum brazing process to join components, providing a self-centering, cost-effective, and durable connection suitable for highly stressed regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tongue-and-groove joint is used for brazing a face plate to a club body, then the joint strength is improved, but the manufacturing complexity and cost increase due to precise fitment requirements and tight corners
Solution Approach 1:
Instead of using a tongue-and-groove joint where one component fits into another, the patent inverts the approach by using a simple butt joint where two flat surfaces are placed together. This inversion eliminates the need for complex interlocking geometries while maintaining joint strength through proper brazing technique and surface preparation.
Solution Approach 2:
The patent segments the joint design into simple, manufacturable features that can be easily produced. By dividing the complex tongue-and-groove geometry into simpler butt joint surfaces, the manufacturing process becomes less complex while achieving the same functional outcome of a strong, reliable joint.
2Strength
If a tongue-and-groove joint is used, then the joint provides structural integrity, but the joint width increases by about 30% making it expensive in both cost and volume
Solution Approach 1:
The patent inverts the traditional approach by eliminating the protruding tongue and recessed groove that increase joint volume. Instead, it uses a butt joint configuration where components meet at their surfaces, reducing the required joint width by approximately 30% while maintaining structural integrity through proper brazing.
3Strength
If a tongue-and-groove joint with tight corners is used, then the joint provides secure connection, but stress concentration increases in highly stressed regions
Solution Approach 1:
Rather than using tight corners in a tongue-and-groove joint that create stress concentration points, the patent inverts to a butt joint configuration with smooth, continuous surfaces. This eliminates the geometric discontinuities that cause stress concentration while maintaining secure connection through the brazed joint.
4Reliability
If a larger joint width is used for tongue-and-groove, then the brazing process becomes more secure, but the locations where the joint can be implemented are limited
Solution Approach 1:
The patent inverts the approach by using a butt joint that requires minimal width, thereby increasing adaptability and versatility. This allows the joint to be implemented in various locations including thin cross-sectional areas where a tongue-and-groove joint would not fit, while maintaining brazing reliability through proper surface preparation and brazing technique.
5Strength
If a tongue-and-groove joint interfaces thin portion to thick portion, then the joint can be formed, but heat management challenges arise during brazing
Solution Approach 1:
Instead of forcing a thin portion to interface with a thick portion in a tongue-and-groove configuration, the patent inverts to a butt joint where surfaces of comparable thickness can be joined. This simplifies heat management during brazing by eliminating the extreme thermal gradients that occur when heating from a small area to a large mass.
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
The miter joint achieves improved strength, reduced complexity, and cost-effectiveness in joining dissimilar materials, particularly in the topline region of golf clubs, minimizing weight and cross-sectional area while maintaining structural integrity.
Implementation Method 1
A miter joint using a nickel-based or copper-based filler material is employed in a vacuum brazing process to join components
Implementation Method 2
The miter joint achieves improved strength, reduced complexity, and cost-effectiveness in joining dissimilar materials
Implementation Method 3
A miter joint using a nickel-based or copper-based filler material is employed in a vacuum brazing process to join components
Data Source
AI summary
A golf club head with a mitered joint for joining components of dissimilar materials is disclosed herein. The golf club head has a body with an internal edge defining a recess, and a face component having an internal edge. The face component is disposed over the recess. The internal edge of the body and the internal edge of the face have an angle ranging from about 10 degrees to about 80 degrees.