US20080149267A1 - Methods for fabricating composite face plates for use in golf clubs and club-heads for same - Google Patents

Methods for fabricating composite face plates for use in golf clubs and club-heads for same Download PDF

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Publication number
US20080149267A1
US20080149267A1 US11/825,138 US82513807A US2008149267A1 US 20080149267 A1 US20080149267 A1 US 20080149267A1 US 82513807 A US82513807 A US 82513807A US 2008149267 A1 US2008149267 A1 US 2008149267A1
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Prior art keywords
lay
resin
time
maximum
pressure
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US11/825,138
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Bing-Ling Chao
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TaylorMade Golf Co Inc
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TaylorMade Golf Co Inc
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Priority to US11/825,138 priority Critical patent/US20080149267A1/en
Assigned to TAYLOR MADE GOLF COMPANY, INC. reassignment TAYLOR MADE GOLF COMPANY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHAO, BING-LING
Priority to JP2007331326A priority patent/JP4922912B2/ja
Priority to US12/156,947 priority patent/US7874938B2/en
Publication of US20080149267A1 publication Critical patent/US20080149267A1/en
Priority to US12/970,804 priority patent/US8163119B2/en
Priority to US13/452,370 priority patent/US20120199282A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2707/00—Use of elements other than metals for preformed parts, e.g. for inserts
    • B29K2707/04—Carbon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/108—Flash, trim or excess removal

Definitions

  • This disclosure pertains generally to golf clubs and club-heads. More particularly the disclosure pertains to, inter alia, wood-type club-heads and other types of club-heads that have a face insert or the like.
  • An exemplary metal-wood golf club such as a fairway wood or driver typically includes a hollow shaft having a lower end to which the club-head is attached. Most modern versions of these club-heads are made, at least in part, of a light-weight but strong metal such as titanium alloy.
  • the club-head comprises a body to which a strike plate (also called a face plate) is attached or integrally formed.
  • the strike plate defines a front surface or strike face that actually contacts the golf ball.
  • club-heads The current ability to fashion metal-wood club-heads of strong, light-weight metals and other materials has allowed the club-heads to be made hollow. Use of light-weight materials has also allowed club-head walls to be made thinner, which has allowed increases in club-head size, compared to earlier club-heads. Larger club-heads tend to provide a larger “sweet spot” on the strike plate and to have higher club-head inertia, thereby making the club-heads more “forgiving” than smaller club-heads.
  • Characteristics such as size of the sweet spot are determined by many variables including the shape profile, size, and thickness of the strike plate as well as the location of the center of gravity (CG) of the club-head.
  • the distribution of mass around the club-head typically is quantified by parameters such as rotational moment of inertia (MOI) and CG location.
  • Club-heads typically have multiple rotational MOIs, each associated with a respective Cartesian reference axis (x, y, z) of the club-head.
  • a rotational MOI is a measure of the club-head'head's resistance to angular acceleration (twisting or rotation) about the respective reference axis.
  • the rotational MOIs are related to, inter alia, the distribution of mass in the club-head with respect to the respective reference axes.
  • Each of the rotational MOIs desirably is maximized as much as practicable to provide the club-head with more forgiveness.
  • the club-head's mass budget at least some of the mass budget must be dedicated to providing adequate strength and structural support for the club-head. This is termed “structural” mass. Any mass remaining in the budget is called “discretionary” or “performance” mass, which can be distributed within the club-head to address performance issues, for example.
  • Some current approaches to reducing structural mass of a club-head are directed to making at least a portion of the club-head of an alternative material.
  • the bodies and face plates of most current metal-woods are made of titanium alloy
  • several “hybrid” club-heads are available that are made, at least in part, of components formed from both graphite-composite (or another suitable composite material) and a metal alloy.
  • graphite carbon-fiber
  • titanium alloy is used as the primary face-plate material.
  • Other club-heads are made entirely of one or more composite materials.
  • Graphite composites have a density of approximately 1.5 g/cm 3 , compared to titanium alloy which has a density of 4.5 g/cm 3 , which offers tantalizing prospects of providing more discretionary mass in the club-head.
  • Composites that are useful for making club-head components comprise a fiber portion and a resin portion.
  • the resin portion serves as a “matrix” in which the fibers are embedded in a defined manner.
  • the fiber portion is configured as multiple fibrous layers or plies that are impregnated with the resin component.
  • the fibers in each layer have a respective orientation, which is typically different from one layer to the next and precisely controlled.
  • the usual number of layers is substantial, e.g., fifty or more.
  • the layers are placed superposedly in a “lay-up” manner. After forming the prepreg lay-up, the resin is cured to a rigid condition.
  • component performance typically will be drastically reduced whenever these components are subjected to complex loads, such as dynamic and repetitive loads (i.e., repetitive impact and consequent fatigue).
  • An embodiment of such a method is directed to the fabrication of composite face plates for club-heads of golf clubs.
  • the method comprises forming a lay-up that comprises multiple prepreg layers.
  • Each prepreg layer comprises at least one layer of respective fibers at a respective orientation, and the at least one fiber layer is impregnated with a resin.
  • the lay-up is exposed to an initial tool temperature T i and an initial pressure P 1 . Beginning at a time t 1 at which the resin exhibits a minimal liquid viscosity, the temperature of the lay-up is increased from T i , and the pressure of the lay-up is increased from P 1 .
  • the temperature of the lay-up to is increased to T s >T i
  • the pressure of the lay-up is increased to P 2 >P 1 .
  • the resin exhibits a relatively rapid progressive increase in viscosity.
  • the lay-up is maintained substantially at the temperature T s and substantially at the pressure P 2 , which allows the resin to undergo a relatively slow but continued increase in viscosity to a specified pre-cure viscosity level.
  • the increase in temperature of the lay-up from T i is ramped, and the increase in pressure of the lay-up from P 1 is ramped.
  • the temperature of the lay-up desirably is ramped up to T s
  • the pressure of the lay-up desirably is ramped up to P 2 .
  • the temperature desirably is decreased from T s
  • the pressure desirably is decreased from P 2
  • a full-cure of the lay-up can be completed.
  • a full-cure generally is characterized by the resin exhibiting a maximal viscosity.
  • the method can further comprise shaping the lay-up (full-cured or not) to have specified dimensions and shape for use as a face plate for a club-head.
  • the lay-up is formed in a tool configured to hold the lay-up as the lay-up is being exposed to the temperatures T i and T s and to the pressures P 1 and P 2 .
  • the lay-up can be removed from the tool when the lay-up has reached the specified pre-cure viscosity level. While the lay-up is in the tool, the contour of the lay-up can be shaped.
  • the pressure P 1 is within a range 0-100 psig. This range can be 0-100 psig ⁇ P, wherein ⁇ P is a maximum of 50 psi.
  • the pressure P 2 is within a range 200-500 psig. This range can be 200-500 psig ⁇ P, wherein ⁇ P is a maximum of 50 psi.
  • the temperature T s T r ⁇ T, wherein T r is a manufacturer's recommended cure temperature for the resin, and ⁇ T is a maximum of 75° F.
  • the temperature T i can be equal to T s /2 ⁇ T.
  • the minimum viscosity of the resin can be in a range of ⁇ x, wherein ⁇ x is a maximum of 25%.
  • the time t 1 can be in a range of ⁇ t, and ⁇ t is a maximum of 10 minutes.
  • the resin has reached 80% of its maximum viscosity X m , X m is in a range of ⁇ x, and ⁇ x is a maximum of 25%.
  • the time t 2 is in a range of ⁇ t, wherein ⁇ t is a maximum of 10 minutes.
  • the resin has reached 90% of its maximum viscosity X m , X m is in a range of ⁇ x, and ⁇ x is a maximum of 25%.
  • the time t 3 can be in a range of ⁇ t, wherein ⁇ t is a maximum of 10 minutes.
  • the pressure P 1 is within the range 0-100 psig ⁇ P, wherein ⁇ P is a maximum of 50 psi.
  • the pressure P 2 can be within a range 200-500 psig ⁇ P, wherein ⁇ P is a maximum of 50 psi.
  • the temperature T s can be equal to T r ⁇ T, wherein T r is a manufacturer's recommended cure temperature for the resin, and ⁇ T is a maximum of 75° F.
  • the temperature T i can be equal to T s /2 ⁇ T.
  • the minimum viscosity of the resin can be in a range of ⁇ x, wherein ⁇ x is a maximum of 25%, the time t 1 is in a range of ⁇ t, and ⁇ t is a maximum of 10 minutes.
  • the resin can have reached 80% of its maximum viscosity X m , wherein X m is in the range of ⁇ x, and the time t 2 is in the range of ⁇ t.
  • the resin can have reached 90% of its maximum viscosity X m , wherein X m is in the range of ⁇ x, and the time t 3 is in the range of ⁇ t.
  • the pressure is increased (desirably ramped) from P 1 to P 2 at a rate in which the pressure P 2 is reached before the resin viscosity ceases its relatively rapid increase.
  • the prepreg layers comprise carbon fiber and epoxy resin.
  • FIG. 1 is a perspective view of a “metal-wood” club-head, showing certain general features pertinent to the instant disclosure.
  • FIG. 2 is a schematic diagram showing an exemplary manner in which plies can be stacked in making a composite face plate.
  • FIGS. 3(A)-3(C) are plots of temperature, viscosity, and pressure, respectively, versus time in a representative embodiment of a process for forming composite components.
  • FIGS. 4(A)-4(C) are plots of temperature, viscosity, and pressure, respectively, versus time in a representative embodiment of a process in which each of these variables can be within a specified respective range (hatched areas).
  • FIG. 5 is a partial sectional view of the upper lip region of an embodiment of a club-head of which the face plate comprises a composite plate and a metal cap.
  • the club-head 10 comprises a face plate 12 and a body 14 .
  • the face plate 12 typically is convex, and has an external (“striking”) surface (face) 13 .
  • the body 14 defines a front opening 16 .
  • a face support 18 is disposed about the front opening 16 for positioning and holding the face plate 12 to the body 14 .
  • the body 14 also has a heel 20 , a toe 22 , a sole 24 , a top or crown 26 , and a hosel 28 .
  • the transition zone 15 Around the front opening 16 is a “transition zone” 15 that extends along the respective forward edges of the heel 20 , the toe 22 , the sole 24 , and the crown 26 .
  • the transition zone 15 effectively is a transition from the body 14 to the face plate 12 .
  • the hosel 28 defines an opening 30 that receives a distal end of a shaft (not shown).
  • the opening 16 receives the face plate 12 , which rests upon and is bonded to the face support 18 and transition zone 15 , thereby enclosing the front opening 16 .
  • the transition zone 15 includes a sole-lip region 18 d , a crown-lip region 18 a , a heel-lip region 18 c , and a toe-lip region 18 b . These portions can be contiguous, as shown, or can be discontinuous, with spaces between them.
  • the face plate 12 is made of a composite including multiple plies or layers of a fibrous material (e.g., graphite, or carbon, fiber) embedded in a cured resin (e.g., epoxy).
  • a fibrous material e.g., graphite, or carbon, fiber
  • a cured resin e.g., epoxy
  • An exemplary thickness range of the composite is 4.5 mm or less.
  • the composite is configured to have a relatively consistent distribution of reinforcement fibers across a cross-section of its thickness to facilitate efficient distribution of impact forces and overall durability.
  • the composite portion is made as a lay-up of multiple prepreg plies.
  • the fiber reinforcement and resin are selected in view of the club-head's desired durability and overall performance.
  • FAW is the weight of the fiber portion of a given quantity of prepreg, in units of g/m 2 .
  • FAW values below 100 g/m 2 , and more desirably below 70 g/m 2 can be particularly effective.
  • a particularly suitable fibrous material for use in making prepreg plies is carbon fiber, as noted. However, more than one fibrous material can be used.
  • stacked plies of prepreg materials having a higher FAW tend to have more significant resin-rich regions, particularly at the interfaces of adjacent plies, than stacked plies of low-FAW materials. Resin-rich regions tend to reduce the efficacy of the fiber reinforcement, particularly since the force resulting from golf-ball impact is generally transverse to the orientation of the fibers of the fiber reinforcement.
  • each low-FAW prepreg ply desirably has a prescribed fiber orientation, and the plies are stacked in a prescribed order with respect to fiber orientation.
  • the fiber orientation of each ply is measured from a horizontal axis of the club-head's face plane to a line that is substantially parallel with the fibers in the ply. Referring to FIG. 2 , for example, fiber orientation is indicated by dashed lines.
  • a first low-FAW ply 120 is oriented at 0 degrees, followed by multiple unit-groups 122 , 124 , 126 of low-FAW plies each having four plies oriented at 0, +45, 90, and ⁇ 45 degrees, respectively.
  • the resulting stack of unit-groups of low-FAW plies is sandwiched between an “outer” ply 128 and an “inner” ply 130 .
  • the outer ply 128 is oriented at 90 degrees, and the inner ply 130 is oriented at 0 degrees.
  • the inner and outer plies 128 , 130 are formed of prepreg reinforced by glass fibers, such as 1080 glass fibers.
  • the other plies are formed of prepreg reinforced by carbon fiber.
  • the number of unit groups desirably ranges from ten to fourteen, with twelve unit groups providing 48 plies being a preferred embodiment.
  • An example carbon fiber is “34-700” carbon fiber, available from Grafil (Sacramento, Calif.), having a tensile modulus of 234 Gpa (34 Msi) and a tensile strength of 4500 Mpa (650 Ksi).
  • Another Grafil fiber that can be used is “TR50S” carbon fiber, which has a tensile modulus of 240 Gpa (35 Msi) and a tensile strength of 4900 Mpa (710 Ksi).
  • Suitable epoxy resins are types “301” and “350” available from Newport Adhesives and Composites (Irvine, Calif.).
  • An exemplary resin content (R/C) is 40%.
  • stacking the prepreg plies in predetermined orientations may be done by first stacking individual plies in unit-groups 122 , 124 , 126 , and then stacking a desired number of unit-groups (and any additional desired plies) to form the final thickness of the composite.
  • the inner ply 128 and outer ply 130 desirably are made of a different fiber material than used in the plies of the unit-groups.
  • the number of unit-groups can be varied as desired.
  • One embodiment comprises twelve unit-groups.
  • the following aspects desirably are controlled to provide composite components that are capable of withstanding impacts and fatigue loadings normally encountered by a club-head, especially by the face plate of the club-head. These three aspects are: (a) adequate resin content; (b) fiber straightness; and (c) very low porosity in the finished composite. These aspects can be controlled by controlling the flow of resin during curing, particularly in a manner that minimizes entrapment of air in and between the prepreg layers. Air entrapment is difficult to avoid during laying up of prepreg layers.
  • air entrapment can be substantially minimized by, according to various embodiments disclosed herein, imparting a slow, steady flow of resin for a defined length of time during the laying-up to purge away at least most of the air that otherwise would become occluded in the lay-up.
  • the resin flow should be sufficiently slow and steady to retain an adequate amount of resin in each layer for adequate inter-layer bonding while preserving the respective orientations of the fibers (at different respective angles) in the layers.
  • Slow and steady resin flow also allows the fibers in each ply to remain straight at their respective orientations, thereby preventing the “wavy fiber” phenomenon.
  • a wavy fiber has an orientation that varies significantly from its naturally projected direction.
  • the composite face plate can be provided with its final desired shape and dimensions by die cutting. Any desired bulge and roll of the face plate may be formed during the last of two or more “debulking” or compaction steps (performed before curing, to remove and/or reduce air trapped between plies). To form the bulge or roll, the “last” debulking step can be performed against a die panel having the final desired bulge and roll. If desired, yet another (and subsequent) debulking step can be performed using the die panel to achieve the final face-plate thickness. The weight and thickness of the face plate desirably are measured before the curing step.
  • FIGS. 3(A)-3(C) depict an embodiment of a process (pressure and temperature as functions of time) in which slow and steady resin flow is performed with minimal resin loss.
  • FIG. 3(A) shows temperature of the lay-up as a function of time.
  • the lay-up temperature is substantially the same as the tool temperature.
  • the tool is maintained at an initial tool temperature T i , and the uncured prepreg lay-up is placed or formed in the tool at an initial pressure P 1 (typically atmospheric pressure).
  • P 1 typically atmospheric pressure
  • the tool and uncured prepreg is then placed in a hot-press at a tool-set temperature T s , resulting in an increase in the tool temperature (and thus the lay-up temperature) until the tool temperature eventually reaches equilibrium with the set temperature T s of the hot-press.
  • This temperature increase desirably is “ramped,” by which is meant a progressive increase.
  • the temperature increase of the tool and lay-up is continuous. Exemplary rates of change of temperature and pressure are: ⁇ T ⁇ ( 60 C)/(120 sec) up to t 1 , and ⁇ P ⁇ (150 psi)/(300 sec) from t 1 to t 2 .
  • tool pressure desirably is gradually increased in the time span from t 1 to t 2 to allow (and to encourage) adequate and continued (but nevertheless controlled) resin flow.
  • the rate at which pressure is increased should be sufficient to reach maximum pressure P 2 slightly before the end of rapid increase in resin viscosity.
  • a desired rate of change is ⁇ P ⁇ (150 psi)/(300 sec) from t 1 to t 2 .
  • the resin viscosity desirably is approximately 80% of maximum.
  • Curing continues after time t 2 and follows a schedule of relatively constant temperature T s and constant pressure P 2 . Note that resin viscosity exhibits some continued increase (typically to approximately 90% of maximum) during this phase of curing.
  • This curing (also called “pre-cure”) ends at time t 3 at which the component is deemed to have sufficient rigidity (approximately 90% of maximum) and strength for handling and removal from the tool, although the resin may not yet have reached a “full-cure” state (at which the resin exhibits maximum viscosity).
  • a post-processing step typically follows, in which the components reach a “full cure” in a batch mode or other suitable manner.
  • the components are subjected to manufacturing techniques (machining, forming, etc.) that achieve the specified final dimensions, size, contours, etc., of the components for use as face plates on club-heads.
  • T s the tool-set temperature (or typical resin-cure temperature), established according to manufacturer's instructions
  • T i the initial tool temperature, usually set at approximately 50% of T s (in ° F.
  • processing parameters can be expressed as follows (see FIGS. 4 (A)- 4 (C)):
  • T i initial tool temperature (or T s /2) ⁇ T.
  • the potential mass “savings” obtained from fabricating at least a portion of the face plate of composite, as described above, is about 10-30 g, or more, relative to a 2.7-mm thick face plate formed from a titanium alloy such as Ti-6Al-4V, for example.
  • the methods described above provide improved structural integrity of the face plates and other club-head components manufactured according to the methods, compared to composite component manufactured by prior-art methods.
  • the subject methods are especially advantageous for manufacturing face plates because face plates are the most severely loaded components in golf club-heads.
  • Conventional (and generally less expensive) composite-processing techniques e.g., bladder-molding, etc. can be used to make other parts of a club-head not subject to such severe loads.
  • Attaching a composite face plate to the club-head body may be achieved using an appropriate adhesive (typically an epoxy adhesive or a film adhesive).
  • an appropriate adhesive typically an epoxy adhesive or a film adhesive.
  • the composite face plate can be recessed from or can be substantially flush with the plane of the forward surface of the metal body at the junction. Desirably, the composite face plate is sufficiently recessed so that the ends of the fibers in the plies are not exposed.
  • the face plate 12 comprises a metal “cap” 90 formed or placed over a composite plate 92 to form the strike surface 13 .
  • the cap 90 includes a peripheral rim 94 that covers the peripheral edge 96 of the composite plate 92 .
  • the rim 94 can be continuous or discontinuous, the latter comprising multiple segments (not shown).
  • the thickness of the titanium desirably is less than about 1 mm, and more desirably less than 0.2 mm.
  • the candidate titanium alloys are not limited to Ti-6Al-4V, and the base metal of the alloy is not limited to titanium. Other materials or titanium alloys can be employed as desired. In one example, in which the thickness of the composite plate 92 was about 3.65 mm, a titanium cap 90 was used having a thickness of about 0.3 mm.
  • the metal cap 90 desirably is bonded to the composite plate 92 using a suitable adhesive 98 , such as an epoxy, polyurethane, or film adhesive.
  • the adhesive 98 is applied so as to fill the gap completely between the cap 90 and the composite plate 92 (this gap usually in the range of about 0.05-0.2 mm, and desirably is approximately 0.1 mm).
  • the face plate 12 desirably is bonded to the body 14 using a suitable adhesive 100 , such as an epoxy adhesive, which fills the gap completely between the rim 94 and the peripheral member 80 of the face support 18 . When thus assembled, the face plate 12 contacts the rear member 84 of the face support 18 .
  • the face plate 12 lacks a metal cap 90
  • the face plate can be placed on the face support 18 and bonded to the body 14 using a suitable adhesive that fills the gap completely between the peripheral edge 96 of the composite plate and the peripheral member 80 as the composite plate contacts the rear member 84 .
  • a particularly desirable metal for the cap 90 is titanium alloy, such as the particular alloy used for fabricating the body (e.g., Ti-6Al-4V).
  • the thickness of the titanium desirably is less than about 1 mm, and more desirably less than 0.2 mm.
  • the candidate titanium alloys are not limited to Ti-6Al-4V, and the base metal of the alloy is not limited to Ti. Other materials or Ti alloys can be employed as desired.
  • a titanium cap 90 was used having a thickness of about 0.3 mm.
  • Surface roughness can be imparted to the composite plate 92 (notably to any surface thereof that will be adhesively bonded to the body of the club-head and/or to the metal cap 92 ).
  • a layer of textured film is placed on the composite plate 92 before curing the film (e.g., “top” and/or “bottom” layers discussed above).
  • An example of such a textured film is ordinary nylon fabric.
  • Conditions under which the adhesives 98 , 100 are cured normally do not degrade nylon fabric, so the nylon fabric is easily used for imprinting the surface topography of the nylon fabric to the surface of the composite plate.
  • adhesion of urethane or epoxy adhesive such as 3M® DP 460, to the surface of the composite plate so treated is improved compared to adhesion to a metallic surface, such as cast titanium alloy.
  • texture can be incorporated into the surface of the tool used for forming the composite plate 92 , thereby allowing the textured area to be controlled precisely and automatically.
  • texture can be located on surfaces where shear and peel are dominant modes of failure.
  • the composite face plate as described above need not be coextensive (dimensions, area, and shape) with a typical face plate on a conventional club-head.
  • a subject composite face plate can be a portion of a full-sized face plate, such as the area of the “sweet spot.” Both such composite face plates are generally termed “face plates” herein.
  • the resin was Newport 301-1 epoxy resin.
US11/825,138 2003-05-21 2007-07-02 Methods for fabricating composite face plates for use in golf clubs and club-heads for same Abandoned US20080149267A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US11/825,138 US20080149267A1 (en) 2006-12-26 2007-07-02 Methods for fabricating composite face plates for use in golf clubs and club-heads for same
JP2007331326A JP4922912B2 (ja) 2006-12-26 2007-12-25 ゴルフクラブおよびそのクラブ・ヘッドに使用される複合材フェース・プレートの加工方法
US12/156,947 US7874938B2 (en) 2003-05-21 2008-06-03 Composite articles and methods for making the same
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US7874938B2 (en) 2011-01-25
JP4922912B2 (ja) 2012-04-25
US20120199282A1 (en) 2012-08-09
US20080300068A1 (en) 2008-12-04
US20110083800A1 (en) 2011-04-14
US8163119B2 (en) 2012-04-24
JP2008161679A (ja) 2008-07-17

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