Composite articles and methods for making the same

• US 20090163292A1
• Filed: 12/19/2007
• Published: 06/25/2009
• Est. Priority Date: 12/19/2007
• Status: Active Grant

• Current Assignee: Taylor Made Golf Co., Inc.
• Original Assignee: Taylor Made Golf Co., Inc.
• Inventors: Chao, Bing-Ling
• Granted Patent: US 7,874,937 B2
• Time in Patent Office: Days
• US Class Current: 473/342
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 2209/023 Long, oriented fibres, e.g. wound filaments, woven fabrics, mats
• CPC Class Codes: A63B 2209/10 with adhesive type surfaces, i.e. hook and loop-type fastener
• CPC Class Codes: A63B 53/0408 characterised by specific dimensions, e.g. thickness
• CPC Class Codes: A63B 53/0416 Heads having an impact surface provided by a face insert
• CPC Class Codes: A63B 53/0425 the face insert comprising two or more different materials
• CPC Class Codes: A63B 53/0445 Details of grooves or the like on the impact surface
• CPC Class Codes: A63B 53/0458 with non-uniform thickness of the impact face plate
• CPC Class Codes: A63B 53/0462 characterised by tapering thickness of the impact face plate
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: A63B 53/047 iron-type
• CPC Class Codes: A63B 53/0487 for putters A63B53/065 takes precedence
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/088 and with one or more layers of non-plastics material or non-specified material, e.g. supports
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29L 2031/5227 Clubs

Abstract

The present disclosure pertains to composite articles, and in particular a composite face plate for a golf club-head, and methods for making the same. In certain embodiments, a composite face plate for a club-head is formed with a cross-sectional profile having a varying thickness. The face plate comprises a lay-up of multiple, composite prepreg plies. At least a portion of the plies comprise a plurality of elongated prepreg strips arranged in a predetermined criss-cross pattern in the lay-up. The prepreg strips create one or more areas of increased thickness where the strips overlap each other, thereby creating a desired profile for the plate. Metallic or polymer covers or cover layers can be used to define a striking surface.

Claims

1. A method for making a composite face plate for a club-head of a golf club, the method comprising:

forming a lay-up of multiple prepreg plies, each prepreg ply comprising at least one layer of reinforcing fibers impregnated with a resin;

at least partially curing the lay-up;

water-jet cutting the at least partially cured lay-up to form a composite part having specified dimensions and shape for use as a face plate or part of a face plate in a club-head.

2. The method of claim 1, wherein the lay-up, prior to cutting, has a central portion and a sacrificial portion completely surrounding the central portion, and the act of water-jet cutting comprises water-jet cutting the sacrificial portion from the central portion, which forms the composite part.

3. The method of claim 2, wherein the act of at least partially curing the lay-up leaves no more than one void in the central portion of the partially cured lay-up.

4. The method of claim 2, wherein the act of at least partially curing the lay-up removes all voids from the central portion of the partially cured lay-up.

5. The method of claim 1, further comprising placing an outer layer on the composite part, the outer layer defining a striking surface of the face plate.

6. The method of claim 5, wherein the outer layer comprises a polymeric layer.

7. The method of claim 5, wherein the outer layer comprises a metal layer.

8. The method of claim 7, wherein the metal layer is made of titanium, aluminum, magnesium, steel, or alloys thereof.

9. The method of claim 1, wherein the lay-up has a varying thickness.

10. The method of claim 1, wherein at least a portion of the plies comprise a plurality of elongated prepreg strips arranged in a criss-cross pattern defining an overlapping region where the strips overlap each other, the lay-up having a first thickness at a location spaced from the overlapping region and a second thickness at the overlapping region, the second thickness being greater than the first thickness.

11. The method of claim 10, wherein:

the lay-up, prior to cutting, has a central portion and a sacrificial portion completely surrounding the central portion, each prepreg strip extending continuously through the central portion and having opposite end portions extending into the sacrificial portion;

and the act of water-jet cutting comprises water-jet cutting the sacrificial portion from the central portion, which forms the composite part.

12. A method for making a composite face plate for a club-head of a golf club, the method comprising:

forming a lay-up of multiple prepreg composite plies, a portion of the plies comprising elongated strips arranged in a criss-cross pattern defining one or more areas of increased thickness in the lay-up where one or more of the strips overlap each other;

at least partially curing the lay-up;

trimming the at least partially cured lay-up by water-jet cutting to form a part having specified dimensions and shape for use as a face plate or part of a face plate for a club-head.

13. The method of claim 12, wherein the part, after trimming, has a void content of about 1.7×

10<sup>−

6</sup> percent or less by volume.

14. The method of claim 12, wherein the part, after trimming, does not have any voids.

15. The method of claim 12, wherein:

the lay-up, prior to trimming, has a central portion and a sacrificial portion completely surrounding the central portion, each strip extending continuously through the central portion and having opposite end portions extending into the sacrificial portion;

and the act of trimming comprises trimming the sacrificial portion from the central portion by water-jet cutting to form the part.

16. The method of claim 12, further comprising placing an outer layer on a front surface of the part to form a striking face of a face plate.

17. The method of claim 12, wherein the strips are arranged within the lay-up to form a central projection of the lay-up having a first thickness and a peripheral portion surrounding the projection having a second thickness that is less than the first thickness.

18. The golf club-head of claim 12, wherein strips are arranged within the lay-up to form an annular projection of the lay-up having a first thickness and a recessed portion of the lay-up surrounded by the projection, the recessed portion having a second thickness that is less than the first thickness.

19. The method of claim 12, wherein another portion of the plies comprise a plurality of oversized plies each having a central portion and a peripheral sacrificial portion completely surrounding the central portion, and the act of trimming the at least partially cured lay-up comprises water-jet cutting the partially cured lay-up to remove the sacrificial portion from the central portion, which forms the part.

20. The method of claim 19, wherein the oversized plies are arranged in groups of oversized plies, and the strips are arranged in groups of strips that are interspersed between the groups of oversized plies.