Investment casting of golf club heads with high density inserts
First Claim
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1. A method of making a composite golf club head containing at least one insert comprising the steps:
- (a) forming a disposable pattern of a golf club head that includes at least one insert at least a portion of which protrudes from the exterior of said pattern so as to form at least one protruding insert;
(b) forming a multi-layered mold around said pattern and said protruding insert, said mold comprising (i) at least one face coat layer of metallic or ceramic particles and a metallic oxide binder, and (ii) a multiplicity of backup layers of progressively coarser particles and a metallic oxide binder, wherein said metallic particles in said at least one face coat layer are selected from the group consisting of Nb, Ta, Mo and W;
(c) removing said pattern from said mold;
(d) curing said mold to form a refractory mold;
(e) filling said refractory mold at ambient temperature with a molten reactive metal to form a golf club head in the shape of said pattern and containing said at least one protruding insert;
(f) removing said mold from said golf club head; and
(g) removing the protruding portion of said at least one protruding insert.
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Abstract
Composite golf club heads having high density inserts cast by investment casting of reactive metals such as titanium that result in a high degree of bonding between the head and the insert.
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Citations
12 Claims
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1. A method of making a composite golf club head containing at least one insert comprising the steps:
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(a) forming a disposable pattern of a golf club head that includes at least one insert at least a portion of which protrudes from the exterior of said pattern so as to form at least one protruding insert; (b) forming a multi-layered mold around said pattern and said protruding insert, said mold comprising (i) at least one face coat layer of metallic or ceramic particles and a metallic oxide binder, and (ii) a multiplicity of backup layers of progressively coarser particles and a metallic oxide binder, wherein said metallic particles in said at least one face coat layer are selected from the group consisting of Nb, Ta, Mo and W; (c) removing said pattern from said mold; (d) curing said mold to form a refractory mold; (e) filling said refractory mold at ambient temperature with a molten reactive metal to form a golf club head in the shape of said pattern and containing said at least one protruding insert; (f) removing said mold from said golf club head; and (g) removing the protruding portion of said at least one protruding insert. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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Specification