Composite articles and methods for making the same
First Claim
1. A golf club-head comprising:
- a body having a crown, a heel, a toe, and a sole, the body defining a front opening; and
a variable-thickness face insert closing the front opening of the body, the insert comprising a lay-up of multiple, composite prepreg plies, 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.
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Accused Products
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.
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Citations
29 Claims
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1. A golf club-head comprising:
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a body having a crown, a heel, a toe, and a sole, the body defining a front opening; and a variable-thickness face insert closing the front opening of the body, the insert comprising a lay-up of multiple, composite prepreg plies, 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A golf club-head comprising:
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a body having a crown, a heel, a toe, and a sole, the body defining a front opening; and a variable-thickness face insert closing the front opening of the body, the insert comprising a lay-up of multiple, composite prepreg plies, the lay-up having a front surface, a peripheral edge surrounding the front surface, and a width, wherein at least a portion of the plies comprise elongated strips that are narrower than the width of the lay-up and extend continuously across the front surface, the strips being arranged within the lay-up so as to define a cross-sectional profile having a varying thickness. - View Dependent Claims (16, 17, 18, 19)
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20. A composite face plate for a club-head of a golf club, comprising:
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a composite lay-up comprising multiple prepreg layers, each prepreg layer comprising at least one resin-impregnated layer of longitudinally extending fibers at a respective orientation, the lay-up having an outer peripheral edge defining an overall size and shape of the lay-up; wherein at least a portion of the layers comprise a plurality of composite panels, each panel comprising a set of one or more prepreg layers, each prepreg layer in the panels having a size and shape that is the same as the overall size and shape of the lay-up; and wherein another portion of the layers comprise a plurality of sets of elongated strips, the sets of strips being interspersed between the panels within the lay-up, the strips extending continuously from respective first locations on the peripheral edge to respective second locations on the peripheral edge, the strips defining one or more areas of increased thickness of the lay-up where the strips overlap within the lay-up. - View Dependent Claims (21, 22, 23, 24, 25)
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26. A method for making a composite face plate for a club-head of a golf club, the method comprising:
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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; shaping the at least partially cured lay-up 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. - View Dependent Claims (27, 28, 29)
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Specification