Multi-Material Golf Club Head Reducing Titanium Cost
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Solution Overview
Problem
Modern golf club heads made from titanium alloys are expensive and difficult to manufacture, and replacing them with alternative materials while maintaining performance and quality is challenging.
Innovation Solution
A driver-type golf club head with a multi-piece construction using multiple materials, including a cast cup made from a high-density material and a ring joined to the cast cup via a joint, reducing the percent composition of titanium alloys while improving manufacturability and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If titanium alloys are used to make golf club heads, then strength and lightweight properties are improved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent applies composite materials by combining titanium alloy with steel alloy and fiber-reinforced polymeric materials in a multi-piece construction. The club head includes a titanium alloy crown portion, a steel alloy body portion, and polymeric material face and sole portions, creating a composite structure that balances strength requirements with manufacturing ease and cost reduction.
Solution Approach 2:
The patent segments the golf club head into multiple separate components made from different materials. The crown portion, body portion, face portion, and sole portion are manufactured separately using appropriate materials for each function, then assembled together. This segmentation allows each component to be optimized for its specific requirements while simplifying overall manufacturing.
2Strength
If titanium alloys are used to make golf club heads, then strength and lightweight properties are improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces cost by using composite materials where expensive titanium alloy is used only for the crown portion requiring lightweight strength, while less expensive steel alloy and fiber-reinforced polymeric materials are used for the body, face, and sole portions. This material substitution strategy maintains overall strength while significantly reducing manufacturing cost.
Solution Approach 2:
The patent applies local quality by using different materials in different locations based on specific functional requirements. Titanium alloy is localized to the crown portion where lightweight strength is critical, while other areas use more cost-effective materials. This localized material selection optimizes both performance and cost.
3Quantity of substance
If multiple materials are used in golf club heads, then titanium alloy percent composition is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent manages manufacturing complexity through segmentation by dividing the club head into distinct components (crown, body, face, sole) that can be manufactured separately using appropriate processes for each material, then assembled through standardized joining methods. This modular approach simplifies the overall manufacturing process despite using multiple materials.
Data Source
AI summary
Disclosed herein is a driver-type golf club head that is made from at least one first material, having a density between 0.9 g/cc and 3.5 g/cc, at least one second material, having a density between 3.6 g/cc and 5.5 g/cc, and at least one third material, having a density between 5.6 g/cc and 20.0 g/cc. The first material has a first mass no more than 55% and no less than 25% of the total mass of the golf club head. The second material has a second mass no more than 65% and no less than 20% of the total mass of the golf club head. The third material has a third mass equal to the total mass of the golf club head less the first mass of the first material and the second mass of the second material.