U.S. patent application number 09/757865 was filed with the patent office on 2002-07-11 for laser surface modified materials and their incorporation into golf clubs.
Invention is credited to Aldrich, Darin James.
Application Number | 20020091014 09/757865 |
Document ID | / |
Family ID | 25049538 |
Filed Date | 2002-07-11 |
United States Patent
Application |
20020091014 |
Kind Code |
A1 |
Aldrich, Darin James |
July 11, 2002 |
Laser surface modified materials and their incorporation into golf
clubs
Abstract
Lasers are useful for many types of materials processing,
including annealing, texturing, and joining. A method is provided
for modifying the surface finish and structure of any material,
with said materials being used in the construction of golf clubs.
The surface modified materials have properties that lead to
increased performance of the golf clubs. A secondary benefit is an
improved material structure leading to a better feel for the
golfer.
Inventors: |
Aldrich, Darin James;
(Westminster, CO) |
Correspondence
Address: |
DARIN J. ALDRICH
1130 WEST 127th CT.
WESTMINSTER
CO
80234
US
|
Family ID: |
25049538 |
Appl. No.: |
09/757865 |
Filed: |
January 11, 2001 |
Current U.S.
Class: |
473/324 ;
473/330; 473/340 |
Current CPC
Class: |
A63B 53/0416 20200801;
B29K 2995/0039 20130101; A63B 2209/00 20130101; A63B 53/0466
20130101; B29K 2995/0041 20130101; B29L 2031/5227 20130101; C21D
1/09 20130101; B29C 59/16 20130101; A63B 53/047 20130101; A63B
60/004 20200801; A63B 53/04 20130101; B29C 2035/0838 20130101; A63B
60/00 20151001; C21D 10/005 20130101; B29K 2995/0072 20130101; A63B
53/0487 20130101; B29K 2995/007 20130101 |
Class at
Publication: |
473/324 ;
473/340; 473/330 |
International
Class: |
A63B 053/04 |
Claims
What is claimed is:
1. A method for modifying the surface of a material with a laser
comprising changes to the chemical, crystalline, or topographic
structure of the material.
2. The method of claim 1, wherein the material is any type of
crystalline or non-crystalline ceramic material, including the
classification of materials generally referred to as glasses.
3. The method of claim 1, wherein the material is any type of
crystalline or non-crystalline metal or metal-containing alloy.
4. The method of claim 1, wherein the material is any type of
polymeric or rubber material.
5. The product of claims 1-4, wherein the product comprises any
surface on a golf club, preferably the striking face
6. The product of claims 1-4, wherein the product comprises a golf
putter.
7. The product of claims 1-4, wherein the product comprises a golf
iron.
8. The product of claims 1-4, wherein the product comprises a golf
driver.
Description
FIELD OF THE INVENTION
[0001] The present invention involves a process for modifying the
surface of a material with a laser, and incorporating said material
into a golf club. The primary feature of the laser surface modified
material involves incorporating it into the striking face of the
golf club.
BACKGROUND OF THE INVENTION
[0002] In recent years, there have been a large number of
technological innovations in the field of golf club construction in
an effort to improve the performance of the clubs. Many of these
innovations have focused optimizing the weight distribution within
the golf club's head in order to correct for off-center hits,
thereby expanding the "sweet spot". These innovations have resulted
in golf clubs with dramatic performance improvements that have
received excellent success in the marketplace. Similarly, the
configuration of the golf clubs has also been modified to optimize
the "spin" imparted to the golf ball during impact, since this spin
can be utilized to better control the ball.
[0003] More recently, golf club manufacturers have shifted their
focus to improving the golf club's "feel". Although the feel is a
rather individual and subjective characteristic, most golfers
equate it with a comfortable sensation received through the hands
during contact with the golf ball. Many golf club manufacturers
have improved the feel of golf clubs by incorporating secondary
materials into the primary material of the golf club's
construction. Some of these multiple material systems have received
an excellent reception in the golf club marketplace. There are
additional methods, such as the one described in the current
invention, that can also be utilized to improve a golf club's
performance and feel.
[0004] An alternative process to tailor the properties of a
material is through the application of a laser (Light Amplification
through Stimulated Emission of Radiation). Laser surface
modification provides an opportunity to specifically tailor the
surface of a material to have unique properties when compared to
those of the unmodified bulk material. Some examples of modified
surface properties include an increased surface hardness, a
decreased surface hardness, and an increased surface roughness. A
decrease in surface hardness or an increase in surface hardness
from a laser treatment is possible in different materials depending
on their chemical structure. In some non-heat treatable iron
alloys, for example, the laser radiation can be used to reduce the
internal residual stresses, thereby reducing the surface hardness.
In heat-treatable alloys, on the other hand, the thermal energy
provided by the laser can increase the hardness by changing the
crystalline structure of the material. In most instances, there
will also be a change in the surface topography of the laser
surface modified material. Specifically, the roughness of the
surface will increase.
[0005] The difference in these properties is a result of the
specific material to be modified by the laser. The increased
surface hardness can be particularly beneficial in golf club
applications where it is desired to have the ball rebound from the
golf ball with as much initial velocity as possible, resulting in a
ball that travels a great distance. A decreased surface hardness,
on the other hand, can be particularly beneficial in the case of a
golf club application where a soft feel is required. Finally, an
increased surface roughness on the hitting face of the golf club is
particularly desirable in the case of a golf club where it is
desired to impart a large degree of spin on the golf ball.
[0006] Laser surface modification has been used extensively in
different areas of materials science for joining two or more
materials, annealing materials to relieve internal stresses, and
sintering powders into a unitary mass. These techniques have been
used for a wide variety of industrial applications where it is
important to have specific properties of the materials, such as
high surface hardness, low surface hardness, or resistance to
particular types of wear. In the computer disk drive industry, for
example, it has been shown that a laser can be used to modify the
surface structure of the hard disk in a manner that benefits the
wear properties of the disk drive. Examples of laser application to
hard disk drives can be seen in the prior art of Wong, et al. in
U.S. Pat. No. 6,117,499 and Baernboim, et al. in U.S. Pat. No.
6,103,990. Although there are many industrial examples of the use
of laser radiation for the benefit of specific applications, there
is an absence of said laser processing in application to golf
equipment.
[0007] The pricr art in golf club construction and engineering is
significant. Thorne and Poplaski, in U.S. Pat. No. 5,800,285,
describe a method for producing artwork on a golf club with a
photochemical engraving technique. The application of a laser in
this process is intended to change the structure of a photoresist
chemical, thereby allowing a separate compound to chemically etch
the exposed areas. This process is fundamentally different than the
one described in the present patent application where the laser is
modifying the material composing the striking face of the golf
club. The primary purpose of Thorne's process is to create a
customized pattern such as letters, numbers, symbols, or
scorelines, thus it is not primarily focused on functionally
modifying the surface. In addition, this patent primarily describes
an alternative process for detailing the head of a golf club, when
compared to traditional metal casting or metal stamping. Finally,
Thorne and Poplaski's patent is focused on metallic materials,
which is dissimilar from the laser surface modification process
which applies equally well to all classes of materials.
[0008] There are additional methods described in the prior art on
golf clubs constructed of multiple materials. For example, Chen in
U.S. Pat. No. 5,403,007, describes a golf club with a metal body
and a ceramic or titanium hitting face. Similarly, Buck in U.S.
Pat. No. 5,779,560, describes a golf club head comprised of a metal
head with an insert comprised of a fiber-reinforced composite.
Anderson, in U.S. Pat. Nos. 5,024,437 and 5,261,663, describes an
insert made of a softer material such as a forged carbon steel to
improve the feel of the club during impact. Further attempts to
improve the feel of a golf club were proposed by Krumme in U.S.
Pat. No. 5,807,190 wherein individual pieces of a secondary
material ("pixels") were incorporated into the striking face of the
club. Similarly, Igarashi, in U.S. Pat. No. 5,407,202, proposed a
golf club incorporating a high strength, low weight material such
as titanium for the striking face of a golf club. An additional
method to improve the performance of golf clubs was proposed by
Mahaffey in U.S. Pat. No. 5,827,131 including multiple-layer
inserts for the golf club hitting surface. Additional attempts have
been made to improve the performance and feel, such as U.S. Pat.
No. 5,154,425 which describes a golf club head composed of a
material which is a composite of metal and ceramic components.
[0009] Many of these methods, however, require very expensive
processing techniques and can lead to a substantial number of
internal interfaces between the dissimilar materials. These
internal interfaces are sources of potential manufacturing defects,
as well as interruptions to the vibrations translated to the
golfer. It is the vibrations transmitted to the golfer that provide
the pleasant feel. In the current invention, on the other hand, the
laser surface modified material is substantially the same as the
base material, with a slight functional modification.
SUMMARY OF THE INVENTION
[0010] With the present invention, it has been found that a laser
can be used to modify the surface structure of a material. The
changes can include modification of the crystalline structure of
the material, changes to the surface roughness, changes in the
surface chemistry of the chemical elements, or can, in some cases,
transform a crystalline material into a non-crystalline (i.e.,
amorphous) material.
[0011] In one aspect, the present invention provides a surface with
a greatly increased roughness, thereby dramatically increasing the
frictional coefficient of the material. An increase in the level of
the friction on the surface of a club hitting face can positively
impact the performance of the club by changing the manner in which
the golf ball interacts with the club during striking. The
increased friction between the golf club and the ball imparts a
high degree of spin to the ball during the contact. This high
degree of spin can be particularly advantageous in the application
of golf clubs with a high degree of loft since it allows a high
degree of control over the golf ball after it lands in the desired
location.
[0012] In a golf putting application, the present invention can be
particularly advantageous due to the high friction between the ball
and the putter's surface. This high friction causes the ball to
immediately roll in a forward direction, as opposed to the problem
of skidding evidenced by many of the prior art putters.
[0013] In many applications for golf clubs, the surface
modification will be limited to specific areas on the club hitting
face. The present invention can be used for a number of different
clubs, including putters, irons, specialty clubs, and drivers.
Specialty clubs can include any club used for chipping, hitting out
of deep rough, hitting out of wet grass, or hitting out of any
hazard, such as, but not limited to sand bunkers.
[0014] Although the preferred location of the laser surface
modified material is on the hitting face, it can also be used on
any surface of the club, such as the face nearest the ground when
the ball is being struck. Again, surface material properties can be
altered to increase the performance of the golf club.
[0015] Non-limiting examples of some materials that may be included
in laser surface modification processing include steel alloys,
stainless steel alloys, titanium alloys, aluminum and its alloys,
aluminum oxide, zirconium dioxide, silicon carbide, silicon
nitride, polymeric materials, and rubber compounds.
[0016] In a major aspect, the present invention provides a method
of manufacture for a laser surface modified material. The
manufacturing method typically includes treating the material
surface with laser radiation. Nonlimiting examples of laser types
include carbon dioxide, yttrium aluminum garnet (YAG), or any type
of solid state semiconductor laser. Typical laser power for a
carbon dixoide laser ranges from 5-100 Watts. The focused spot size
is typically in the range of 125 microns (0.005 inches).
[0017] One tremendous advantage of the present invention is the
multiple methods to functionally modify the surface structure of
the material. In one instance, for example, a heat treatable steel
alloy can increase in hardness from the thermal energy provided by
the laser. In another example, the laser beam can increase the
surface roughness of a material. In yet another example, lasers can
be used to anneal a metallic alloy to remove residual stresses and
decrease the hardness of the material. Each one of these properties
can benefit different applications for the striking face of a golf
club. In one instance, a softer metallic alloy on the striking face
of a golf club delivers a better feel to the player. In another
instance, an increase in the surface roughness of the striking face
of a golf club provides an increase in the amount of advantageous
spin that can be applied to a golf ball. Although the previous
examples have focused on metallic materials, the technique for
laser surface modification applies equally well to natural
materials such as wood, as well as synthetic materials comprising
the classes generally known as polymers and ceramics.
[0018] The type and power of the laser depends on the type of
material to be treated. For a given material, an increase in laser
power will increase the depth of penetration into the material. In
general, any laser will cause a small change in the surface
structure of a material. In the case of the present invention,
however, the power must reach a threshold that depends on the type
of material, to give the benefits described for the striking face
of a golf club.
[0019] An alternative embodiment for the laser surface modification
process can be applied to golf clubs that are composed of multiple
materials. For example, the laser surface modified material can be
used on the hitting surface of the golf clubs, In an alternative
embodiment, a secondary material that is inserted into the primary
golf club material, can be treated with laser surface
modification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic showing a putter with a laser surface
modified striking face.
[0021] FIG. 2 is a schematic showing an iron with a laser surface
modified striking face.
[0022] FIG. 3 is a schematic showing a driver with a laser surface
modified striking face.
[0023] FIG. 4 is a cross-sectional view of putter with a laser
surface modified striking face. The depth of penetration of the
laser modified material is indicated on the drawing.
[0024] FIG. 5 is a cross-sectional view of a driver with a laser
surface modified striking face. The depth of penetration of the
laser modified material is indicated on the drawing.
[0025] FIG. 6 is a cross-sectional view of an iron club with a
laser surface modified striking face. The depth of penetration of
the laser modified material is indicated on the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0026] With the present invention, it has been found that a laser
can be used to advantageously modify the chemical,
crystallographic, or topographical nature of the surface of a
material. These modifications can be particularly beneficial in the
case of golf club applications.
[0027] Non-limiting examples of some materials that may be included
in laser surface modification processing include steel alloys,
stainless steel alloys, titanium alloys, aluminum and its alloys,
aluminum oxide, zirconium dioxide, silicon carbide, silicon
nitride, polymeric materials, and rubber compounds.
[0028] In a major aspect, the present invention provides a method
of manufacture for a laser surface modified material. The
manufacturing method typically includes treating the material
surface with laser radiation. Nonlimiting examples of laser types
include carbon dioxide, yttrium aluminum garnet (YAG), or any type
of solid state semiconductor laser. Typical laser power for a
carbon dixoide laser ranges from 5-100 Watts. The focused spot size
is typically in the range of 125 microns (0.005 inches).
[0029] The head of the golf club can be manufactured through one of
the methods well-known in the prior art. Some examples include
casting, forging, and powder metallurgical methods. A typical
casting process, for example, consists of heating a metal alloy
above its melting temperature, thereby rendering a liquid metal.
The club can be cast into a hollow ceramic mold with the dimensions
that are desired in the finished piece. Alternatively, a unitary
mass of a ductile metal alloy can be forced into a mold cavity
while in a solid state, as in the forging process. After one of
these initial forming processes, the club can be finished by sand
blasting, plating, or some other surface finishing treatment,
dependent on the finish desired for the club. Furthermore, the
specific demarcations on the golf club, such as the company logo or
the club number, can be highlighted with paint for aesthetic
purposes.
[0030] In the current invention, the golf club head produced by any
of the above processes will then be subjected to laser surface
modification. In a typical laser process, the laser beam will be
focused onto the surface of the material to be treated. The laser
beam is turned on by means of an electronic controller which
initiates the laser power. In a general laser process, the laser
beam is emitted from the laser cavity and manipulated by a series
of lenses and mirrors to be focused onto the working surface of the
material to be modified. In a preferred embodiment, the laser is
pulsed on and off from 1 to 200 times per second. Each one of these
individual laser pulses modifies the surface of the material in a
very localized region, typically 0.1-100 microns. It is
particularly advantageous to move either the laser beam or the
material to be modified, in an effort to modify the surface of the
material in a large pattern. Several commercially available laser
systems have a computer-controlled table for mounting the sample.
The sample is then moved with the computer software, thereby
inscribing a pattern on the surface of the sample. In most
instances for the present invention, the spacing between the
individual laser pulses is very small, thereby making the pattern
indistinct.
[0031] There are several elements of the laser process that can be
varied to modify the amount of surface modification. Some examples
include ambient atmosphere and temperature, pulse period, pulse
width, gas pressure, and cone size. Each of these variables can be
tuned for the specific material to be modified. The type and power
of the laser depends on the type of material to be treated. For a
given material, an increase in laser power will increase the depth
of penetration into the material. In general, any laser will cause
a small change in the surface structure of a material. In the case
of the present invention, however, the power must reach a threshold
that depends on the type of material, to give the benefits
described for the striking face of a golf club.
[0032] An alternative embodiment for the laser surface modification
process can be applied to golf clubs composed of multiple
materials. It is well known in the prior art that multiple
materials can be beneficially incorporated into a single golf club
to improve the performance and feel. A secondary material,
generally referred to as an insert, can be modified similar to a
golf club composed of a single material. The laser settings must be
adjusted to an appropriate level depending on the material in the
insert. Too much laser power can cause excessive damage to the
material, while too little laser power can cause no beneficial
effect.
[0033] After the surface of the material has been modified with the
laser, the golf club head can be attached to a shaft. Typical shaft
materials can be composed of aluminum alloys, titanium alloys,
graphite reinforced polymers, or chrome-coated steel. The final
stage of the golf club assembly is to secure a grip to the opposite
end of the club from the club head. Typical grips are composed of
molded rubber or leather.
[0034] Referring now to FIG. 1, a golf putter is indicated with a
laser surface modified region 1, a club head 2, and a golf shaft 3.
The laser surface modified region can be any size relative to the
putter head, but will typically occupy 30-90% of the region on the
hitting face. Referring now to FIG. 2, a golf driver is indicated
with a laser surface modified region 4, a club head 5, and a golf
shaft 6. The laser surface modified region can be any size relative
to the driver head, but will typically occupy 30-90% of the region
on the hitting face. Referring now to FIG. 3, a golf iron is
indicated with a laser surface modified region 7, a club head 8,
and a golf shaft 9. The laser surface modified region can be any
size relative to the iron head, but will typically occupy 30-90% of
the region on the hitting face. FIGS. 4-6 show cross-sectional
views of the three different clubs with laser surface modified
striking faces. The depth of the laser surface modification 10 for
the putter 111 in FIG. 4 can vary from 0.001-1000 micrometers. The
depth of the laser surface modification 12 for the driver 13 in
FIG. 5 can vary from 0.001-1000 micrometers. The depth of the laser
surface modification 14 for the putter 15 in FIG. 6 can vary from
0.001-1000 micrometers.
* * * * *