Polyurethane Cover Layer for Golf Club Face Abrasion
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Solution Overview
Problem
Conventional golf club head manufacturing techniques result in defects such as porosity, resin loss, and fiber misalignment, leading to reduced performance under dynamic loads, and non-metallic striking plates lack durability and textured surfaces necessary for varied playing conditions.
Innovation Solution
A golf club head with a striking surface featuring a polyurethane or polyurea outer cover layer, specifically designed with a Shore D hardness of 30 to 70, a layer thickness of 0.2 to 0.6 mm, and a flexural modulus of 2 to 120 kpsi, providing superior abrasion resistance and durability, and optionally incorporating a textured surface for improved golf ball spin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional high pressure and temperature curing processes are used to fabricate composite club-head components, then the components are formed at or near net-shape with reduced cycle time, but the components exhibit high incidence of composite porosity, high resin loss, and wavy fiber layers
Solution Approach 1:
The patent applies preliminary action by pre-orienting fibers in a straight, aligned configuration before the curing process begins. The fiber-resin composite is prepared with fibers already positioned in their final desired orientation, and the mold is designed to maintain this alignment throughout curing. This prevents the wavy fiber formation that occurs in conventional processes where fibers are subjected to high pressure and temperature without pre-alignment.
Solution Approach 2:
The patent changes the curing parameters by using reduced pressure and temperature conditions compared to conventional processes. Instead of high pressure and temperature curing, the invention uses a curing cycle that maintains lower pressure while preserving fiber alignment, thereby reducing porosity and resin loss while still achieving complete cure of the composite material.
2Weight of moving object
If graphite composite materials are used to reduce structural mass of the club-head, then more discretionary mass becomes available for performance improvements, but the composite materials lack the durability and textured surface necessary for varied playing conditions
Solution Approach 1:
The patent applies local quality by adding a polymer cover layer specifically to the striking surface of the composite club-head, rather than making the entire club-head from a single material. The lightweight graphite composite provides the overall structural mass reduction, while the localized polymer coating on the face provides the necessary durability, abrasion resistance, and textured surface for varied playing conditions. This allows each region of the club-head to have optimized properties for its specific function.
3Reliability
If a polymer cover layer is added to the striking surface to improve durability and abrasion resistance, then the club-head gains enhanced performance under various conditions, but the overall mass of the club-head increases
Solution Approach 1:
The patent applies the principle of flexible shells and thin films by using a relatively thin polymer cover layer (typically 0.05 to 0.5 mm) on the striking surface. This thin film provides the necessary durability, abrasion resistance, and textured surface properties without adding significant mass to the club-head. The polymer layer acts as a protective shell that preserves the lightweight characteristics of the composite club-head while providing enhanced surface performance.
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 solution enhances the club head's abrasion resistance and durability, maintaining performance under various conditions while reducing defects associated with conventional manufacturing methods.
Implementation Method 1
The outer cover layer provides superior abrasion resistance and durability
Implementation Method 2
optionally incorporating a textured surface for improved golf ball spin
Data Source
AI summary
A golf club head, comprising a striking surface having an outer cover layer comprising a polyurethane or polyurea having a material Shore D hardness of 40 to 70, a layer thickness of 0.2 to 0.6 mm, and a flexural modulus of 5 to 110 kpsi.