Putter Face Insert with Variable Radius Holes

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Solution Overview

Problem

Existing golf club face inserts fail to provide optimal feedback and performance, particularly in putter-type golf clubs, as they do not effectively combine improved feel with performance characteristics.

Innovation Solution

A golf club face insert featuring a planar member with oval-shaped holes and a variable perimeter edge radius, combined with a polymeric backing, which enhances grip and control by varying the radius of the edges to interact differently with the golf ball on upswing and downswing, and includes protrusions for additional absorption and control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional solid face insert is used, then structural strength is maintained, but feedback and feel quality are insufficient

Engineering Contradiction:

Improvefeedback and feel qualityVSAvoidface insert structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The face insert employs a porous or cellular internal structure within the planar member, allowing the material to maintain structural integrity while creating micro-compliance zones that enhance feedback and feel during ball impact. The porous structure enables controlled deformation and energy absorption characteristics.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention uses composite construction by combining the planar member with a polymeric backing layer, creating a multi-material system that integrates the rigidity of the planar member with the cushioning and feedback properties of the polymer material, thereby improving overall feel quality.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If the face insert structure is simplified, then manufacturing is easier, but control over ball spin and launch angle deteriorates

Engineering Contradiction:

Improveface insert manufacturingVSAvoidball spin and launch angle control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The face insert features localized variations in the planar member's geometry, including regions with different thicknesses, the oval-shaped holes with variable radius perimeter edges, and strategically positioned protrusions. These local structural variations create specific contact characteristics with the ball that enable precise control over spin and launch angle while maintaining overall manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

3Reliability

If the perimeter edge radius is made uniform, then manufacturing precision is easier to achieve, but interaction with the golf ball on upswing and downswing is less effective

Engineering Contradiction:

Improveball interaction performanceVSAvoidperimeter edge radius consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The oval-shaped holes incorporate perimeter edges with asymmetric radius variations, where different segments of the perimeter have different radii. This asymmetry creates differentiated interaction zones that respond differently to upswing and downswing motions, enhancing ball control performance.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Specific portions of the perimeter edges are designed with localized radius variations, creating areas of concentrated contact and areas of distributed contact. This local quality variation optimizes the interaction with the ball during different swing phases while keeping the overall manufacturing process feasible.

Inventive Principle:

Principle #3Local quality

4Strength

If the planar member thickness is increased, then structural strength is improved, but feedback and feel are reduced

Engineering Contradiction:

Improveplanar member structural strengthVSAvoidfeedback and feel

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The planar member incorporates a porous or cellular internal structure that provides structural strength through the geometric arrangement of the porous network while maintaining overall thinness. This allows the member to be sufficiently thin for good feedback and feel while still achieving required strength through the porous architecture.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The combination of the planar member with the polymeric backing creates a composite structure where the thin planar member provides structural integrity and the polymer layer provides cushioning and feedback, eliminating the need to increase planar member thickness for improved feel.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9555300B2Putter face insert

Publication Date: 2017.01.31 CALLAWAY GOLF COMPANY

AI summary

A face insert comprising a planar member composed of a rigid material such as plastic or metal and a polymeric backing is disclosed herein. The planar member, which makes contact with a golf ball during use, includes a plurality of geometrically-shaped holes, each of which comprises a perimeter edge that has a variable radius to further optimize performance of the face insert. In some embodiments, one or more of the holes extends completely through the planar member, i.e. is a through-hole, and the polymeric backing includes at least one protrusion with an angled upper surface that is sized to extend into a through-hole and further improve performance of the face insert. The face insert described herein can be used with any type of golf club head, including putters, woods, irons, and hybrids, and the holes may take any shape, including oval, hexagonal, and chevron.