Composite Golf Club Head Wrap-Around Molding for Complex Geometries

Solution Overview

Problem

Existing methods for manufacturing golf club heads with composite materials struggle to form intricate geometries such as hosel geometries or parts that wrap over the skirt of the club head, limiting the ability to create components with high strength and low weight.

Innovation Solution

A golf club head design featuring a metallic front component and a composite rear wrap-around component, where the wrap-around component is injection molded to form the crown and sole, incorporating thickened regions to facilitate material flow and distribution during molding, resulting in a lightweight and durable structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fiber-impregnated sheets are used to form composite components, then the components can be manufactured with simple shapes, but the ability to form intricate geometries such as hosel geometries or parts that wrap over the skirt is limited

Engineering Contradiction:

Improveease of forming composite componentsVSAvoidability to form intricate geometries

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The club head is divided into multiple components: a metal body and a separate composite wrap-around component. This segmentation allows the composite component to be independently molded with intricate geometries using injection molding, while the metal body provides structural support. The composite component can then be attached to the metal body, combining the advantages of both materials and manufacturing methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite materials (fiber reinforcement embedded in polymer matrix) for the wrap-around component to achieve a balance between strength and weight reduction. The composite material allows for intricate geometries to be formed through injection molding while maintaining the necessary structural integrity for golf club application.

Inventive Principle:

Principle #40Composite materials

2Productivity

If traditional composite manufacturing methods are used, then production time is reduced, but the ability to create lightweight and high-strength components with complex shapes is limited

Engineering Contradiction:

Improveproduction timeVSAvoidcomplexity of shapes that can be formed

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention replaces traditional mechanical composite manufacturing methods (such as hand-layup or preimpregnated sheet forming) with injection molding technology. Injection molding uses a mold cavity to directly form the composite component with the desired complex geometry, eliminating the need for manual forming operations and enabling mass production of intricately shaped components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the manufacturing parameters by using injection molding temperature and pressure control to achieve proper fiber impregnation and component formation. The molten polymer matrix is injected under controlled conditions to ensure complete filling of the mold cavity while maintaining fiber orientation and distribution, resulting in high-quality composite components with complex geometries.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If composite materials are used to reduce weight, then the weight of the club head is reduced, but the manufacturing capability for intricate geometries remains limited

Engineering Contradiction:

Improveweight of club headVSAvoidmanufacturability of complex shapes

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The club head is divided into multiple components: a metal body and a separate composite wrap-around component. This segmentation allows the composite component to be independently molded with intricate geometries using injection molding, while the metal body provides structural support. The composite component can then be attached to the metal body, combining the advantages of both materials and manufacturing methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite materials (fiber reinforcement embedded in polymer matrix) for the wrap-around component to achieve a balance between strength and weight reduction. The composite material allows for intricate geometries to be formed through injection molding while maintaining the necessary structural integrity for golf club application.

Inventive Principle:

Principle #40Composite materials

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 method produces a golf club head with a low weight, high strength, and improved acoustic response, while reducing production time and enabling complex geometries that enhance performance characteristics like reduced spin and increased forgiveness.

Implementation Method 1

The wrap-around component can be injection molded from a gate at a rear peripheral edge of the crown

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentEP4480682B1Method of forming a golf club head

Publication Date: 2026.04.15 KARSTEN MFG CORP

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AI summary

A multi-component golf club head and a method to said club head are generally described herein. The method of manufacturing the golf club head can comprise providing a main component, providing a mold, injection molding a wrap-around component, plasma treating the wrap-around component, joining the wrap-around component onto the main component to form a golf club head, and finishing the golf club head. Other embodiments may be described and claimed.