Patent Application
20250041681
This disclosure relates to a golf club head comprising Damascus steel and the process of preparing the golf club heads. More specifically it related to Damascus steel golf club heads with optimal sweet spot and patterns for visual appeal.
In this section prior art is cited:
“The present invention is a golf club head made of a damascene patterned metal The golf club head may be a putter head or an iron-type club head with a majority of the club head body formed of the damascene patterned metal, or a wood-type club head or an iron-type club head with a damascene patterned metal face insert.” [U.S. Pat. No. 7,172,519B2, titled, “Golf club head composed of damascene patterned metal”].
“The distinctive damascene pattern of pattern welded Damascus steel comes from alternating sheets of high and low-carbon steels. The different sheets of steel are repeatedly drawn, folded, and forged welded together. The forge welded steel may then be polished and etched to enhance the contrast between the two steels.” [U.S. Pat. No. 7,172,519B2, titled, “Golf club head composed of damascene patterned metal”].
“The invention provides a method of manufacturing a golf club face plate having substantial thickness variation for enhanced performance. The method includes the steps of providing a rolled sheet of metal material having an initial thickness and forming a blank having a prescribed outer shape from the material. The method also includes machining a second side of the blank such that the resulting face plate has a variable thickness. The variable thickness includes a first thickness less than or equal to the initial thickness, a second thickness less than the first thickness and a third thickness less than the second thickness. The machining is performed over a substantial portion of the surface area of the second side.” [U.S. Pat. No. 6,904,663B2, titled, “Method for manufacturing a golf club face”].
“[A] golf club head having an improved striking surface. The golf club head of the present invention has a flat striking face, preferably being milled. This allows a greater degree of flatness than typically seen. Preferably, the face is flat within ±0.002 inch. Grooves or score lines are then cut into the flattened face. Typically, grooves are formed in the face as part of the head-forming process. For example, if the head is cast, typical grooves are formed as part of the casting process. The face—including the grooves—is then subject to post-casting process steps, such as polishing. Similar finishing steps are also typically performed on club heads that are formed by forging. Machining grooves in the face after it has been milled beneficially saves them from being affected by any face post-manufacturing processes, which can adversely effect, for example, the groove-face interface, making it inconsistent along the length of the groove.” [U.S. Pat. No. 9,403,068B2, titled, “Golf club head having a grooved and textured face”].
Therefore, there is a need for golf irons made of Damascus steel to improve the performance, aesthetics, and feel of the golf club.
The following is a summary to provide a basic understanding of one or more embodiments described herein. This summary is not intended to identify key or critical elements or delineate any scope of the different embodiments and/or any scope of the claims. The sole purpose of the summary is to present some concepts in a simplified form as a prelude to the more detailed description presented herein.
According to an embodiment, it is a golf club head comprising a body comprising a shell and a face; the shell comprising a hosel, a first periphery, and a back made of a non-layered material; the face comprising a Damascus Steel comprising a plurality of layers of at least a first material and a second material; the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; a cavity formed behind the face and within the body, the cavity extending rearward from the face to the back of the shell; wherein a first thickness of a sweet spot of the face is greater than a second thickness of other areas of the face; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the golf club head is an iron type golf club head.
According to an embodiment of the golf club head, the face has a surface area at least 60 square centimeters.
According to an embodiment of the golf club head, a first thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters.
According to an embodiment of the golf club head, the second periphery of the face is attached via a welding to the first periphery of the shell.
According to an embodiment of the golf club head, the first material and the second material are selected from a group consisting of titanium, steel, Stainless steel, Amorphous Alloys, and composites thereof.
According to an embodiment of the golf club head, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the golf club head, the sweet spot of the face is at least 10% thicker than the other areas of the face.
According to an embodiment of the golf club head, the Damascus steel comprises a stainless steel 304L and a stainless steel 316L.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the toe edge and the heel edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the crown edge and the sole edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the first thickness is distributed circularly along the sweet spot of the face.
According to an embodiment of the golf club head, the first thickness to the second thickness is a continuous variation in the thickness from most thick region being at the sweet spot.
According to an embodiment of the golf club head, the first thickness to the second thickness is an abrupt variation in the thickness from most thick regions at the sweet spot.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound upon impact of a golf ball based on the location where the golf ball is hit on the face.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound and is configured such that it produces an audio feedback to a user of the golf club.
According to an embodiment of the golf club head, the sweet spot on the face further comprises colored rings around the decorative pattern formed from the Damascus Steel; and wherein a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
According to an embodiment of the golf club head, the Damascus Steel has at least 2 times yield strength of that of a material used for the shell.
According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the Damascus Steel comprises plurality of layers and wherein the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the golf club head, the face comprises Damascus Titanium.
According to an embodiment of the golf club head, the face comprises Amorphous Alloys.
According to an embodiment, the golf club head is part of a golf club.
According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by at least 3%.
According to an embodiment of the golf club head, each layer of the plurality of layers are selected to comprise material with properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment of the golf club head, the face comprising Damascus Steel is heat treated.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate a sweet spot on the face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the cavity behind the face is filled with an insert configured to dampen a sound generated by the face upon hitting a golf ball.
The golf club of claim 1, wherein the insert comprises at least one of a Thermoplastic Elastomers (TPE) and a Polyurethane (PU) foam.
According to an embodiment, it is a method comprising: casting a shell comprising a hosel, a first periphery, and a back made of a non-layered material; producing a face comprising a Damascus Steel from plurality of layers, by repeated rolling and forging, wherein the plurality of layers comprises at least a first material and a second material, and wherein the face comprises a second periphery; generating a first thickness of a sweet spot of the face greater than a second thickness of other areas of the face; attaching the second periphery to the first periphery of the shell via a welding, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; forming a cavity behind the face and within a body, the cavity extending rearward from the face to the back of the shell; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the method is configured for manufacturing a golf club head of an iron type.
According to an embodiment of the method, a material for the shell comprises casting stainless steel.
According to an embodiment of the method, the shell is made using investment casting.
According to an embodiment of the method, the golf club head is heat treated to improve a grain structure.
According to an embodiment of the method, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the method, each of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
Aspects of the present invention will now be described in more detail, with reference to the appended drawings showing exemplary embodiments of the present invention, in which:
For simplicity and clarity of illustration, the figures illustrate the general manner of construction. The description and figures may omit the descriptions and details of well-known features and techniques to avoid unnecessarily obscuring the present disclosure. The figures exaggerate the dimensions of some of the elements relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numeral in different figures denotes the same element.
Although the detailed description herein contains many specifics for the purpose of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the details are considered to be included herein.
Accordingly, the embodiments herein are without any loss of generality to, and without imposing limitations upon, any claims set forth. The terminology used herein is for the purpose of describing particular embodiments only and is not limiting. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one with ordinary skill in the art to which this disclosure belongs.
Other specific forms may embody the present invention without departing from its spirit or characteristics. The described embodiments are in all respects illustrative and not restrictive. Therefore, the appended claims rather than the description herein indicate the scope of the invention. All variations which come within the meaning and range of equivalency of the claims are within their scope.
While this specification contains many specifics, these do not construe as limitations on the scope of the disclosure or of the claims, but as descriptions of features specific to particular implementations. A single implementation may implement certain features described in this specification in the context of separate implementations. Conversely, multiple implementations separately or in any suitable sub-combination may implement various features described herein in the context of a single implementation. Moreover, although features described herein are acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
Similarly, while operations depicted herein in the drawings in a particular order to achieve desired results, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order or that all illustrated operations be performed to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems may be integrated together in a single software product or packaged into multiple software products.
Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of possible implementations. Other implementations are within the scope of the claims. For example, the actions recited in the claims may be performed in a different order and still achieve desirable results. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim may directly depend on only one claim, the disclosure of possible implementations includes each dependent claim in combination with every other claim in the claim set.
The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Unless otherwise defined herein, scientific, and technical terms used in connection with the present disclosure shall have meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.
The following terms and phrases, unless otherwise indicated, shall be understood to have the following meanings.
As used herein, the articles “a” and “an” used herein refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element. Moreover, usage of articles “a” and “an” in the subject specification and annexed drawings construe to mean “one or more” unless specified otherwise or clear from context to mean a singular form.
As used herein, the terms “example” and/or “exemplary” mean serving as an example, instance, or illustration. For the avoidance of doubt, such examples do not limit the herein described subject matter. In addition, any aspect or design described herein as an “example” and/or “exemplary” is not necessarily preferred or advantageous over other aspects or designs, nor does it preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art.
As used herein, the terms “first,” “second,” “third,” and the like in the description and in the claims, if any, distinguish between similar elements and do not necessarily describe a particular sequence or chronological order. The terms are interchangeable under appropriate circumstances such that the embodiments herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” “have,” and any variations thereof, cover a non-exclusive inclusion such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limiting to those elements, but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.
As used herein, the terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like, in the description and in the claims, if any, are for descriptive purposes and not necessarily for describing permanent relative positions. The terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
No element act, or instruction used herein is critical or essential unless explicitly described as such. Furthermore, the term “set” includes items (e.g., related items, unrelated items, a combination of related items and unrelated items, etc.) and may be interchangeable with “one or more”. Where only one item is intended, the term “one” or similar language is used. Also, the terms “has,” “have,” “having,” or the like are open-ended terms. Further, the phrase “based on” means “based, at least in part, on” unless explicitly stated otherwise.
As used herein, the terms “couple,” “coupled,” “couples,” “coupling,” and the like, refer to connecting two or more elements mechanically, electrically, and/or otherwise. Two or more electrical elements may be electrically coupled together, but not mechanically or otherwise coupled together. Coupling may be for any length of time, e.g., permanent, or semi-permanent or only for an instant. “Electrical coupling” includes electrical coupling of all types. The absence of the word “removably,” “removable,” and the like, near the word “coupled” and the like does not mean that the coupling, etc., in question is or is not removable.
As used herein, the terms “system,” “device,” “unit,” and/or “module” refer to a different component, component portion, or component of the various levels of the order. However, other expressions that achieve the same purpose may replace the terms.
As used herein, the term “or” means an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from context, “X employs A or B” means any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances.
As used herein, the term “approximately” can mean within a specified or unspecified range of the specified or unspecified stated value. In some embodiments, “approximately” can mean within plus or minus ten percent of the stated value. In other embodiments, “approximately” can mean within plus or minus five percent of the stated value. In further embodiments, “approximately” can mean within plus or minus three percent of the stated value. In yet other embodiments, “approximately” can mean within plus or minus one percent of the stated value.
As used herein, two or more elements or modules are “integral” or “integrated” if they operate functionally together. Two or more elements are “non-integral” if each element can operate functionally independently.
The term “Damascus steel” as used herein refers to various pattern-welded steels produced around the world. While the historical origins of Damascus steel lie in the Middle East, the technique of pattern welding has been adopted by craftsmen in different regions, including Germany. Therefore, German Damascus steel refers specifically to steel made in Germany using the pattern-welding technique but does not necessarily imply that the steel originates exclusively from Germany. The term Damascus steel may include German Damascus steel but is not limited only to German Damascus steel and may include various types that exhibit layered patterns including Stainless Damascus steel. Damascus steel is referring to a type of steel that exhibits a distinctive layered pattern.
The term “sweet spot” as used herein, in the context of golf clubs, refers to a specific area on the clubface that is considered ideal for achieving optimal performance and accuracy when striking the golf ball. When the ball is hit precisely at the sweet spot, it results in maximum energy transfer and a more controlled shot. The sweet spot is typically located near the center of the clubface, and it represents the point where the clubface meets the ball most effectively. When the golf ball contacts the sweet spot, it reduces the amount of twisting or misalignment of the clubface, leading to a more solid and accurate shot.
Hitting the ball on the sweet spot tends to produce desirable outcomes, such as greater distance, improved control, and a better feel. It allows the golfer to achieve the maximum potential of the club's design and technology. Golfers often strive to consistently meet the sweet spot of their clubs with the golf ball to optimize their performance on the golf course.
The term, “irons” in golf refers to a specific category of golf clubs that are used for approach shots to the green and offer a range of lofts and distances. They are numbered from 2 to 9, with lower numbers indicating lower lofts and longer shots. Irons are designed to provide accuracy, control, and versatility for different situations on the course.
Bulk-solidifying amorphous alloys, or bulk metallic glasses (“BMG”), are a recently developed class of metallic materials. These alloys may be solidified and cooled at relatively slow rates, and they retain the amorphous, non-crystalline (i.e., glassy) state at room temperature. Amorphous alloys have many superior properties, e.g., physical properties, then their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form inside the alloy during cooling, so that the unique benefits of the amorphous state can be lost. For example, one challenge with the fabrication of bulk amorphous alloy parts is the partial crystallization of parts due to cither slow cooling or impurities prevalent in the raw alloy material. As a high degree of amorphicity (and, conversely, a low degree of crystallinity) is desirable in BMG parts, there is a need to develop methods for casting BMG parts having predictable and controlled amount of amorphicity. The terms “bulk metallic glass” (“BMG”), bulk amorphous alloy (“BAA”), and bulk solidifying amorphous alloy are used interchangeably herein.
Additive is something added to alter or improve the quality of an item.
The term “metal” or “metallic” refers to an electropositive chemical element.
Amorphous is defined as lacking in long-range order. It is also characterized by random atomic orientation. It excludes partially crystalline and metastable crystalline metal alloys.
An “amorphous alloy” is an alloy having an amorphous content of more than 50% by volume, preferably more than 90% by volume of amorphous content, more preferably more than 95% by volume of amorphous content, and most preferably more than 99% to almost 100% by volume of amorphous content. Note that, as described above, an alloy high in amorphicity is equivalently low in degree of crystallinity. An “amorphous metal” is an amorphous metal material with a disordered atomic-scale structure. In contrast to most metals, which are crystalline and therefore have a highly ordered arrangement of atoms, amorphous alloys are non-crystalline. Materials in which such a disordered structure is produced directly from the liquid state during cooling are sometimes referred to as “glasses.” Accordingly, amorphous metals are commonly referred to as “metallic glasses” or “glassy metals.” In one embodiment, a bulk metallic glass (“BMG”) can refer to an alloy, of which the microstructure is at least partially amorphous. However, there are several ways besides extremely rapid cooling to produce amorphous metals, including physical vapor deposition, solid-state reaction, ion irradiation, melt spinning, and mechanical alloying. Amorphous alloys can be a single class of materials, regardless of how they are prepared. Bulk-solidifying amorphous alloys, or bulk metallic glasses (“BMG”) may be solidified and cooled at relatively slow rates, and they retain the amorphous, non-crystalline (i.e., glassy) state at room temperature. Amorphous alloys have many superior properties than their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form inside the alloy during cooling, so that the benefits of the amorphous state can be lost. For example, one challenge with the fabrication of bulk amorphous alloy parts is partial crystallization of the parts due to either slow cooling or impurities in the raw alloy material. As a high degree of amorphicity (and, conversely, a low degree of crystallinity) is desirable in BMG parts, there is a need to develop methods for casting BMG parts having controlled amount of amorphicity.
Golf clubs are the essential tools used by golfers to hit the golf ball. They are designed to provide different trajectories, distances, and control for various shots on the golf course. Golf clubs are used in the sport of golf to hit a golf ball.
The Grip: The grip of the golf club is important because it connects the club to the golfer's hands. According to the rules of golf, the grip has to be round, without obvious bumps, lumps, or hollows.
The Shaft: The shaft of the golf club connects the grip to the head and, like the grip, must be basically round in the cross section. Most modern golf club shafts are made of either steel or a carbon-fiber and resin composite. Carbon fiber has the advantage of being lighter than steel, but clubs with carbon-fiber shafts also tend to be more expensive.
The Head: The head of the golf club is where all the energy of the swing is transferred to the golf ball. There is more variation in the appearance of golf club heads than there is in either shafts or grips, but all the variations fall into one of three broad categories: the heads of woods, irons, and putters.
Putters: These clubs are used on the green to roll the ball into the hole. They have a flat face and are designed to provide accuracy and control for short-distance shots.
Wedges: These clubs have the highest lofts and are designed for shots that require a high trajectory and a short distance, such as pitching, chipping, and bunker shots. Common wedge types include pitching wedges, sand wedges, gap wedges, and lob wedges.
Hybrids: Also known as utility clubs, hybrids combine the characteristics of woods and irons. They are easier to hit than long irons and are commonly used for long shots from challenging lies or rough.
Golf Irons: Irons are clubs with a solid, all-metal head featuring a flat angled face, and a shorter shaft and more upright lie angle than a wood, for ease of access. Irons are designed for a variety of shots from all over the course, from the tee box on short or dog-legged holes, to the fairway or rough on approach to the green, to tricky situations like punching through or lobbying over trees, getting out of hazards, or hitting from tight lies requiring a compact swing. Most of the irons have a number from 1 to 9 (the numbers in most common use are from 3 to 9), corresponding to their relative loft angle within a matched set. Irons are typically grouped according to their intended distance (which also roughly corresponds to their shaft length and thus their difficulty to hit the ball); in the numbered irons, there are long irons (2-4), medium irons (5-7), and short irons (8-9), with progressively higher loft angles, shorter shafts, and heavier club heads.
As with woods, “irons” get their name because they were originally made from forged iron. Modern irons are investment-cast out of steel alloys, which allows for better-engineered ‘cavity-back’ designs that have lower centers of mass and higher moments of inertia, making the club easier to hit and giving better distance than older forged ‘muscle-back’ designs. Forged irons with less perimeter weighting are still seen, especially in sets targeting low-handicap and scratch golfers, because this less forgiving design allows a skilled golfer to intentionally hit a curved shot (a ‘fade’ or ‘draw’), to follow the contour of the fairway or ‘bend’ a shot around an obstacle.
Irons are a crucial category of golf clubs that offer versatility and precision for various shots on the golf course. They are typically numbered from 2 to 9, indicating the loft and length of the club. Here's some more information about irons:
Long Irons (2-4): Long irons have lower lofts and longer shafts, making them suitable for long-distance shots, especially from the fairway or tec. They are generally more challenging to hit due to their lower loft, which requires more clubhead speed and precise ball striking. Long irons are often used for shots where distance is the priority, such as tee shots on par-4 or par-5 holes or approach shots on longer holes.
Mid-Irons (5-7): Mid-irons provide a balance of distance and control, making them versatile clubs for approach shots and longer par-3 holes. They have slightly higher lofts compared to long irons, making them easier to hit and allowing for better accuracy and trajectory control. Mid-irons are commonly used for shots from the fairway, rough, or tee where a combination of distance and control is required.
Short Irons (8-9): Short irons have higher lofts, shorter shafts, and a more compact clubhead design, offering increased control and accuracy. They are primarily used for precise approach shots to greens and shorter holes where distance is less of a concern. Short irons allow golfers to generate a steeper angle of descent, enabling the ball to stop quickly on the green. The 9-iron is often the highest-lofted iron in a standard iron set, and it can be used for delicate shots around the green, known as “bump-and-run” shots.
Wedges: Although wedges are technically a type of iron, they deserve special attention due to their unique characteristics and specialized uses.
Each iron in a set has a specific purpose and is designed to provide golfers with different distances, trajectories, and levels of control. Choosing the right iron for a particular shot depends on factors such as the distance to the target, the line of the ball, and the golfer's individual preferences and skill level.
The standard size for irons in golf is determined by the United States Golf Association (USGA) and the R&A, who set the standards for golf equipment. According to their rules, the maximum length for a golf club, including irons, is 42 inches. The standard size for the heads of irons typically ranges from 2 to 4 inches in length, with the length of the head increasing as the club number gets higher (e.g., a 9 iron has a smaller head than a 5 iron). Typically, the head size of irons increases as the club number gets higher, meaning that a 9 iron will have a smaller head than a 5 iron. However, the exact dimensions can vary greatly and can range from 2 to 4 inches in length, depending on the club. According to an embodiment, the design and manufacture of the golf head conforms to the USGA equipment rules (accessible at https://www.usga.org/content/dam/usga/pdf/Equipment/Equipment%20Rules%20Final.pdf).
The area of an iron golf club head is not a standardized measurement and can vary greatly between different manufacturers and models. The size and shape of the club head can impact the performance of the club and is often a factor that golfers consider when choosing a set of irons. Typically, the head size of an iron club is measured by its length, width, and height. These measurements can be used to calculate the approximate volume and surface area of the club head.
The United States Golf Association (USGA) provides guidelines for the design and construction of golf clubs, including irons. Some of the relevant guidelines for irons according to the USGA's Rules of Golf are:
Length: The maximum length for a golf club, including irons, is 42 inches.
Weight: There is no specific weight limit for irons, but the total weight of a player's clubs must not exceed 14 pounds.
Head size: There is no specific limit on the size of the head of an iron club, but it must not be designed or manufactured to be substantially different from the traditional shape of a club head.
Grooves: The grooves on the face of an iron club must conform to the rules set by the USGA, which specify the maximum dimensions and spacing of the grooves. The purpose of these rules is to limit the effectiveness of grooves in creating backspin on the ball, thus promoting fair play.
Shaft: The shaft of an iron club must not be designed or manufactured to be significantly different from a conventional shaft.
The size of the head is one factor that can impact the performance of an iron, and other factors, such as the weight, center of gravity, and design of the club, can also influence the performance of an iron. The volume of irons can vary greatly between different models and manufacturers. The volume of a club head is one factor that can impact the performance of the club and is often used to determine its overall weight and balance.
In general, irons with a larger volume head will tend to have a higher moment of inertia, making them more forgiving on off-center hits. Irons with a smaller volume head may provide more control and feel but can be less forgiving on off-center hits.
Tests usually measure factors such as accuracy, distance, ball speed, spin rate, and launch angle. Golf clubs can be tested using launch monitors, robot testers, and human testers who hit shots and measure the results. These tests provide valuable information for golfers, to determine which clubs perform best for their individual swing and help manufacturers design and improve their products.
Launch Monitors: Launch monitors are devices that track and measure the flight of a golf ball after it has been hit. They use radar, cameras, or a combination of both to track the ball's trajectory, spin rate, ball speed, and other parameters. This information is then displayed on a screen or device for the golfer to review and analyze. Golfers commonly use launch monitors to help improve their performance, as well as club fitters to assess a golfer's swing and recommend clubs that are best suited for their needs.
Robot Testers: Robot testers are automated systems that simulate a golf swing and measure the performance of golf clubs. The robots are programmed to swing clubs at a consistent speed and launch angle, allowing for accurate and consistent testing of multiple clubs. Manufacturers and club fitters typically use these testers to evaluate the performance of new clubs and prototypes, and to compare the performance of different clubs in a controlled environment. Robot testers provide precise measurements and can test a large number of clubs in a short amount of time, making them an efficient and effective tool for evaluating golf club performance.
Golf is a challenging sport for the majority of the population. Although drivers and woods have seen some new technologies, such as titanium alloys and composite technologies, irons have seen little material advancements over the past 50 years.
Damascus steel is a special version of maraging steel. For 700 plus years, the Japanese swords and Damascus steels were developed to produce the most durable swords. These alloys which are forged by repeated heating, folding, and forging to produce thousands of layers are still the preferred material of choice for best swords. Damascus steels can cost over $800/kg whereas the steel used for casting golf irons is around $2 to $3 per kg.
Maraging steel is a type of high-strength, low-carbon alloy that exhibits exceptional toughness and excellent resistance to fatigue and stress corrosion cracking. It is primarily composed of iron, along with nickel, cobalt, molybdenum, and small amounts of other elements. The unique properties of maraging steel are achieved through a specialized heat treatment process known as aging. Unlike Stainless Damascus steel or traditional Damascus steel, which are primarily known for their visual appeal and patterned aesthetics, maraging steel is specifically designed for its mechanical properties. It is characterized by its high tensile strength and excellent impact resistance, making it suitable for applications that require high-performance and lightweight components, such as aerospace, defense, and high-end sporting equipment.
Stainless Damascus steel, on the other hand, is a combination of different grades of stainless steel that are layered and forged together to create a visually striking patterned appearance. It offers the corrosion resistance and strength associated with stainless steel while providing an attractive and unique aesthetic.
According to an embodiment, it is a golf club head comprising a body comprising a shell and a face; the shell comprising a hosel, a first periphery, and a back made of a non-layered material; the face comprising a Damascus Steel comprising a plurality of layers of at least a first material and a second material; the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell, wherein the first periphery is attached along a boundary connecting a heel edge 403, a crown edge 402, a toe edge 401, and a sole edge 404 of the second periphery; a cavity formed behind the face and within the body, the cavity extending rearward from the face to the back of the shell; wherein a first thickness of a sweet spot of the face is greater than a second thickness of other areas of the face; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the golf club head is an iron type golf club head.
According to an embodiment, the golf club head is part of a golf club.
According to an embodiment, the Damascus steel face is along a heel edge, a crown edge, a toc edge, and a sole edge without any margins provided from any edge. In
Damascus steel allows for a thinner club face to generate higher golf ball speed and height at impact and allows for a larger golf club head area equating to a larger sweet spot.
According to an embodiment of the golf club head, the Damascus Steel has at least 2 times yield strength of that of a material used for the shell. According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the Damascus Steel comprises plurality of layers and wherein the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1. According to an embodiment of the golf club head, the face comprises Damascus Titanium.
According to an embodiment of the golf club head, a frictional loss of a golf ball during impact is configured to be reduced by at least 3%. According to an embodiment of the golf club head, each layer of the plurality of layers are selected to comprise material with properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face. According to an embodiment of the golf club head, the face comprising Damascus Steel is heat treated.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate a sweet spot on the face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the cavity behind the face are filled with an insert configured to dampen a sound generated by the face upon hitting a golf ball.
According to an embodiment, the insert comprises at least one of a Thermoplastic Elastomers (TPE) and a Polyurethane (PU) foam.
Although Bulk Metallic Glasses have 2% elastic limit, which makes them great springs, they tend to be brittle under certain conditions. Monolithic solid BMG structures lack the mechanism to blunt crack propagation, similar to a single piece of silica glass. By combining structures that can withstand greater amount of load for a given weight, the net stress and elastic load applied to a specific area of BMG can be reduced. Thus, a golf club face can be designed to fully utilize the elastic properties of BMG while maintaining a significant margin of safety in term of material toughness and durability.
INCREASED LOAD CAPACITY—By combining thin honeycomb structures behind the BMG face, one can increase the load strength of the combined structure to be multiple that of a monolithic solid structure for specific weight. This structure can also be designed to fail plastically. Best method to avoid brittle fracture is to make the wall sections thin enough to buckle elastically.
The strengths of the out-of-plane structures shown as 460 are about 5-10 times higher than for the in-plane structures
ELASTIC AND TOUGH-During impact with a golf ball, the striking surface of the club goes into compression, while the back structure of the face is under tension. A honeycomb structure made of thin wall sections (0.05 mm-0.5 mm) can easily accommodate 2% sheer properties of BMG. Honeycomb BMG structure increase compressive strength, toughness, and elasticity.
Basically, a honeycomb structure flexes well beyond the 2% limit of solid BMG structures, and it shape changes to accommodate stress. This makes BMG springy and tough. Therefore, the hitting surface may be made comprising 100% BMG material with honeycomb structure or honeycomb like structures. There are several honeycomb-like structures that can be designed for similar advantages to traditional honeycomb designs. Foam structures, including foam plastics and metal foams, replicate the cellular arrangement of honeycombs and provide lightweight, high-strength, and energy-absorbing properties. Truss structures, consisting of interconnected beams or struts in a repeating pattern, offer high strength-to-weight ratios and customizable load-bearing capabilities. Lattice structures, composed of interconnected beams or nodes in a 3D framework, exhibit comparable mechanical properties to honeycombs. Grid structures, featuring interconnected rods or beams in a grid pattern, offer high stiffness and case of fabrication. Woven structures, formed by interlaced fibers or filaments, provide flexibility, durability, and formability. Tubular structures, comprising interconnected tubes, offer lightweight, flexible, and energy-absorbing properties. Corrugated structures, characterized by repeating folds or ridges, offer enhanced stiffness and strength while maintaining lightweight construction.
In addition, there are several other honeycomb-like configurations that may be designed. Hexagonal grids, featuring a repeating hexagonal pattern of cells, provide efficient packing and load distribution, found in natural systems like beehives and replicated in engineering for lightweight panels. Biomimetic structures draw inspiration from natural honeycomb formations in organisms such as bees and plants, offering combinations of strength, flexibility, and energy absorption. Origami-inspired techniques create complex folding patterns resulting in honeycomb-like structures with tailored mechanical properties, beneficial in deployable structures and biomedical applications. Fractal-based structures utilize self-similar patterns at different scales, providing scalability, multifunctionality, and structural efficiency. Chiral honeycombs feature helical or spiral arrangements, offering tunable stiffness and anisotropic behavior. While not strictly honeycomb-like, certain auxetic structures with cellular arrangements resembling honeycombs exhibit unique mechanical properties like enhanced energy absorption and increased fracture toughness. These diverse honeycomb-like structures may be used in place of honeycomb structures.
The honeycomb structure offers advantages due to its unique geometric configuration due to high strength-to-weight ratio, that is reducing weight without compromising strength. The design distributes loads, enhancing its capacity to bear heavy weights. Honeycomb structures excel in energy absorption providing impact protection. Honeycomb structures can be designed for good clastic behavior, making them advantageous for flexibility and resilience. The configuration of honeycomb cells allows these structures to deform elastically under stress and return to their original shape once the load is removed. This clastic behavior is beneficial in enhancing shock absorption, enabling to mitigate impacts, reducing damage to the impact prone surface. Additionally, the elastic properties help in damping vibrations for reducing wear and tear. The flexibility and resilience of honeycomb structures make them suitable for repeated loading and unloading for golf club heads. The elastic behavior may be tailored by adjusting cell size, shape, and material, allowing precise control over the mechanical properties to meet specific requirements as designed. Furthermore, the ability to withstand cyclic loading without significant degradation in performance enhances the fatigue resistance and extends the lifespan of the hitting surface. The calibrated clastic behavior of honeycomb structures provides a balance of flexibility, strength, durability, and aesthetics making them a suitable design for resilience and structural integrity.
Amorphous materials, such as amorphous metals (also known as metallic glasses) and certain polymers, offer unique advantages when structured in a honeycomb configuration. This combination results in high-performance materials. The intrinsic properties of amorphous materials, coupled with the geometric benefits of a honeycomb structure, provide significant advantages. Amorphous metals, in particular, exhibit superior strength and hardness compared to their crystalline counterparts, offering excellent load-bearing capacity and resistance to deformation. These materials also have higher elastic limits, enabling significant deformation without permanent damage, making the honeycomb structure resilient and capable of efficiently absorbing and dissipating energy in impact-resistant applications. Moreover, the absence of grain boundaries in amorphous materials leads to superior corrosion resistance, ensuring longevity and durability in harsh environments. They also exhibit high wear resistance and superior fatigue properties, and durability under cyclic loading conditions. With the good thermal stability of amorphous materials, they can maintain their properties over a wide range of temperatures. The combination of the honeycomb structure and amorphous materials results in enhanced mechanical performance, including higher strength-to-weight ratios and improved energy absorption capabilities.
Using amorphous materials in a honeycomb structure also reduces overall weight while maintaining or enhancing mechanical properties. The structure may be tailored to specific needs by adjusting the cell size, shape, and type of amorphous material, allowing precise control over the mechanical and physical properties of the final product. Manufacturing techniques, such as additive manufacturing and precision casting, enable the straightforward fabrication of complex amorphous material honeycomb structures, facilitating the production of high-performance components with intricate designs. Amorphous material honeycomb structures are designed for fatigue loads of the golf club head. In an embodiment, amorphous material is a bulk metallic glass material. According to an embodiment, it is a golf head club comprising a hitting surface comprising honeycomb structure and amorphous material. In an embodiment, the amorphous material is BMG. In an embodiment, the hitting surface is made of 100% BMG. In an embodiment, it is made in on more layers. In an embodiment, the material comprises Damascus steel and amorphous material. In an embodiment, the material is toughened.
Toughening amorphous materials, such as metallic glasses, involves various processes aimed at enhancing their ability to absorb energy and resist fracture. Although amorphous materials inherently possess high strength and hardness, they can be brittle, hence requiring toughening. One effective method is microalloying, where small amounts of additional elements are introduced to control shear band formation and improve ductility. Creating composites by embedding amorphous materials with ductile phases or reinforcing fibers also significantly enhances toughness. Controlled thermal treatments, such as annealing, relieve internal stresses and reduce brittleness, while surface engineering techniques like coating, ion implantation, and laser treatment improve resistance to crack initiation and propagation. In an embodiment, Nano structuring is used achieved through rapid solidification or adding nanoparticles, helps distribute stress evenly and prevents catastrophic failure. Mechanical alloying refines the microstructure and distributes alloying elements uniformly, enhancing overall toughness. Designing multilayered structures with alternating layers of amorphous and crystalline materials can arrest cracks and distribute stress, improving toughness. Additionally, including tough phases, such as ductile metals or polymers, in the amorphous matrix absorbs energy during deformation and blunts cracks, preventing propagation. These processes may often be used in combination to achieve the desired balance of toughness, strength, and other mechanical properties, making amorphous materials durable and suitable for golf club heads.
Amorphous materials are often not considered in engineering applications due to their low fracture toughness, difficulty in joining to other materials, and structure scale-up challenges. In addition, several methods, processes, and materials have been used to manufacture clad surfaces including roll bonding, co-extrusion, weld overlay and laser cladding. They are not only labor and time intensively, but also may have difficulties achieving the desired specifications.
A number of additive manufacturing (AM) technologies have shown the ability to produce amorphous metal structures due to high cooling rates in melt pools or low processing temperatures.
Processing of novel materials, manufacturing complex-shaped parts, reduction in part manufacturing, reduction in finishing time, and lowering the cost are the drivers for using AM. AM is particularly suitable for the manufacture of products with complex features using traditionally difficult-to-process materials without the use of traditional tools, such as molds or dies. AM, also referred to as 3D printing, is a cladding layer-by-layer technique of producing three-dimensional (3D) objects directly from a digital model. AM has become a very disruptive field in the manufacturing sector and continues to grow in use.
This manufacturing disruption is allowing scale-up and creation of complex amorphous structures outside of traditional casting methods. Consequently, amorphous alloy use is actively expanding into new application areas which were previously deemed impossible. However, the ductility and fracture toughness of printed and cast amorphous alloys remains subpar of many crystalline metals, which continues to limit use in many engineering applications. By mixing amorphous alloys with other metals with high ductility and fracture toughness, these limitations may be overcome.
Bulk Metallic Glass (BMG) laminate composites have been created in prior art, yet these are epoxy based structures. Epoxy is unfavorable for extreme temperature conditions, which is where many BMGs are used. Additionally, these epoxy joints do not hold-up to high cycling and loading due to poor bond strength. One example of this poor bond strength is shown in a BMG ball and cone locator (obtained from Aerospace Science and Technology, Vols. 82-83, pp. 513-519, November 2018). The ball and cone locator are used for docking and moving things around in low earth orbits and space. For low earth orbits, low melting point materials are of interest such that materials burn-up or disperse during re-entry to earth. This greatly minimizes the risk of solid's entering and potentially causing damage, i.e., steels and titanium alloys. Consequently, BMGs are of interest to replace titanium ball and cone locators due to their high hardness and low melting point. However, the bond strength with epoxy is not adequate. A solution to this bond problem would be to replace the body of the cone with aluminum and use BMGs only on the cone face.
Cladding of surfaces with BMGs currently does not use metallic joining as the mechanism. Instead, mechanical interlocking is used by depositing BMG droplets via cold spray onto a mechanically roughened surface. This mechanical interlocking has limitations in its operating temperature and strength, similar to epoxy. By replacing this bond with a metallurgical one, operating temperature and strength becomes less of a concern.
Out of the available additive technologies for BMG production, Ultrasonic Additive Manufacture (UAM) has the lowest processing temperature, which in turn allows the creation of dissimilar or multi-metal structures since solidification is absent and high temperature chemistry and diffusion are suppressed. UAM is frequently used to create dissimilar metal laminate composites or clad metal surfaces due to these attributes. Dissimilar metal composites created using UAM are frequently composed of a soft ductile material and a harder brittle material to create tailorable mechanical response and failure behavior. Similarly, cladding of surfaces often begins by joining hard, wear-resistant metals to softer underlying structure. Cladding of hard metals to hard metals has also been achieved but is less commonly encountered.
Amorphous metals are a new class of materials that have a disordered, non-crystalline, glassy structure, lacking long-range periodicity of the atomic arrangement, that are created when metals or their alloys are either cooled very quickly or because of a unique alloy combination, bypassing crystallization during solidification.
Due to their unique microstructure, amorphous metals combine high corrosion resistance, high strength, high hardness, and substantial ductility in one single metal. The unique properties of amorphous metals comes from the lack of long-range periodicity, related grain boundaries and crystal defects such as dislocations. There has been a limitation regarding manufacturing net-shape components with Amorphous Metals until only recently with the additive manufacturing. Traditionally, components were limited in thickness to 3-5 mm due to the fast cooling rate requirement of the alloy (critical casting thickness).
Amorphous materials are often not considered in engineering applications due to their low fracture toughness, difficulty in joining to other materials, and structure scale-up challenges. In addition, several methods, processes, and materials have been used to manufacture clad surfaces including roll bonding, co-extrusion, weld overlay and laser cladding. They are not only labor and time intensively, but also may have difficulties achieving the desired specifications.
Additive manufacturing has remedied some of these challenges by enabling more complex features and larger structures above the critical casting thickness. Yet, printed structures demonstrate lower ductility and fracture toughness due to micro defects from printing. This decrease in fracture toughness creates pause for design engineers, which ultimately influences BMG use. Applicant believes this decrease in fracture toughness and ductility can be overcome by mixing cast BMG foils with more ductile alloys, i.e., form a metallic composite.
The UAM process works by building up solid metal objects through ultrasonically welding a succession of metal tapes or foils into a 3D shape, with periodic machining operations to create the detailed features of the resultant object. The process creates a joint between the foils through plastic deformation and not heat. The bond zone is typically near 10 microns in size and composed of equiaxed recrystallized grains when joining similar metals. For dissimilar metal joints, the bond zone is sub-micron in size and does not always contain new crystals. Due to the small bond zone relative to the foil stock size, bulk material property changes are negligible and identical to the incoming foil stock.
Furthermore, the Damascus steel has high strength and is resistant to cracking. By folding layers of steel up to 1,000,000 layers, Damascus steels maximize strength and hardness with minimal loss of toughness.
In addition, repeated forging aligns the grains in such a way that they are significantly tougher and resistant to cracking in specific orientation. Each layer of steel and its properties can be selected to optimize the best combination, strength, toughness, corrosion resistance, and even edge retention. Golf clubs according to an embodiment may have grooved edges. When the effects of layering and forging are combined, the resulting steels can double or triple its strength and impact toughness.
According to an embodiment of the golf club head, the Damascus Steel comprises a plurality of layers, wherein the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1. According to an embodiment of the golf club head, the Damascus Steel has high strength and resistance to cracking due to reducing the effect of imperfection by confining a defect within each layer of the plurality of layers when compared to at least one of stainless steel, carbon steel, and maraging steel.
However, some Damascus steels can be more than 100,000 to 1,000,000 layers which represents 10,000 to 100,000 times reduction in thickness of initial steel bar or plate.
According to an embodiment of the golf club head, the Damascus Steel produces high resistance to strain when compared to at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the Damascus Steel is heat treated from an initial hardness of approximately 38 Rockwell Hardness Scale (HRC), to result in a final hardness of approximately 50 HRC to 60 HRC. According to an embodiment of the golf club head, an impact toughness is approximately 2 to 3 times higher when compared with a golf club made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the first face further comprises Damascus Titanium.
Stainless—As shown in
Damascus steel: A new class of Stainless Damascus Steels are developed to combine hardness in excess of 45 Rockwell Hardness Scale (HRC), while surpassing the impact toughness of softer stainless steels. In an embodiment, the hardness of the Damascus steel may be approximately around 59 to 65 HRC. Achieving a hardness level above 45 HRC requires careful selection of the steel alloys used in the layering process and proper heat treatment techniques. In an embodiment, the hardness of the Damascus steel may be at least 45 HRC. In an embodiment, the hardness of the Damascus steel may be at least 50 HRC. In an embodiment, the hardness of the Damascus steel may be at least 55 HRC. In an embodiment, the hardness of the Damascus steel may be in the range of 40-60 HRC.
Damascus steel is renowned for its unique patterned appearance and excellent strength. Traditionally, it was produced by forging layers of different types of steel together, resulting in a distinctive wavy pattern on the surface. While the traditional Damascus steel was primarily used for blades, modern versions can be found in various applications, including knives, jewelry, and even watches.
In an embodiment, the golf club head is made of German Damascus steel. German Damascus steel, also known as German pattern-welded steel, is a type of steel that is produced using traditional techniques similar to those used in the creation of historical Damascus steel. While the term “German Damascus steel” is often used colloquially, it is important to note that it does not refer to steel made exclusively in Germany, but rather steel made using a specific pattern-welding technique.
The process of creating German Damascus steel involves forging together layers of different steel alloys to create a billet. These layers are typically composed of high-carbon steel and low-carbon steel or iron, which have contrasting properties. The high-carbon steel provides hardness and edge retention, while the low-carbon steel or iron contributes to toughness and flexibility. The layers of steel are stacked and then heated to a high temperature. Once the billet reaches the correct forging temperature, it is hammered and folded to create a homogeneous and layered structure. This folding process helps to distribute the carbon content evenly throughout the material and create the characteristic patterns seen on the surface.
After the folding and forging process, the steel billet is often twisted, manipulated, or otherwise patterned to enhance the visual appeal. The precise patterns created during this stage can vary, ranging from intricate swirls to more uniform ladder or raindrop patterns. These patterns are a result of the alternating layers of different steel alloys.
German Damascus steel is known for its visual beauty and the contrast between the light and dark layers of steel. The intricate patterns created by the layering and folding process give each piece a unique and distinctive appearance. In terms of its properties, German Damascus steel offers a combination of hardness, toughness, and corrosion resistance. The high-carbon steel layers provide excellent edge retention and hardness, while the low-carbon steel or iron layers contribute to the overall strength and durability of the material.
In an embodiment, the golf club head is made of Stainless Damascus steel. Stainless Damascus steel is a type of steel that combines the qualities of stainless steel and Damascus steel. In an embodiment, the hardness of the Stainless Damascus steel may be approximately around 59 to 65 HRC. In an embodiment, the hardness of the Stainless Damascus steel may be at least 45 HRC.
Stainless Damascus steel takes this concept further by incorporating stainless steel alloys into the layering process. Stainless steel is known for its corrosion resistance, making it suitable for applications where maintaining a rust-free surface is essential. By combining the aesthetics and strength of Damascus steel with the corrosion resistance of stainless steel, stainless Damascus steel offers a balance between functionality and visual appeal. One important characteristic of stainless Damascus steel is its hardness. Hardness is typically measured on the Rockwell Hardness Scale (HRC), which measures the resistance of a material to indentation or penetration. Achieving a hardness level above 45 HRC requires careful selection of the steel alloys used in the layering process and proper heat treatment techniques.
Stainless Damascus steel is created through a process called pattern welding or layering. In this process, layers of different steel alloys are forged together, and then the billet (a solid block of layered steel) is repeatedly folded, twisted, and manipulated to create the desired pattern. The number of layers and the complexity of the folding process contribute to the final visual appearance of the steel.
The specific stainless steel alloys used in the layering process can vary depending on the manufacturer and the desired properties of the final product. Common stainless steel alloys used in stainless Damascus steel include various grades of stainless steel such as 304, 316, or 440C. These alloys are known for their high strength, corrosion resistance, and wear resistance.
To achieve the desired hardness of 45 HRC or higher, the stainless Damascus steel undergoes heat treatment. Heat treatment involves a combination of heating, quenching, and tempering processes. Heating the steel to specific temperatures and then rapidly cooling it (quenching) helps to increase its hardness, while tempering reduces brittleness and improves toughness.
Stainless Damascus steel offers excellent hardness and corrosion resistance. The actual performance of the golf club made from this material can also depend on other factors, such as the design, geometry, and overall craftsmanship of the item. Stainless Damascus steel combines the desirable qualities of stainless steel and Damascus steel, resulting in a visually stunning material with high hardness and corrosion resistance.
German Damascus steel and Stainless Damascus steel are similar in many ways but also have notable differences:
Both German Damascus steel and Stainless Damascus steel share similarities in terms of the layering technique and visual appeal, their differences lie in the steel alloys used, corrosion resistance, hardness levels, and applications. German Damascus steel emphasizes hardness and cutting performance, while Stainless Damascus steel prioritizes corrosion resistance while still offering attractive patterns. Golf club heads produced using the German Damascus steel or Stainless Damascus steel can be custom designed.
50% thinner Face thickness: Superior strength and toughness allow the face thickness of irons to be reduced by 50%.
The size of the hitting surface can be easily increased by 15% to 20% with the weight saving of using an ultra-high strength Damascus steel on the hitting surface.
A Damascus Steel Face will have 40% to 60% of the material removed when compared to normal cast irons. This results in overall weight reduction of an iron by 20%. The extra weight saving allows the club designers to move weight away from the impact zone thus making the club more forgiving on misaligned shots. The size of the club can also be enlarged, effectively increasing the size of the sweet spot.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first weight of the golf club head is at most a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the thickness of the first face is reduced approximately 50% when compared to that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel. According to an embodiment of the golf club head, the Damascus Steel has at least 2 times yield strength of that of another material used for the shell. According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising a Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first weight of the golf club head is less than a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first area of the first face comprising the Damascus Steel is equal to a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first weight of the golf club head is approximately 20% to 25% less than the second weight of the head of the golf club made of at least one of stainless steel, carbon steel, and maraging steel. This reduction is weight is utilized to produce “hitting surfaces” that are approximately 20% to 25% larger According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to a second face made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, a weight in the first face is moved away from an impact zone. According to an embodiment of the golf club head, the sweet spot of the first face is thicker relative to other areas surrounding the sweet spot on the first face. According to an embodiment of the golf club head, the sweet spot comprises colored rings around the decorative patterns formed from the Damascus Steel. In an embodiment, a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
In an embodiment, a colored ring or colored rings may be formed to provide an aesthetic appeal around the sweet spot on a frontside of the face. In an embodiment, a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
The following unexpected benefits were observed: Variable thickness of the face produces distinct vibrations and sounds during impact depending on how close to the sweet spot impact takes place. Impact near the “sweet spot” generates lower pitch and tone vs impact that is further from the optimal zone which results in a higher pitch and with more vibration. In an experimental setup measurements of the frequencies are noted. It is possible to tune the sound so that a golfer has the benefit of getting immediate acoustic feedback on the quality of the impact. The thickness of the face can be continuously variable to generate distinguishable tones as the impact moves away from the sweet spot. This has the benefit of providing immediate feedback, which in turn can be used to train the golfer to repeat swings that produce the best results.
Current steel irons on the market may also generate slight variance in tone depending on the proximity of impact to the sweet spot. However, it is difficult or impossible to perceive the slight variance or no variance in tone for a human ear.
According to an embodiment of the golf club head, the first thickness is distributed circularly along the sweet spot of the face.
According to an embodiment of the golf club head, the first thickness to the second thickness is a continuous variation in the thickness from most thick region being at the sweet spot.
According to an embodiment of the golf club head, the first thickness to the second thickness is an abrupt variation in the thickness from most thick regions at the sweet spot. According to an embodiment of the golf club head, the golf club head produces a distinguishing sound upon impact of a golf ball based on a location where the golf ball is hit on the face. According to an embodiment of the golf club head, the golf club head produces a distinguishing sound and is configured such that it produces an audio feedback to a user of the golf club.
The audio feedback/audible response, also known as sound feedback, refers to the sound produced by an object, such as a golf club, when it is stimulated or subjected to an external force, such as golf club hitting the golf ball. The characteristics of the audible response of the golf club head depend on factors such as the resonant frequency, material composition of the head and the face, shape of the head and the face, size of the head and the face, surface area of the head and the face, thickness of the head and the face, joint type and joint position between the body and the face, etc. along with the type of stimulation applied. The audible response is also influenced by the type of inserts and whether inserts are present in the golf club head or not. The resonant frequency of the golf club head, determined by its inherent vibrational properties, plays a significant role in the sound produced. The golf club heads material composition affects how sound waves are generated and propagated, while its shape and size influence acoustic properties such as reflection, absorption, and transmission of sound. The type and intensity of the applied force also impact the audible response.
Measuring the audible response often involves techniques like sound recording, spectral analysis, frequency analysis, and comparative evaluation. These methods help analyze the recorded sound, extract relevant parameters, identify frequency components, and compare the audible response to reference sounds or pitches. In an embodiment, the thickness and its variation in the golf club face is such that the golf club produces a specific distinct frequency when the golf ball is hit at the sweet spot versus when the golf ball misses to hit the sweet spot. Specific distinct frequency may be achieved by designing and optimizing various parameters as mentioned herein.
Varying the thickness of the face of the golf club head aids in fine-tuning the audible response for a target frequency. The target frequency may be chosen such that a user of the golf club or a trainer can distinguish when the ball is hit at the sweet spot versus when it misses to hit the sweet spot or hits slightly off to the sweet spot. In an embodiment, additional equipment to measure the frequency may be employed for accuracy and training. In an embodiment, no additional equipment is necessary to distinguish the sound, which means a human car can distinguish the sound emanating from the golf club head when the ball is impacted at sweet spot versus off the sweet spot. By adjusting the thickness of the face, one may influence the resonant behavior and affect the target frequency. Thicker sections tend to have lower resonant frequencies, while thinner sections have higher resonant frequencies. Therefore, increasing the thickness in specific areas can lower the resonant frequency, while decreasing the thickness can raise it. The distribution of thickness throughout the face is strategically designed to achieve a desired target frequency. For example, thicker regions can be incorporated in areas where a lower resonant frequency is desired, while thinner regions can be used for higher frequency regions. This variation in thickness may further help fine-tune the overall audible response and achieve the desired frequency characteristics. The effect of thickness variation on resonant frequencies depends on the material properties and the overall golf club head geometry. By balancing the thickness distribution along with other variables, such as material selection, shape, size, and structural modifications, the desired resonant behavior and the desired audible response for a specific frequency may be achieved.
According to an embodiment of the golf club head, the sweet spot on the face further comprises colored rings around the decorative pattern formed from the Damascus Steel. In an embodiment, a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
According to an embodiment of the golf club head, the first thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters. In an embodiment, the first thickness of the face is in the range of 0.1 to 0.3 centimeters. In an embodiment, the first thickness of the face is in the range of 0.1 to 0.5 centimeters. According to an embodiment of the golf club head, the second thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters. In an embodiment, the second thickness of the face is in the range of 0.1 to 0.3 centimeters. In an embodiment, the second thickness of the face is in the range of 0.1 to 0.5 centimeters. In an embodiment, the face has a surface area of at least 60 square centimeters. In an embodiment, the thickness variation may be in more than two levels. In an embodiment, the thickness variation may be three levels.
Tennis racket head size seems to have settled around 100 square inches with advanced materials as shown in
Irons have seen very little or no change in their designs over the years. With advanced materials, like Damascus steel, the optimal size increase may be around 15% of current steel clubs. Too large of a head or a face is not optimal as it would be difficult to move through grass. When Titanium, which is 40% lighter than Steel, came on the market, consumers felt that the titanium irons were too bulky and difficult to control. So, having design flexibility to move 20% of weight to cither make the hitting surface larger or to simply alter the center of gravity is of great advantage.
There will be a greater transfer of impact energy to the velocity of the ball as the thinner plate flexes more. Golf balls will bounce back 80% to 90% of dropped distance, indicating that approximately 15% of the energy was lost due to internal friction during the compression/decompression cycle of the golf ball as it was bouncing off a solid floor.
A golf ball coming off the face of Irons can lose 10% to 15% of potential velocity due to internal friction generated during compression and depression cycle of the polymer material. However, certain alloys such as Damascus steel and Amorphous alloys experience almost near 0% loss during the compression/decompression cycle. Thus, if greater percentage of the energy generated and released during impact can be transferred into the Damascus Steel face, greater the effect of reducing the compression of the golf ball and thus reducing the amount of energy lost due to internal friction in balls. In essence, the impact of golf iron with a golf club can be described as two springs working in harmony. By allowing the more efficient spring to store more energy of the impact, less kinetic energy is lost during impact and the golf ball propels off the face of the club with greater velocity.
Steel and metal alloys will lose less than 1% of energy through internal friction of the steel ball during the compression/decompression cycle.
“Speed of ball=Mass of Club×Velocity2×% loss from internal friction”—If a club face is allowed to flex and take on more of the spring action during the compression/decompression cycle, the golf ball will come off the face of the club with greater velocity. This is exactly the reason that USGA implemented the rule of limiting Coefficient of Restitution (COR) for drivers when they observed the Liquidmetal Ball bounding demonstration. The coefficient of restitution (COR) is a measure of the “bounciness” or elasticity of a golf ball. In the context of drivers, the COR refers to the rebound effect when the ball strikes the clubface. The USGA (United States Golf Association) has specific rules regarding the maximum allowable COR for drivers. According to the USGA rules, the maximum COR limit for drivers is 0.830. This means that the COR of a driver's face must not exceed 0.830 to be considered conforming to the rules of golf. The USGA imposes this limit to ensure fair play and to prevent drivers from providing an unfair advantage by generating excessive ball speed. While the USGA sets the COR limit for drivers at 0.830. Since the 0.830 limit can only be achieved by Titanium drivers with head size of 350 CC to 400 CC, irons were far from approaching this limit. The case might be that average irons only can achieve around 0.780 to 0.800. An ultra-thin Damascus Irons can gain up to 10% in distance without having to violate the USGA rules. As it is stated clearly in this disclosure herein, a 3% gain COR can gain a 9% in distance. In addition, a larger sweet spot can contribute significantly to consistent distance gain. The COR of irons can vary depending on the design and construction of the clubhead. Irons are typically designed to provide a combination of distance, control, and feel, with an emphasis on accuracy and precision rather than maximizing ball speed. Manufacturers may employ various materials, face technologies, and designs to optimize the performance of irons within the broader guidelines and principles set forth by the USGA. According to an embodiment, the golf club comprising a Damascus steel face is configured to follow the aspects such as club dimensions, weight, and other characteristics as per USGA rules and regulations or any regulatory body related to the golf game.
The golf club faces that are thinner, maximize the “trampoline effect” or coefficient of restitution (COR). The COR is a measure of how efficiently the club face transfers energy to the golf ball upon impact, influencing the distance the ball travels. A thinner face allows for greater flexing or deflection at impact, resulting in increased ball speed and distance. According to an embodiment, the face conforms to the USGA and R&A regulations that limit the maximum COR value allowed for golf club faces.
Damascus golf clubs are not commonly found in mainstream golf equipment manufacturers' product lines. Damascus steel, known for its unique patterns and strength, has historically been used in the production of knives, swords, and decorative items. While some custom club makers or boutique manufacturers may offer limited editions or specialty Damascus golf clubs, they are relatively rare and often produced in limited quantities for collectors or enthusiasts. These golf clubs may feature Damascus steel accents or components, such as decorative inserts or clubhead details, or may be entirely constructed from Damascus steel, but none of the prior art golf clubs were designed to leverage the strength of Damascus steel.
The mainstream golf equipment industry typically utilizes materials and manufacturing techniques that have been extensively researched and optimized for performance and consistency. Construction of golf clubs, especially irons and drivers, typically involves the use of specific alloys, materials, and manufacturing techniques that prioritize factors such as performance, forgiveness, and durability.
Damascus steel, with its unique properties, unless engineered carefully, may not be the most optimal choice for golf club production from a performance standpoint. Golf clubs require specific characteristics such as high strength, stiffness, and controlled flex to maximize energy transfer and achieve desired launch conditions. While Damascus steel can be strong, its stiffness and flex properties may not match those of modern materials like stainless steel or titanium, which are extensively used in golf club manufacturing. Therefore, the Damascus steel properties are combined with design aspects, such as reducing the thickness of the face and increasing the area of the face, to increase the performance characteristics. Designs are carefully combined with traditional material for the hosel and the back of the iron, while layered (Damascus) alloys arc welded to the front of the face of the irons to produce unique patterns. According to an embodiment, Damascus steel and Damascus Titanium are utilized in the face portions of the irons to customize a wide range of patterns that are possible and to increase performance.
Assuming that frictional loss can be reduced by 2%, from 15% loss to 13% loss, the speed of the golf ball coming off the impact is increased by 2%. Net distance gained is square the speed as shown in
None of the prior art golf clubs were designed to leverage the strength of Damascus steel to improve distance and enlarge the sweet spot. Our design combined traditional material for the hosel and the back of the iron, while layered (Damascus) alloys are welded to the front of the face of the irons to produce unique patterns.
Since most golfers rarely hit the sweet spot of their irons, an iron that makes the sweet spot 20% larger will make the clubs more forgiving. The ball will travel straighter and further with the Damascus Steel irons.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel generates a higher golf ball speed at impact on the first face of the golf club head when compared with a second face of a golf club head made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, a golf ball dropped on the first face comprising the Damascus Steel from a dropping distance bounces back 80% to 90% of the dropping distance. According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by approximately 2% so as to increase the speed of a golf ball coming off an impact on the first face comprising the Damascus Steel by approximately 2%. According to an embodiment of the golf club head, a net distance achieved by a golf ball coming off an impact on the first face comprising the Damascus Steel of the golf club head is greater than a net distance achieved by the golf ball coming off an impact on the second face of the golf club head made of at least one of stainless steel, carbon steel, and maraging steel.
Increasing the size of hitting face by 20% to 25%, and reducing the face thickness by 30%-50% can add 1% to 2%+ increase in ball speed. This is achieved from greater deflection of the Damascus steel Plate due to its reduction in thickness and greater size. Based on this formula, D=Mass×V2, a 2% increase in ball initial ball velocity will result in a 4% increase in distance. However, for average golfers, the greater benefit could be the reduction in lost distance due to missing the sweet spot at impact and slicing the ball off the desired trajectory.
An Official Liquidmetal® Ball Bouncer Demonstration (available at https://www.youtube.com/watch?v=RAQIioLteuM&ab_channel=LiquidmetalTechnologies) demonstrates the amazing coefficient of restitution of Liquidmetal Technologies bulk metallic glass alloys. The balls are made of stainless steel, while the plates on which the balls bounce are made of three different materials namely Stainless Steel, liquidmetal, and Titanium. The Liquidmetal plate transfers almost all the kinetic energy of the falling ball back into the ball instead of absorbing that energy into itself by yielding. The very high coefficient of restitution of liquidmetal has given it a clear advantage over other materials in applications such as golf clubs.
A stainless steel ball bouncing on an amorphous alloy plate, which is a liquidmetal plate, nearly 99% of the energy is returned during the impact. Most of the loss comes from friction with the air. Steel sees less than 1% loss of energy at impact. In an embodiment, the face comprises Liquidmetal®. It may be in the form of bands, strips, or a coating on the Damascus steel face.
Various patterns of the Damascus steel can be used to produce unique patterns and patina that personalize each club. If desired, the Damascus pattern itself can be used to mark the perfect center of the hitting zone, either on the front and/or back of the clubs as shown in
Titanium Damascus steel, also known as Ti Damascus or Timascus, is a unique and striking material that combines the strength and durability of titanium with the beauty and intricacy of Damascus steel patterns. It is a composite material made by layering different titanium alloys and then applying heat and pressure to forge them together. Damascus steel itself is renowned for its distinctive patterns that are created through a process called pattern welding. In traditional Damascus steel, layers of different types of steel are forge-welded together, folded, and manipulated to create intricate patterns known as Damascus patterns or Damascus designs. These patterns are characterized by wavy lines, swirls, and organic shapes that result from the folding and layering process. When titanium is used in the pattern welding process instead of steel, it brings its own unique properties and aesthetics to the final product. Titanium is a lightweight, strong, and corrosion-resistant metal, making it an excellent choice for various applications. By combining it with the Damascus steel technique, titanium Damascus steel achieves a distinctive appearance that blends the colors of titanium with the intricate patterns of traditional Damascus steel.
The patterns formed in titanium Damascus steel can vary depending on the specific alloys used, the number of layers, and the forging techniques employed. Some common patterns include Mokume Gane, which resembles wood grain and is achieved by layering and forging different colored titanium alloys together; Twist, formed by twisting the layers of titanium alloys before forging them, resulting in a spiral-like pattern; Raindrop, consisting of small, rounded shapes reminiscent of raindrops scattered across the surface; Ladder, featuring parallel lines running across the material, resembling the rungs of a ladder; and Random, a more chaotic and irregular arrangement of colors and textures.
The patterns formed in titanium Damascus steel may be enhanced through various finishing techniques, such as etching, polishing, or anodizing. Etching reveals the contrast between the different layers of titanium alloys, while polishing creates a reflective surface. Anodizing involves applying an electrical current to the titanium, which creates a controlled oxide layer, resulting in vibrant and colorful effects.
The preparation of Damascus titanium involves a series of steps to create the desired patterns. The process begins with the selection of titanium alloys, such as Ti-6Al-4V or commercially pure titanium, which contribute to the final appearance of the material. Thin sheets or strips of these alloys are layered and stacked, followed by forge-welding in a high-temperature furnace, where heat and pressure fuse them together. This initial welding is then followed by forging, shaping, and consolidating the material under force to create a solid billet. To enhance the pattern, the billet may undergo folding, cutting, and restacking, repeating the welding and forging process. Etching, using an acid or chemical solution, is often performed to reveal the contrasting layers and enhance the pattern's visibility. Additional finishing techniques such as polishing or anodizing may also be applied to achieve the desired appearance and texture.
According to an embodiment of the golf club head, the second periphery of the face is attached via a welding to the first periphery of the shell. According to an embodiment of the golf club head, the first material and the second material are selected from a group consisting of titanium, steel, Stainless steel, Amorphous Alloys, and composites thereof.
According to an embodiment of the golf club head, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel. According to an embodiment of the golf club head, the sweet spot of the face is at least 10% thicker than the other areas of the face.
According to an embodiment of the golf club head, the Damascus steel comprises a stainless steel 304L and a stainless steel 316L. According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the toe edge and the heel edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the crown edge and the sole edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel is changed in at least one of a height and a width as compared to the second face made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the first area of the first face comprising the Damascus Steel is increased in area approximately 15% to 25% than that of the second face made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the width of the first face comprising the Damascus Steel is increased approximately 3% to 10% than the second face made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the height of the first face of the golf club head is increased approximately 10% to 20% than the second face made of at least one of stainless steel, carbon steel, and maraging steel. According to an embodiment of the golf club head, the first face comprising the Damascus Steel has a larger sweet spot when compared with a sweet spot on the second face made of at least one of stainless steel, carbon steel, and maraging steel.
Noise damping materials can be incorporated into golf clubs to reduce vibrations and minimize the sound generated upon impact. Thermoplastic Elastomers (TPE) are commonly used due to their rubber-like properties and excellent damping characteristics. These materials can be strategically placed in specific areas of the club head or grip to absorb impact energy and provide a softer feel while damping vibrations and reducing noise.
Polyurethane (PU) foam is another versatile material that offers good damping properties. It can be used as a filler or insert in the club head to reduce vibrations and improve sound quality. Polyurethane (PU) foam effectively absorbs and disperses energy, resulting in a quieter sound upon ball contact.
Vibration-damping inserts made from various composite materials or composite structures can also be integrated into the club head. These inserts are strategically placed to absorb and dissipate energy, contributing to a more muted sound during impact. They are often made from a combination of rubber, foam, or composites.
High-density materials, such as tungsten or high-density polymers, can be incorporated in specific areas of the club head to dampen vibrations and minimize noise. These materials effectively absorb and dissipate energy, resulting in a quieter sound upon impact.
Additionally, specialized damping films or coatings can be applied to specific components of the club head, such as the face and/or crown. These films or coatings are designed to absorb and dissipate energy, helping to reduce vibrations and minimize noise during play.
The choice of noise damping material and its application depends on various factors, including the desired level of noise reduction, the design of the club head, and the overall performance objectives. Manufacturers carefully consider these factors to optimize the balance between sound, feel, and performance in golf clubs. By incorporating noise damping materials, golf clubs can offer a more pleasant and muted sound experience without compromising performance.
Traditional irons for golf club heads have been crafted using materials such as carbon steel and stainless steel. Carbon steel, favored for its soft and responsive feel, has an approximate weight range of 250 grams (8.8 ounces) to 290 grams (10.2 ounces) for standard irons. Stainless steel, known for its durability and resistance to corrosion, typically weighs between 270 grams (9.5 ounces) to 310 grams (10.9 ounces). Forged irons may incorporate tungsten inserts to optimize the center of gravity and enhance forgiveness, weighing around 260 grams (9.2 ounces) to 300 grams (10.6 ounces). In modern designs, irons with multi-material construction feature combinations of carbon steel or stainless steel bodies with lightweight inserts like aluminum or polymer. The specific weight of these multi-material irons can vary depending on the design and materials employed. Weight ranges are approximate and can be influenced by factors such as club model, loft, and customization preferences chosen by the golfer.
Once a traditional or modern iron is selected, then a Damascus steel face golf club head designed for the same model and class will have increased size of the club face while its thickness is reduced. The weight of the iron remains within the appropriate range when compared to the respective model and class of the selected traditional or modern design. Thus, a Damascus steel face club provides an increased sweet spot and better performance. The weight and sizes are not absolute as provided in the embodiments. Traditional/standard design golf club head versus the Damascus golf club head should be compared within a class and size, for example, a 3-iron is a specific golf club commonly referred to as “Iron 3.” In terms of its specifications, a 3-iron golf club head generally weighs around 245 grams (8.6 ounces) to 260 grams (9.2 ounces). The weight can vary based on factors such as the design, materials used, and customization options. The size of a 3-iron golf club head is typically measured by the dimensions of its face and the volume of the club head. The face of a 3-iron is approximately 38-40 millimeters wide and 85-95 millimeters high, while the club head volume ranges from around 150-175 cubic centimeters. In terms of material, stainless steel or carbon steel is commonly employed in constructing 3-iron golf club heads. When the Damascus gold club head as defined in this application for its dimensions, weight, and performance is compared, it is within the class, size, and weight range. Golf club heads of irons are typically made of a single material. The most common materials used for iron club heads are stainless steel, carbon steel, and maraging steel. Some modern designs may also incorporate multi-material constructions with lightweight inserts or features made of materials like aluminum or polymer. Specifications can also vary depending on the specific brand, model, and customization choices made by individual golfers.
Furthermore, in an embodiment, the net change in the face area or size when compared with similar category irons is approximately 25%. The contribution due to the change in the length (/width) of the face is approximately 5% and the contribution due to the change in the height is approximately 20%. But the overall weight of the clubhead remains the same even with the increased hitting surface area. The larger the face area, the more forgiving the golf club is. This means the sweet spot gets bigger, and it is not necessary to be precise all the time. The golf head becomes more forgiving. In an embodiment, the golf club is heat treated on the surface. In an embodiment, the face has a surface area of at least 60 square centimeters. In an embodiment, the face has a surface area of at least 50 square centimeters. In an embodiment, the face has a surface area in the range of 50-80 square centimeters based on the category (1-9) of iron.
Materials that May be Suitable for Damascus Steel Golf Club Head:
Damascus steel, with its unique properties, may not be the most optimal choice for golf club production from a performance standpoint unless properly designed to exploit the material properties. Damascus steel, while prized for its strength and aesthetic appeal, may not possess the ideal combination of properties required for golf club performance. Golf clubs require specific characteristics such as high strength, stiffness, and controlled flex to maximize energy transfer and achieve desired launch conditions. While Damascus steel can be strong, its stiffness and flex properties may not match those of modern materials like stainless steel or titanium, which are extensively used in golf club manufacturing. This could lead to suboptimal energy transfer, inconsistent ball flight, and reduced overall performance unless they are designed for target performance.
Weight distribution is a crucial aspect of golf club design. Modern golf clubs are carefully engineered to optimize the center of gravity (CG) and moment of inertia (MOI), which affect forgiveness, launch, and spin control. Damascus steel's layered structure and variability in material properties may make it challenging to achieve precise weight distribution. In an embodiment, the variability in the Damascus materials is taken care of such that it allows for more precise control over the weight distribution, enabling club designers to fine-tune Center of Gravity (CG) and Moment of Inertia (MOI) for enhanced performance and playability.
Damascus steel production involves a complex process of layering and forging different steels to create distinctive patterns. This process can introduce potential inconsistencies and structural irregularities within the material, which may adversely affect club performance unless the layering materials and the layering techniques are chosen carefully.
A stainless steel comprises Iron, Chromium, Nickel, Manganese; and Damascus steel comprises multiple players of stainless steel, whereas Damascus steel or German Damascus steel comprises multiple layers of different steels. Both steel and stainless steel are alloys primarily composed of iron and carbon. Stainless steel contains additional elements, particularly chromium, which provides superior corrosion resistance compared to standard steel. Stainless steel is a type of steel alloy that contains iron, carbon, and a minimum of 10.5% chromium. The presence of chromium creates a protective layer of chromium oxide on the surface of the steel, which acts as a barrier against corrosion. This makes stainless steel highly resistant to rust and corrosion, even in challenging conditions. Additionally, stainless steel may contain other elements such as nickel, molybdenum, or titanium, which further enhance its corrosion resistance and other properties.
In an embodiment, manufacturers may use specific proprietary alloys or variations of the steels mentioned above to create their own unique blends for Damascus steel and Damascus steel.
According to an embodiment, it is a method 2400 comprising: casting a shell comprising a hosel, a first periphery, and a back made of a non-layered material as shown at step 2402; producing a face comprising a Damascus Steel from plurality of layers, by repeated rolling and forging, wherein the plurality of layers comprises at least a first material and a second material, and wherein the face comprises a second periphery at step 2404; generating a first thickness of a sweet spot of the face greater than a second thickness of other areas of the face at step 2406; attaching the second periphery to the first periphery of the shell via a welding, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery at step 2408. A cavity behind the face and within a body is formed when the first periphery is attached to the second periphery, the cavity extending rearward from the face to the back of the shell; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the method is configured for manufacturing a golf club head of an iron type.
According to an embodiment of the method, a material for the shell comprises casting stainless steel. According to an embodiment of the method, the shell is made using investment casting. According to an embodiment of the method, the golf club head is heat treated to improve a grain structure. According to an embodiment of the method, the shell comprises at least one of an Aluminum Alloy (AI) 6061, a 431 stainless steel, and 17-4PH stainless steel.
According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1. According to an embodiment of the method, each of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment, it is a method comprising: casting a shell of a golf club head comprising a hosel and a back; producing by repeated rolling and forging of a plurality of layers, a first face comprising Damascus Steel of the golf club head; and welding the first face to the shell of the golf club head; wherein the first face comprises a decorative pattern formed by the Damascus Steel; wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first weight of the first golf club head is at most a second weight of a second golf club head made of at least one of stainless steel, carbon steel, and maraging steel; wherein the method is configured for manufacturing an iron-type of the golf club head and is configured for enhanced performance.
According to an embodiment of the method, a material for the shell comprises casting stainless steel. According to an embodiment of the method, the shell is made using investment casting. According to an embodiment of the method, the first golf club head is heat treated to improve grain structure. According to an embodiment of the method, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel. According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1. In an embodiment, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 100 to 1. According to an embodiment of the method, each layer of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
Welding technologies that may be employed in joining a face plate to the body of the golf club head: In golf club head manufacturing, as well as in various other industries, advanced face welding technologies play a crucial role in achieving high-performance products. One notable technology is the use of Electron Beam Welding (EBW). EBW utilizes a focused beam of high-energy electrons to precisely melt and fuse the materials together. This technology offers several advantages, including minimal heat-affected zones, precise control over the welding parameters, and the ability to join dissimilar materials with varying thicknesses. The result is a strong and reliable bond between the face material and the club head body, ensuring improved energy transfer and increased forgiveness on off-center hits. Another innovative welding technique employed in golf head manufacturing is Laser Welding. This technology utilizes a high-intensity laser beam to melt and join the materials. Laser Welding offers benefits such as fast processing times, high precision, and excellent control over the heat input. It allows for intricate and complex weld patterns, enabling manufacturers to optimize the face design for maximum performance. Laser Welding also provides the flexibility to work with a wide range of materials, including stainless steels, titanium alloys, and carbon composites, making it suitable for various club head constructions. Furthermore, Advanced Resistance Spot Welding (RSW) techniques can be used to enhance the welding process in golf club head production. These technologies involve using advanced welding controls, precise electrode designs, and monitoring systems to achieve consistent and reliable welds. By carefully controlling the heat input and pressure, manufacturers can create strong bonds between the face material and the club head body, ensuring durability and performance.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first weight of the golf club head is at most a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a thickness of the first face is reduced approximately 50% when compared to that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the thickness of the first face is reduced about 30% to 40% in a sweet spot and approximately 60% in rest of the first face when compared to that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel is changed in at least one of a height and a width as compared to the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first area of the first face comprising the Damascus Steel is increased in area approximately 15% to 25% than that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a width of the first face comprising the Damascus Steel is increased approximately 10% to 15% than the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a height of the first face of the golf club head is increased approximately 5% to 25% based on a design objective than the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel has a larger sweet spot when compared with a sweet spot on the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to a second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a weight in the first face is moved away from an impact zone.
According to an embodiment of the golf club head, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the golf club head, the Damascus Steel has at least 2 times the yield strength of that of another material used for the shell.
According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the Damascus Steel comprises a plurality of layers and wherein the plurality of layers thickness is reduced from an initial thickness to a final thickness in a range of approximately 100 to 1.
According to an embodiment of the golf club head, the Damascus Steel has high strength, and resistance to cracking due to reducing an effect of imperfection by confining defects within each layer of the plurality of layers when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the Damascus Steel produces high resistance to fracture strain when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the Damascus Steel is heat treated from an initial hardness of approximately 38 Rockwell Hardness Scale (HRC) to result in a final hardness of approximately 50 HRC to 60 HRC.
According to an embodiment, the golf club head comprising Damascus Steel has an impact toughness is approximately 2 to 3 times higher when compared to a golf club head made of at least one of monolithic (single layered) stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first face further comprises Damascus Titanium.
According to an embodiment of the golf club head, the decorative pattern is customizable such that it is unique to the golf club head.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate a sweet spot on the first face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel generates a higher golf ball speed at impact on the first face of the golf club head when compared with a second face of a golf club comprising at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a golf ball dropped from a dropping distance on the first face comprising the Damascus Steel bounces back 80% to 90% of the dropping distance. A golf ball coming off the face of Irons can lose 10% to 15% of potential velocity due to internal friction generated during compression and depression cycle of the polymer material. However, certain alloys such as Damascus steel and Amorphous alloys experience almost near 0% loss during the compression/decompression cycle. Thus, if greater percentage of the energy generated and released during impact can be transferred into the Damascus Steel face, greater the effect of reducing the compression of the golf ball and thus reducing the amount of energy lost due to internal friction in balls. In essence, the impact of golf iron with a golf club can be described as two springs working in harmony. By allowing the more efficient spring to store more energy of the impact, less kinetic energy is lost during impact and the golf ball propels off the face of the club with greater velocity
According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by approximately 3% so as to increase a speed of a golf ball coming off an impact from the first face comprising the Damascus Steel by approximately. Increasing the size of hitting face by 20% to 25%, and reducing the face thickness by 30%-50% can add 1% to 2%+ increase in ball speed. This is achieved from greater deflection of the Damascus steel Plate due to its reduction in thickness and greater size. Based on this formula, D=Mass×V2, a 2% increase in ball initial ball velocity will results in 4% increase in distance. However, for average golfers, the greater benefit could be the reduction in lost distance due to missing the sweet spot at impact and slicing the ball off the desired trajectory.
According to an embodiment of the golf club head, a net distance achieved by a golf ball coming off an impact on the first face comprising the Damascus Steel of the golf club head is greater than a net distance achieved by the golf ball coming off an impact on the second face of the golf club made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment, it is a method comprising: casting a shell of a golf club head comprising a hosel and a back; producing, by repeated rolling and forging plurality of layers, a first face of the golf club head comprising Damascus Steel; and welding the first face to the shell of the golf club head; wherein the first face comprises a decorative pattern formed by the Damascus Steel; wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first weight of a first golf club head is at most a second weight of a second golf club head made of at least one of stainless steel, carbon steel, and maraging steel; wherein the method is configured for manufacturing an iron-type of the golf club head and is configured for enhanced performance.
According to an embodiment of the method, a material for the shell comprises casting stainless steel.
According to an embodiment of the method, the shell is made using investment casting.
According to an embodiment of the method, the first golf club head is heat treated to improve a grain structure.
According to an embodiment of the method, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the method, each layer of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising a Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first weight of the golf club head is less than a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, and maraging steel; and wherein a first area of the first face comprising the Damascus Steel is equal to a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first weight of the golf club head is approximately 20% to 25% less than the second weight of the head of the golf club made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a sweet spot of the first face is thicker relative to other areas surrounding the sweet spot on the first face.
According to an embodiment of the golf club head, the sweet spot comprises colored rings around the decorative pattern formed from the Damascus Steel. In an embodiment, a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
According to an embodiment, disclosed is a golf club head comprising a body comprising a shell and a face; the shell comprising a hosel, a first periphery, and a back made of a non-layered material; the face comprising a Damascus Steel comprising a plurality of layers of at least a first material and a second material; the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; and a cavity formed behind the face and within the body, the cavity extending rearward from the face to the back of the shell; wherein a first thickness of a sweet spot of the face is greater than a second thickness of other areas of the face; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the golf club head is an iron type golf club head.
According to an embodiment of the golf club head, the face has a surface area at least 60 square centimeters.
According to an embodiment of the golf club head, the first thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters.
According to an embodiment of the golf club head, the second periphery of the face is attached via a welding to the first periphery of the shell.
According to an embodiment of the golf club head, the first material and the second material are selected from a group consisting of titanium, steel, Stainless steel, Amorphous Alloys, and composites thereof.
According to an embodiment of the golf club head, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the golf club head, the sweet spot of the face is at least 10% thicker than the other areas of the face.
According to an embodiment of the golf club head, the Damascus steel comprises a stainless steel 304L and a stainless steel 316L.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the toe edge and the heel edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the crown edge and the sole edge compared to an identically constructed club that does not contain Damascus Steel face.
According to an embodiment of the golf club head, the first thickness is distributed circularly along the sweet spot of the face.
According to an embodiment of the golf club head, the first thickness to the second thickness is a continuous variation in the thickness from most thick region being at the sweet spot.
According to an embodiment of the golf club head, the first thickness to the second thickness is an abrupt variation in the thickness from most thick regions at the sweet spot.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound upon impact of a golf ball based on a location where the golf ball is hit on the face.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound and is configured such that it produces an audio feedback to a user of the golf club.
According to an embodiment of the golf club head, the sweet spot on the face further comprises colored rings around the decorative pattern formed from the Damascus Steel; and
wherein a backside of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and a conspicuous finish.
According to an embodiment of the golf club head, the Damascus Steel has at least 2 times yield strength of that of a material used for the shell.
According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the plurality of layers are reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the golf club head, the golf club head is part of a golf club.
According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by at least 3%.
According to an embodiment of the golf club head, each layer of the plurality of layers are selected to comprise material with properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment of the golf club head, the face comprising the Damascus Steel is heat treated.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate the sweet spot on the face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the cavity behind the face are filled with an insert configured to dampen a sound generated by the face upon hitting a golf ball.
According to an embodiment of the golf club head, the insert comprises at least one of a Thermoplastic Elastomers (TPE) and a Polyurethane (PU) foam.
According to an embodiment, disclosed is a method comprising casting a shell comprising a hosel, a first periphery, and a back made of a non-layered material; producing a face comprising a Damascus Steel from plurality of layers, by repeated rolling and forging, wherein the plurality of layers comprises at least a first material and a second material, and wherein the face comprises a second periphery; generating a first thickness of a sweet spot of the face greater than a second thickness of other areas of the face; attaching the second periphery to the first periphery of the shell via a welding, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; and forming a cavity behind the face and within a body, the cavity extending rearward from the face to the back of the shell; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the method is configured for manufacturing a golf club head of an iron type.
According to an embodiment of the method, a material for the shell comprises casting stainless steel.
According to an embodiment of the method, the shell is made using investment casting.
According to an embodiment of the method, golf club head is heat treated to improve a grain structure.
According to an embodiment of the method, the shell comprises at least one of an AI 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the method, each of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
The descriptions of the one or more embodiments are for purposes of illustration but are not exhaustive or limiting to the embodiments described herein. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein best explains the principles of the embodiments, the practical application and/or technical improvement over technologies found in the marketplace, and/or to enable others of ordinary skill in the art to understand the embodiments described herein.
All references, including granted patents and patent application publications, referred herein are incorporated herein by reference in their entirety.
This application is continuation in part of U.S. application Ser. No. 18/230,357 filed on 4 Aug. 2023 which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18230357 | Aug 2023 | US |
| Child | 18731754 | US |
