Patent Application
20240091604
This invention relates to golf club heads, and in particular, abrasion resistant material applied to the striking face.
In order to improve the performance of a golf club, golf club designers have constantly struggled with finding different golf club configurations that can hit a golf ball longer and straighter. Designing a golf club that hits a golf ball longer may generally require an improvement in the ability of the golf club head to effectively transfer the energy generated by the golfer onto a golf ball via the golf club. Hitting a golf ball straighter, on the other hand, will generally require an improvement in the ability of the golf club to keep the golf ball on a relatively straight path even if the golf ball is struck off-center; as a golf ball that is struck at the center of the golf club head will generally maintain a relatively straight flight path.
Effectively transferring the energy generated by the golfer onto a golf ball in order to hit a golf ball further may be largely related to the Coefficient of Restitution (COR) between the golf club and the golf ball. The COR between a golf club and a golf ball may generally relate to a fractional value representing the ratio of velocities of the objects before and after they impact each other. U.S. Pat. No. 7,281,994 to De Shiell et al. provides one good example that explains this COR concept by discussing how a golf club head utilizing a thinner striking face may deflect more when impacting a golf ball to result in a higher COR; which results in greater travel distance.
Being able to hit a golf ball relatively straight even when the club strikes a golf ball at a location that is offset from the center of the striking face may generally involve the ability of the golf club to resist rotational twisting; a phenomenon that occurs naturally during off-center hits. U.S. Pat. No. 5,058,895 to Igarashi goes into more detail on this concept by discussing the advantages of creating a golf club with a higher Moment of Inertia (MOI), which is a way to quantify the ability of a golf club to resist rotational twisting when it strikes a golf ball at a location that is offset from the geometric center of the golf club head. More specifically, U.S. Pat. No. 5,058,895 to Igarashi utilizes weights at the rear toe, rear center, and real heel portion of the golf club head as one of the ways to increase the MOI of the golf club head, which in turn allows the golf club to hit a golf ball straighter. It should be noted that although the additional weights around the rear perimeter of the golf club head may increase the MOI of the golf club, these weights cannot be added freely without concern for the overall weight of the golf club head. Because it may be undesirable to add to the overall weight of the golf club head, adding weight to the rear portion of the golf club head will generally require that same amount of weight to be eliminated from other areas of the golf club head.
Based on the two above examples, it can be seen that removing weight from the striking face of the golf club head not only allows the golf club head to have a thinner face with a higher COR, the weight removed can be placed at a more optimal location to increase the MOI of the golf club head. One of the earlier attempts to remove unnecessary weight from the striking face of a golf club can be seen in U.S. Pat. No. 5,163,682 to Schmidt et al. wherein the striking face of a golf club head has a variable thickness by making the part of the striking face that is not subjected to the direct impact thinner.
U.S. Pat. No. 5,425,538 to Vincent et al. shows an alternative way to remove unnecessary weight from the striking face of a golf club by utilizing a fiber-based composite material. Because fiber-based composite materials may generally have a density that is less than the density of traditional metals such as steel or titanium, the simple substitute of this fiber-based composite material alone will generate a significant amount of discretionary weight that can be used to improve the MOI of a golf club. Fiber-based composite materials, because of their relatively lightweight characteristics, tend to be desirable removing weight from various portions of the golf club head. However, because the durability of such a lightweight fiber-based composite material can be inferior compared to a metallic type material, completely replacing the striking face of a golf club with the lightweight fiber-based composite material could sacrifice the durability of the golf club head.
U.S. Pat. No. 7,628,712 to Chao et al. discloses one way to improve the durability of striking face made out of a fiber-based composite material by using a metallic cap to encompass the fiber-based composite material used to construct the striking plate of the golf club head. The metallic cap aids in resisting wear of the striking face that results from repeated impacts with a golf ball, while the rim around the side edges of the metallic ring further protects the composite from peeling and delaminating. The utilization of a metallic cap, although helps improve the durability of the striking face of the golf club head, may not be a viable solution, as severe impact could dislodge the fiber-based composite from the cap.
In addition to the durability concerns of the fiber resin matrix itself, utilizing composite materials to form the striking face of a golf club offers additional challenges. More specifically, one of the major design hurdles arises when a designer attempts to bond a fiber-based composite material to a metallic material, especially at a location that is subjected to high stress levels normally generated when a golf club hits a golf ball. Finally, the usage of composite type materials to form the striking face portion of the golf club head may also be undesirable because it alters the sound and feel of a golf club away from what a golfer are accustomed to, deterring a golfer from such a product.
Ultimately, despite all of the attempt to improve the performance of a golf club head by experimenting with alternative face materials, the prior art lacks a way to create a striking face that saves weight, improves COR, and is sufficiently durable without sacrificing the sound and feel of the golf club head. Hence, as it can be seen from above, there is a need in the field for a golf club head having a fiber based composite striking face that can save weight, improve the COR of the golf club head, and can endure the high stress levels created by the impact with a golf ball, all without sacrificing the sound and feel of the golf club head.
The present invention is directed to improving the abrasion resistance of the striking face of a golf club head without compromising COR or generating unnecessary weight in the club head by applying abrasion resistant material to the striking face. Abrasion resistant material can be applied to the striking face by treating, coating, layering or otherwise, integrating the abrasion material onto the striking face. In one aspect of the present invention, abrasion material can be applied to the golf club striking face by electroplating with a metal, such as chromium. A physical vapor deposition can further be applied to the electroplated striking face.
In another embodiment of the present invention, a veil can be applied to the striking face by co-molding the veil to a composite striking face. The veiled striking face can optionally be further electroplated with a metal, such as chromium. A physical vapor deposition can then be applied to the veiled, electroplated striking face.
In another embodiment of the present invention, a single veil or a combination of veils can be applied directly to the striking face with our without further treatment. The veil can comprise compounds, such as aramid, polyetherimide (PEI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), metals, such as copper, carbon, such as carbon nanotubes, and the like, and any combination thereof.
In accordance with some aspects of the presently disclosed technology, a golf club head is disclosed. The golf club head may include a body. The body may include a back, a topline located at an upper portion of the golf club head, a heel portion located at a proximal end of the golf club head, and a hosel adjacent to the heel portion and the topline. The hosel may define a longitudinal axis and be configured to receive a shaft. The body may include a toe portion located at a distal end of the golf club head opposite the heel portion, a sole located at a lower portion of the golf club head opposite the topline; and a striking face located at a frontal portion of the golf club head opposite the back. The striking face may include a plurality of scorelines, a base layer including fibers and a polymer matrix, and a metal veil layer on top of the base layer. The metal veil layer may include metal veils. The metal veils may include metal-coated fibers. The metal-coated fibers may include a first metal. The striking face may include a metal layer on top of the metal veil layer. The metal layer may include a second metal.
In embodiments, the first metal may include at least one of copper and nickel.
In embodiments, the metal veil layer may be co-molded with the base layer.
In embodiments, the metal veil layer may have a thickness between about 0.5 mm to about 1.5 mm.
In embodiments, the metal veil layer may have an areal weight from about 15 grams per square meter to about 125 grams per square meter.
In embodiments, the fibers may include carbon fibers. The polymer matrix may include epoxy resin.
In embodiments, the metal layer may have a thickness less than about 0.05 mm.
In embodiments, the second metal may include at least one of chrome and nickel.
In embodiments, the base layer may further include carbon nanotubes.
In embodiments, the striking face may further include an intermediate metal layer between the metal veil layer and the metal layer. The intermediate metal layer may include a third metal. The third metal may be different from the first metal and the second metal.
In embodiments, the intermediate metal layer may have a thickness less than about 0.05 mm.
In accordance with some aspects of the presently disclosed technology, a golf club head is disclosed. The golf club head may include a body. The body may include a back portion, a topline located at an upper portion of the golf club head, a heel portion located at a proximal end of the golf club head, and a hosel adjacent to the heel portion and the topline. The hosel may define a longitudinal axis and be configured to receive a shaft. The body may include a toe portion located at a distal end of the golf club head opposite the heel portion, a sole located at a lower portion of the golf club head opposite the topline, and a striking face located at a frontal portion of the golf club head opposite the back. The striking face may include a plurality of scorelines; a base layer including carbon fibers and a thermoset polymer matrix and a metal veil layer on top of the base layer. The metal veil layer may include metal veils. The metal veils may include metal-coated fibers. The metal-coated fibers may include a first metal. The striking face may include a metal layer on top of the metal veil layer. The metal layer may include a second metal. The metal-coated fibers of the metal veil layer may be exposed to a bottom surface of the metal layer.
In embodiments, the first metal may include one of copper and nickel. The second metal may include one of nickel and chrome.
In embodiments, the striking face may be treated with carbon nanotubes.
In accordance with some aspects of the presently disclosed technology, a method of manufacturing a striking face of a golf club head is disclose. The method may include bonding a metal veil layer to a top surface of a base layer. The base layer may include a polymer matrix and fibers distributed therein. The metal veil layer may include metal-coated fibers. The metal-coated fibers may include a first metal. The method may include applying a metal layer to a top surface of the metal veil layer to form a metal-coated fiber composite. The metal layer may include a second metal.
In embodiments, the method may further include coating a top surface of the metal veil layer with an intermediate metal layer. The intermediate metal layer may include a third metal. The metal layer may be applied onto a top surface of the intermediate metal layer.
In embodiments, the metal layer may be applied to the top surface of the metal veil layer by thermal spraying, electroplating, or electroless-plating.
In embodiments, the method may further include distributing carbon nanotubes (CNT) on the base layer to form a CNT base layer. The metal veil layer may be bonded to the CNT base layer.
In embodiments, the method may further include wearing away a top surface of the metal veil layer to expose the metal-coated fibers. Applying the metal layer may occur after the top surface is worn away.
In embodiments, the fibers may include carbon fibers. The polymer matrix may include epoxy resin.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.
The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
For ease of description, the striking face portion will be referred to as the front side of the golf club head 100. As such, the striking face 102 is located at a frontal portion of the golf club head 100. As a result, the back portion 114 is located opposite the striking face portion 112; the topline 104 is located at an upper portion of the golf club head 100; the heel portion 108 is located at a proximal end of the golf club head 100; the toe portion 106 is located at a distal end of the golf club head 100 opposite the heel portion 108; and the sole 102 is located at a lower portion of the golf club head 100 opposite the topline 104. An axis of origin 12 is provided (for reference only for ease and clarity of description) indicating the x-y-z direction relative to the golf club head 100 in the examples provided.
The leading edge 120 can be defined in the current application as approximately the most forward edge of the golf club head 100, with the hosel 110 in an upright 90 degree (perpendicular) position from a ground plane 10 (in the front-to-back, z-axis direction). (The ground plane 10 is an imaginary plane located and in contact with the lowest portion of the golf club head 100, and mimics the surface of the ground upon which the golf ball would lie.) This leading edge 120 is then defined as approximately the forward most edge along the z-axis (as indicated by the axis of origin 12) generally where the striking face 112 meets the sole 102. In addition to illustrating the leading edge 120,
The invention of the present application incorporates improvements to the striking face 112 that dramatically improves abrasion resistance of the golf club head 100 without adding substantial weight to the golf club head 100 by applying abrasion resistant material to the striking face 112. Preferably, the striking face 112 is a composite material.
In some embodiments, the striking face 112 can be integrally formed with the body 101 as a single piece. In the preferred embodiment, the striking face 112 is in the form of an insert, as shown in
In the preferred embodiment, the insert for the striking face 112 can comprise resin composites. By way of example only, the insert can comprise thermoplastic resin, such as thermoplastic polyetherimide (PEI) made by Stratasys under the trademark ULTEM™. In some embodiments, the striking face 112 can comprise a unidirectional carbon fiber layup to reduce the weight of the insert. In some embodiments, striking face 112 can comprise a thermoset carbon fiber composite. In the preferred embodiment, the remainder of the body 101 can be a steel body. In some embodiments, the body 101 can be made of other traditional materials used for golf clubs.
In the present invention, an abrasion resistant material can be applied to the striking face 112 that result in the abrasion resistant material being coated, treated, layered, or otherwise integrated onto the striking face. In some embodiments, the abrasion resistant material can be applied to the striking face 112 of the golf club head 100 using an electroplating technique to create a plated layer 140. Preferably, the plating process comprises chromium, resulting in a chrome plated striking face 112. Standard electroplating techniques can be used. By way of example only, the striking face 112 can be placed in an electrolytic cell having an electrolytic solution, an anode, and a cathode. A DC battery can be connected to the anode and the cathode. The striking face 112 can function as the cathode or be connected to the cathode, and the metal used to plate the striking face 112, such as chromium, can function as the anode or be connected to the anode. The electrolytic solution can be a salt of the metal that is being used for the plating. When the battery is turned on, the metal ions from the anode travel through the electrolytic solution to the striking face 112 creating a thin plated layer 140 of plating on the striking face 112. In some embodiments, the plating layer 140 can be applied directly to the striking face 112. In other embodiments, as shown in
For example, a veil 142 can be applied to the composite striking face 112 by co-molding the composite striking face 112 with the veil 142. Preferably, the veil 142 is a conductive veil. More preferably, the veil 142 is a carbon veil or a glass veil. In embodiments with a veil 142, the plating can be applied directly to the veil 142. An example of a carbon veil is the Optiveil® manufactured by Technical Fibre Products Inc. Having a conductive veil co-molded with the striking face 112 enables the plating, and in particular, chrome plating, to better adhere to the surface of the striking face 112. This technique results in a very thin veil layer 142 having a thickness from about 0.05 mm to about 0.40 mm. In addition, the areal weight can be about 4 g/m2 to about 34 g/m2. In some embodiments, the thickness of the veil can be about 0.12 mm to about 0.20 mm with an areal weight of about 0.3 g/m2 to about 0.5 g/m2. In some embodiments, the thickness of the veil can be about 0.17 mm with an areal weight of about 0.4 g/m2. By contrast, using an injection molding resin onto which chrome plating can be applied results in a resin layer that is over 1 mm.
In some embodiments, the veil 142 can be applied to the striking face 112 with a coating comprising aramid, polyetherimide (PEI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK), metals such as copper, carbon such as carbon nanotubes, or the like, or any combination thereof. For example, in one embodiment, a carbon nanotube coating can be applied for aesthetics, and a PEI or PPS coating can be applied for improved abrasion resistance. In some embodiments, the veil coating can be applied directly to the striking face 112.
In some embodiments, the golf club head 100 comprises a physical vapor deposition (PVD) layer 144 applied to the striking face 112. By way of example only, the striking face 112 can be placed in a chamber with a source material, generally in solid form. Energy can be applied to the source material to produce metal vapors from the source material. The vapor then travels within the chamber and condenses on the striking face 112 creating a thin layer of the vapor deposition on the striking face 112. The chamber is generally in a vacuum state, and can be back-filled with other gases (nitrogen, oxygen, methane, argon, and the like, and any combination thereof) to create the desired properties or appearance on the striking face 112. The energy applied to the source material can be from a cathodic arc source (e.g., plasma energy), magnetron sputtering (thermal energy), or other known energy sources used in PVD. Energy, such as from a DC power supply, can also be applied to the striking face 112 to charge the striking face 112 to improve the attraction of the metal vapors to the striking face 112. The PVD layer 144 can be applied directly to the striking face 112, to a plated layer 140, or to a veil 142.
As such, the striking face 112 can be electroplated to create a plated layer 140 directly on the striking face 112, co-molded with a veil 142 then electroplated, coated with a veil 142 and electroplated to add a plated layer 140, and in any of the aforementioned embodiments, treated further with physical vapor deposition.
In some embodiments, any abrasion resistant material disclosed herein (i.e., plating, veils, and physical vapor depositions), alone or in any combination, can be applied to the striking face 112 only, applied to the striking face 112 and the sole 102, or applied to the striking face 112 and the entire body 101.
Because the improved abrasion of the golf club head is so critical to the present invention,
Before the testing begins, the Abraser 350 is set at a predetermined preset speed of 25 cycles per minute via the Preset Speed Buttons 352 on the Abraser 350. Once the speed is set to the appropriate speed of 25 cycles per minute, the base load of the Abraser 350 is set to approximately 350 grams, as the base load will affect the amount of abrasion that is applied by the Abraser 350. In this current exemplary embodiment, to achieve the base load of approximately 350 grams, 3 different components are attached to the distal end of a movement arm 353 to create the load weight. More specifically, a weight support 354 is selected to have a mass of about 167 grams, a spline shaft 356 is selected to have a mass of about 85 grams, and a weraser collet 358 is selected to have a mass of about 98 grams, all connecting to the movement arm 353 as shown in
Once the speed of the Abraser 350 is set and the base load of the Abraser 350 is established above, the feet 360 of the Abraser 350 are adjusted to make sure the entire Abrasaer 350 is level with the air bubble in the center of the indicator. Subsequent to the leveling of the Abraser 350, the wearaser 362 is inserted to the bottom of the collet kit 358 to prepare the Abraser 350 for engaging a golf club head. In this testing procedure, the wearaser 362 is a Taber® CS-17 Calibrase abrasive wheel for Taber® industries, bearing part number 125322, having a medium-coarse abrading action. The wearaser 362 is installed so that it extends 0.100 inch from the bottom of the collet 358.
Subsequent to the installation of the wearaser 362, the stroke length of the Abraser 302 is set to a 0.5 inch using the stroke length adjuster 364, which is attached to the proximal end of the movement arm 353. The stroke length adjuster 364 in the Abraser 302 is protected by a cover 366 which opens to reveal the stroke length adjuster 364. The stroke length adjuster 364 converts the rotational movement of the Abraser 302 into a translational movement of the movement arm 353 to conduct the testing.
Once the stroke length of the Abraser 350 is set, the golf club can be fixtured to the Abraser 350 to begin testing.
A golf club head in accordance with an exemplary embodiment of the present invention may generally have a Thickness to Abrasion Count Ratio of less than about 0.4, more preferably less than about 0.1, even more preferably less than about 0.025, and most preferably less than about 0.005. The Thickness to Abrasion Count Ratio defined by Eq. (1) below:
Applying the test described above on striking surfaces 112 comprising aramid, PEI, PPS, PEEK, copper, or carbon coating, in particular, passed the abrasion test. The current golf club head 100 containing the abrasion resistant material disclosed herein, in addition to all the benefits discussed above, may also exhibit an improved Characteristic Time (CT) to COR relationship. More details about the CT to COR relationship can be found in the discussion relating to CT slope found in U.S. Patent Publication No. 2022/0227028 to Deshmukh et al., the disclosure of which is incorporated by reference in its entirety.
While it should be appreciated that metal-metal bonds are an ideal type of bond for achieving high adhesive strength between materials, there are situations, where adhesion is required between composites and metals. Existing technology does not effectively address bonding polymers, including, for example, composites, with metals. The presently disclosed technology provides golf club heads and methods that address this issue.
Base layer 502 may include composite material. The composite material may include fibers and a polymer matrix. The fibers may include carbon fibers, graphite fibers, fiberglass, and/or other fibers. The fibers may be continuous or chopped. The polymer matrix may be thermoset, thermoplastic, and/or other polymers. The polymer matrix may include resins and/or other polymers. In embodiments, the fibers may be mixed, embedded, or otherwise distributed in the polymer matrix. An example base layer 502 may be an uncured thermoset epoxy resin with continuous carbon fibers. In some embodiments, there may be multiple plies making up base layer 502. The multiple plies may form a laminate of base layer 502. For example, there may be between about 10 plies to about 40 plies. In some embodiments, there may be between about 15 plies and about 20 plies. The fibers of base layer 502 may have an areal weight expressed as grams per square meter (gsm′). The areal weight may be the areal weight of a unidirectional (UD) ply of the fibers of base layer 502. In some embodiments, plies of base layer 502 may be laid perpendicular to adjacent plies to form a fabric, which may increase the areal weight of base layer 502. In some embodiments, the fibers of base layer 502 may have an areal weight between about 25 gsm and about 150 gsm. In embodiments, the fibers of base layer 502 may have an areal weight between about 50 gsm and about 100 gsm. For example, the areal weight may be about 75 gsm. It should be appreciated that the areal weight of base layer 502 may be affected by a thickness of the material(s) used for the fibers in base layer 502 and/or a density of the material(s) used for the fibers in base layer 502. In some embodiments, base layer 502 may include carbon nanotubes. This may be referred to as a carbon nanotube (CNT) base layer. The carbon nanotubes in the CNT base layer may provide electrical conduction throughout golf club component 500. The number, or density, of carbon nanotubes may vary depending on the application. Base layer 502 may be between about 0.5 mm and about 10 mm thick. In some embodiments, base layer 502 may be between about 1.0 mm and about 6.0 mm thick. Base layer 502 may have a thickness between about 0.05 mm and about 0.3 mm per ply. In some embodiments, base layer 502 may have a thickness between about 0.08 mm and about 0.2 mm per ply. It should be appreciated that the thicknesses and gsm values are critical to the effectiveness of the presently disclosed technology.
Metal veil layer 504 may be layered, disposed, or otherwise placed on a top surface of base layer 502. Metal veil layer 504 may be porous. Metal veil layer 504 may include randomly oriented fibers coated with a metal. The metal-coated fibers here may be the same or similar to the fibers of base layer 502, other than the metal coating. Each fiber may be coated with the metal. The metal may include copper, nickel, titanium, and/or other metals. For the sake of clarification, the metal may be an alloy, or a combination of metallic elements. Metal veil layer 504 may have an areal weight expressed as grams per square meter (gsm). In some embodiments, metal veil layer 504 may have an areal weight between about 15 gsm and about 125 gsm. In embodiments, metal veil layer 504 may have an areal weight between about 25 gsm and about 75 gsm. For example, the areal weight may be about 34 gsm or about 45 gsm. It should be appreciated that the gsm of metal veil layer 504 may be affected by a thickness of the material(s) used in metal veil layer 504 and/or a density of the material(s) used in metal veil layer 504. In embodiments, metal veil layer 504 may have a thickness between about 0.1 mm and about 0.65 mm per ply. In some embodiments, there may be multiple plies making up metal veil layer 504. For example, there may be three plies though it should be appreciated that there may be more or fewer plies. The total thickness of metal veil layer 504 may be between about 0.1 mm and about 3.0 mm thick. In some embodiments, the total thickness of metal veil layer 504 may be between about 0.5 mm and about 1.5 mm thick. It should be appreciated that the thicknesses and gsm values of metal veil layer 504 are critical to the effectiveness of the presently disclosed technology.
In some embodiments, metal veil layer 504 may be distributed into pieces on a top surface of base layer 502. For example, rectangular strips may be distributed on the top surface of base layer 502 such that metal veil layer 504 may not fully cover base layer 502. It should be appreciated that the pieces of metal veil layer 504 may be circular, triangular, and/or otherwise shaped, sized, and/or dimensioned to improve a bond between metal veil layer 504 and metal layer 506. In some embodiments, metal veil layer 504 may be randomly distributed or asymmetrically distributed. The number of metal veils may be more or fewer depending on the metal used in the metal layer, whether an intermediate metal layer is used, the shape, size, and/or dimension of the metal veils, base layer 502, and/or other properties of golf club component 500. In some embodiments, a first set of strips of metal veil layer 504 may fully cover the top surface of base layer 502. In embodiments, there may be multiple sets of strips of metal veil layer 504 applied to golf club component 500.
Base layer 502 may be molded or cured with metal veil layer 504 embedded, disposed, or otherwise distributed in base layer 502. As discussed herein, metal veil layer 504 may be porous, and after being molded or cured with base layer 502, the polymer and/or resin may saturate metal veil layer 504, thereby locking metal veil layer 504 to base layer 502. As base layer 502 hardens and forms a mechanical bond with metal veil layer 504, the fibers in metal veil layer 504 may be partially encapsulated or covered. For example, at least some of the fibers on a top surface of metal veil layer 504 may be exposed or un-encapsulated. In some embodiments, the fibers may be fully encapsulated or covered. In such embodiments, this top surface of metal veil layer 504 may be grinded, grit blasted, sanded, polished, or otherwise worn away to expose or reveal parts of the metal-coated fibers in a top surface of metal veil layer 504. In embodiments with base layer 502 including the carbon nanotubes, metal veil layer 504 may be placed on top of, or otherwise distributed on, base layer 502. This may help enhance electrical conduction through golf club component 500.
Metal layer 506 may be sprayed, plated, or otherwise applied to metal veil layer 504 and/or base layer 502. For example, spraying may include thermal spraying, plasma spraying, wire-arc spraying, flame spraying, high velocity oxy-fuel coating spraying, high velocity air fuel spraying, warm spraying, cold spraying, and/or other spraying techniques. These techniques may be used to spray metal layer 506 onto metal veil layer 504 and/or base layer 502. Thermal spraying may be an effective technique because of the combination of heat and kinetic energy causing metal to melt or semi-melt and rapidly solidify on contact with metal veil layer 504 and/or base layer 502. In liquid form, the metal of metal layer 506 may be reactive and may form a strong metal-metal bond with metal veil layer 504. In embodiments, metal layer 506 may be plated through an electroplating or electroless-plating technique. As discussed herein, the amount of carbon nanotubes on base layer 502 and/or electrically conductive material on metal veil layer 504, including the metal and/or carbon fibers, may be varied to provide sufficient current for electroplating. Metal layer 506 may include metals such as chrome, nickel, titanium, and/or other metals. The metal of metal layer 506 may be selected for specific properties, including, for example, abrasion resistance, coefficient-of-friction, durability, cosmetic appearance, and/or other properties. Metal layer 506 may be less than about 0.05 mm thick. In some embodiments, metal layer 506 may be less than about 0.03 mm thick.
As an example of the presently disclosed technology, golf club component 500 may be fabricated or otherwise manufactured starting with base layer 502. Base layer 502 may include a polymer matrix and fibers distributed therein, that is, distributed within the polymer matrix. Base layer 502 may be a prepreg. In some embodiments, carbon nanotubes (CNT) may be distributed on or in base layer 502 to form a CNT base layer. Metal veil layer 504 may be bonded to or cured with a top surface of base layer 502. For example, before metal veil layer 504 is bonded to the top surface of base layer 502, base layer 502 may be uncured. In embodiments, base layer 502 may be placed into a mold with metal veil layer 504 placed on a top surface of base layer 502 before bonding or curing. The mold may include an undercut or be otherwise shaped, sized, and/or dimensioned to fit the thickness of base layer 502 and/or metal veil layer 504. In some embodiments, metal veil layer 504 may be compressed before bonding or curing to the top surface of base layer 502. Metal veil layer 504 may be compressed to fit the undercut of the mold. In some embodiments, metal veil layer 504 may be trimmed along a perimeter, or shaped, sized, and/or dimensioned, to fit within the mold. As discussed herein, metal veil layer 504 may be co-molded or co-cured with base layer 502. In embodiments, with a CNT base layer, metal veil layer 504 may be bonded or cured to the top surface of the CNT base layer. Metal veil layer 504 may include metal-coated fibers. The metal-coated fibers may include a first metal. In some embodiments, a top surface of metal veil layer 504 may be coated with an intermediate metal layer (at least shown as intermediate metal layer 608 in
The presently disclosed technology may be applied to any composite component of a golf club head, including, for example, a face insert, a part of the body (e.g., an aft body, a crown, a sole, a face cup, and so on), a part of the hosel, and/or other components of a golf club head without departing from the spirit and scope of the presently disclosed technology. The presently disclosed technology may be used to improve abrasion resistance of such composite components.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.
The present application is a continuation-in-part of U.S. application Ser. No. 17/946,950, filed on Sep. 16, 2022, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17946950 | Sep 2022 | US |
| Child | 18237284 | US |
