Golf club head having a composite face insert
First Claim
1. A method of manufacturing a golf club head, comprising:
- forming a face insert to a thickness of about 4.5 mm or less, the face insert at least partially including prepreg plies having a fiber areal weight of less than 100 g/m2;
forming a body having a crown, a skirt and a sole, the body defining a front opening, the body having an annular ledge recessed a depth D in the front opening; and
attaching the face insert to the front opening, wherein the face insert has a thickness less than the depth D of the annular ledge in the front opening of the body.
12 Assignments
0 Petitions
Accused Products
Abstract
A golf club head having a composite face insert attached to a metallic body is provided. The club head preferably has a volume of at least 200 cc and provides superior durability and club performance. The face insert includes prepreg plies having a fiber areal weight (FAW) of less than 100 g/m2. The face insert preferably has a thickness less than 4 mm and a mass at least 10 grams less than an insert of equivalent volume formed of the metallic material of the body of the club head. A metallic cap with a peripheral rim is also provided to protect the ends of the composite material of the face insert. Related methods of manufacturing and alternative materials are disclosed. The resin content of the prepreg plies can be controlled through management of the timing and environment in which the resultant prepreg plies are cured and soaked.
98 Citations
21 Claims
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1. A method of manufacturing a golf club head, comprising:
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forming a face insert to a thickness of about 4.5 mm or less, the face insert at least partially including prepreg plies having a fiber areal weight of less than 100 g/m2; forming a body having a crown, a skirt and a sole, the body defining a front opening, the body having an annular ledge recessed a depth D in the front opening; and attaching the face insert to the front opening, wherein the face insert has a thickness less than the depth D of the annular ledge in the front opening of the body. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of manufacturing a golf club head, comprising:
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forming a cured face insert including prepreg plies having a fiber areal weight of less than about 100 g/m2 and having a resin content, comprising the steps of; stacking and cutting a plurality of plies of low fiber areal weight material to form an uncured face insert having substantially a final desired shape, bulge and roll; placing the uncured face insert into a tool with an initial temperature T1; curing the uncured face insert at a first pressure P1 then initiating heating the tool to a set temperature T2 greater than the initial temperature T1 and curing at a second pressure P2 greater than the first pressure P1, thus obtaining the cured face insert; soaking the cured face insert at a third pressure P3 less than the second pressure P2 such that the resin content in achieved; forming a golf club head body defining a front opening; and coupling the face insert to the front opening. - View Dependent Claims (9, 10, 11, 12, 13)
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14. A method of manufacturing a golf club head, comprising:
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forming a cured face insert including prepreg plies having a fiber areal weight of less than about 100 g/m2 and having a resin content, comprising the steps of; stacking a plurality of plies of low fiber areal weight material; cutting the plurality of plies to a first size; debulking the plurality of plies such that impurities are driven to the edges of the plurality of plies; cutting the plurality of plies to a second size, the second size substantially the same as a final desired size and not including the edges having the impurities; compressing the plurality of plies to form a desired bulge and roll in the plurality of plies; curing the plurality of plies to form a cured face insert; soaking the cured face insert to achieve a resin content in the cured face insert; forming a golf club head body defining a front opening; and coupling the cured face insert to the front opening. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21)
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Specification