TOUGHENED BULK METALLIC GLASS IN GOLF CLUB FACES AND OTHER STRUCTURAL APPLICATIONS
According to an embodiment, disclosed is a sport equipment, comprising: a golf club comprising bulk metallic glass (BMG) having one or more layers, wherein at least one layer comprises a three-dimensional geometric structure having cells, wherein a part of cells has an arched dome bottom. In another embodiment, disclosed is a method comprising taking a mold and injecting a bulk metallic glass (BMG) on the mold using an injection molding technique to form the BMG into a three-dimensional geometric structure having plurality of cells.
This application is related to U.S. Non-Provisional application Ser. No. 18/731,754, titled “DAMASCUS STEEL HITTING SURFACE ON GOLF IRONS”, which is incorporated herein by reference in its entirety.
FIELD OF INVENTIONThis disclosure relates to a toughened amorphous alloy and a method for preparing thereof, more particularly the disclosure relates to a toughened bulk amorphous alloy. In an embodiment, the disclosure relates to application of the toughened amorphous alloy in a sport equipment such as a golf club.
BACKGROUNDIn this section prior art is cited:
“The invention provides a method of manufacturing a golf club face plate having substantial thickness variation for enhanced performance. The method includes the steps of providing a rolled sheet of metal material having an initial thickness and forming a blank having a prescribed outer shape from the material. The method also includes machining a second side of the blank such that the resulting face plate has a variable thickness. The variable thickness includes a first thickness less than or equal to the initial thickness, a second thickness less than the first thickness and a third thickness less than the second thickness. The machining is performed over a substantial portion of the surface area of the second side.” [U.S. Pat. No. 6,904,663B2, titled, “Method for manufacturing a golf club face”].
“[A] golf club head having an improved striking surface. The golf club head of the present invention has a flat striking face, preferably being milled. This allows a greater degree of flatness than is typically seen. Preferably, the face is flat within ±0.002 inch. Grooves or score lines are then cut into the flattened face. Typically, grooves are formed in the face as part of the head-forming process. For example, if the head is cast, typical grooves are formed as part of the casting process. The face—including the grooves—is then subject to post-casting process steps, such as polishing. Similar finishing steps are also typically performed on club heads that are formed by forging. Machining grooves in the face after it has been milled beneficially saves them from being affected by any face post-manufacturing processes, which can adversely effect, for example, the groove-face interface, making it inconsistent along the length of the groove.” [U.S. Pat. No. 9,403,068B2, titled, “Golf club head having a grooved and textured face”].
There is a long felt need to have a golf club head made with materials that provide the golf club head with superior properties.
SUMMARYThe following is a summary to provide a basic understanding of one or more embodiments described herein. This summary is not intended to identify key or critical elements or delineate any scope of the different embodiments and/or any scope of the claims. The sole purpose of the summary is to present some concepts in a simplified form as a prelude to the more detailed description presented herein.
In an aspect the present disclosure relates to a sport equipment, comprising: a golf club comprising a substrate comprising bulk metallic glass (BMG) having one or more layers, wherein at least one layer comprises a three-dimensional geometric structure having cells, wherein a part of cells has an arched dome portion.
According to an embodiment, the three-dimensional geometric structure comprises a honeycomb structure.
According to an embodiment, the thickness of the cells of the honeycomb structure is at least 0.5 mm.
According to an embodiment, BMG comprises BMG composite structure.
According to an embodiment, a composite of BMG comprises an alloy, a metal, a synthetic material, a polymer, or a mixture thereof.
According to an embodiment, the alloy comprises a crystalline alloy or a fully amorphous alloy or a partially amorphous alloy.
According to an embodiment, the alloy comprises steel. In an embodiment, the steel comprises Damascus steel.
According to an embodiment, the polymer comprises a resin, rubber, plastic, and/or foam.
According to an embodiment, the metal comprises aluminum.
According to an embodiment, the second substrate is configured to withstand a temperature around 450° C. at the time of casting of the composite.
According to an embodiment, the synthetic material comprises plastic or epoxy resin.
According to an embodiment, a part of the cells of the honeycomb structure is at least partially filled with a filling material.
According to an embodiment, the filling material comprises a polymer or a fluid.
According to an embodiment, the fluid comprises a shear reducing fluid, a polymer, silicone, an epoxy resin, or a combination thereof.
According to an embodiment, the second substrate is laminated with a first substrate of the composite.
According to an embodiment, a filling material is sandwiched between the first substrate and the second substrate.
According to an embodiment, the substrate having the three-dimensional geometric structure comprises an injection molded substrate.
According to an embodiment, the thickness of the cells of the honeycomb structure of the substrate is less than 5 mm.
According to an embodiment, a ratio of length to thickness of the cells of the honeycomb structure of the substrate is less than 0.5.
According to an embodiment, the second substrate is configured to be coated, glued, or overlaid with the first substrate.
In another aspect, the present disclosure relates to a method comprising taking a mold and injecting a bulk metallic glass (BMG) on the mold using an injection molding technique to form the BMG into a three-dimensional geometric structure having plurality of cells.
According to an embodiment of the method, the three-dimensional geometric structure comprises a honeycomb structure.
According to an embodiment of the method, a part of cells of the honeycomb structure comprises an arched dome structure.
According to an embodiment of the method, a second substrate is added over a first substrate, the first substrate comprising the said BMG.
According to an embodiment of the method, a second substrate is added with a first substrate, the first substrate comprising the said BMG to form a molded structure together.
According to an embodiment of the method, the second substrate is configured to withstand a temperature of about 400° C. or more at the time of molding or casting the material.
According to an embodiment, the second substrate is coated on the first substrate.
According to an embodiment, the second substrate is laminated on the first substrate.
According to an embodiment, the second substrate is glued to the first substrate.
According to an embodiment, further comprises adding a fluid between the first substrate and the second substrate.
According to an embodiment, the fluid comprises a gas or a liquid.
According to an embodiment, the liquid comprises a shear thickening fluid.
According to an embodiment, the fluid is configured to fill a part of cells of the honeycomb structure.
According to an embodiment, the fluid is configured to fill a part of voids formed between the first substrate and the second substrate.
According to an embodiment, the thickness of the cells of the honeycomb structure of the substrate is at least 0.5 mm.
According to an embodiment, the ratio of length to thickness of the cells of the honeycomb structure is less than 0.5.
Aspects of the present invention will now be described in more detail, with reference to the appended drawings showing exemplary embodiments of the present invention, in which:
For simplicity and clarity of illustration, the drawing Figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawing Figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the Figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numerals in different Figures denotes the same elements.
The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.
The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
No element, act, or instruction used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include items and may be used interchangeably with “one or more.” Furthermore, as used herein, the term “set” is intended to include items (e.g., related items, unrelated items, a combination of related items, and unrelated items, etc.), and may be used interchangeably with “one or more.” Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements mechanically and/or otherwise. Two or more electrical elements may be electrically coupled together, but not be mechanically or otherwise coupled together. Coupling may be for any length of time, e.g., permanent, or semi-permanent or only for an instant. “Electrical coupling” and the like should be broadly understood and include electrical coupling of all types. The absence of the word “removably,” “removable,” and the like near the word “coupled,” and the like does not mean that the coupling, etc. in question is or is not removable.
As defined herein, “approximately” or “about” or “substantially” or similar can, in some embodiments, mean within plus or minus ten percent of the stated value. In other embodiments, “approximately” or “about” can mean within plus or minus five percent of the stated value. In further embodiments, “approximately” or “about” can mean within plus or minus three percent of the stated value. In yet other embodiments, “approximately” or “about” can mean within plus or minus one percent of the stated value.
Unless otherwise defined herein, scientific, and technical terms used in connection with the present disclosure shall have the meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities, and plural terms shall include the singular. Generally, nomenclatures used in connection with, and techniques of, health monitoring described herein are those well-known and commonly used in the art.
The methods and techniques of the present disclosure are generally performed according to conventional methods well known in the art and as described in various general and more specific references that are cited and discussed throughout the present specification unless otherwise indicated. The nomenclatures used in connection with, and the procedures and techniques of embodiments herein, and other related fields described herein are those well-known and commonly used in the art.
The following terms and phrases, unless otherwise indicated, shall be understood to have the following meanings.
“Crystalline material” is defined as a solid material whose constituents (such as atoms, molecules, or ions) are arranged in an ordered microscopic structure, forming a crystal lattice that extends in all directions. Crystals are also defined as crystalline material.
“Composites” or a composite material or similar is broadly defined as a material made from two or more constituent materials with similar or different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure, differentiating composites from mixtures and solid solutions. A composite is made up of several parts or elements or, with respect to constructional material, made up of recognizable constituents.
“Laminate” is a material formed by bonding two or more different materials together.
In an embodiment, laminate refers to a specific type of composite that consists of multiple layers (or “laminates”) bonded together, often with adhesives.
A “three-dimensional geometric structure” is a shape that has length, width, and height, occupying space in a three-dimensional environment. In an embodiment, three-dimensional geometric structures can be trapezoidal shaped, circular or semi-circular, ovular or semi-ovular, square, rectangular, or triangular, hexagonal shaped peaks and valleys in shape. However, the 3-dimensional geometric structure is not limited to these shapes and may take any shape suitable to create the desired 3D pattern in the sheet.
“Honeycomb structure” includes honeycomb structure as well as honeycomb-like structures. They derive inspiration from natural honeycomb formations in organisms such as bees and plants, offering combinations of strength, flexibility, and energy absorption. There are several honeycomb-like configurations, for example, hexagonal grids featuring a repeating hexagonal pattern of cells to for efficient packing, beehives, and lightweight panels. Origami-inspired techniques create complex folding patterns resulting in honeycomb-like structures with tailored mechanical properties, beneficial in deployable structures and biomedical applications. Fractal-based structures utilize self-similar patterns at different scales, providing scalability, multifunctionality, and structural efficiency. Chiral honeycombs feature helical or spiral arrangements, offering tunable stiffness and anisotropic behavior. While not strictly honeycomb-like, certain auxetic structures with cellular arrangements resembling honeycombs exhibit unique mechanical properties like enhanced energy absorption and increased fracture toughness.
“Arched dome structure” refers to an architectural element like a hollow half hemisphere.
“Sports equipment” refers to the tools, gear, or apparatus used in various sports and physical activities. This can include items necessary for playing a sport, training, or ensuring safety. The sport equipment is designed to enhance performance, ensure safety, or improve the overall experience of the sport. Various examples of sports equipment, without limitation, are golf balls, golf clubs, racquets, etc.
“Golf club” refers to a tool used by golfers to hit a golf ball. They are designed to provide different trajectories, distances, and control for various shots on the golf course. A golf club typically has a shaft with a lance (grip) and a golf club head.
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- The Grip: The grip of the golf club is important because it connects the club to the golfer's hands. According to the rules of golf, the grip has to be round, without obvious bumps, lumps, or hollows.
- The Shaft: The shaft of the golf club connects the grip to the head.
- The Head: The head of the golf club is where all the energy of the swing is transferred to the golf ball. There is more variation in the appearance of golf club heads than there is in either shafts or grips.
“Polymers” is a macromolecule compound prepared by polymerizing monomers of the same or different type. Polymers include homopolymers, copolymers, terpolymers, tetra polymers, and so on. “Homopolymer” is a polymer by polymerizing one monomer and having that same repeating unit in the polymer chain. “Copolymer” is a polymer derived from more than one species of monomers or comonomers. “Terpolymer” is a polymer made by polymerizing three different monomers and “Tetrapolymer” is a polymer by polymerizing four different monomers, and so on.
“Plastic” is an organic polymer, primarily composed of carbon-based compounds. They are classified by their chemical structure of the polymer's backbone and side chains. Important groups classified in this way, without limitation, include acrylics, polyesters, silicones, polyurethanes, and halogenated plastics. The plastic can be a flexible plastic, a rigid plastic, a semi-flexible plastic or a combination thereof.
“Synthetic materials” are man-made materials created through chemical processes, designed to mimic, or enhance the properties of natural materials. The examples of synthetic materials are, but not limited to, plastics, epoxy resin, rubbers, and composites.
“Resin” is a natural or a synthetic material that could be converted into polymers. Resin is widely used in various applications due to its durability, flexibility, and ability to be molded into different shapes. Various exemplary synthetic resin such as, but not limited to, acrylic resins, vinyl acetate resins, vinyl pyrrolidone resins, urethane resin, epoxy resin and vinyl methyl ether resins, of varying ionicity such as anionic, cationic, nonionic or amphoteric ionicity, are widely known and contemplated herein.
“Foam or foamed material” or similar is broadly defined as are two-phase material systems where a gas is dispersed in a second, non-gaseous material, specifically, in which gas cells are enclosed by a distinct liquid or solid material. Solid foams can be closed-cell or open-cell. In closed-cell foam, the gas forms discrete pockets, each completely surrounded by the solid material. In open-cell foam, gas pockets connect to each other. In an embodiment, the multicellular open-cell or closed-cell foam exhibits a unique balance of properties such as high energy efficiency or energy return, and low specific gravity. (Exemplary foams may be found in U.S. Pat. No. 9,437,372, U.S. Ser. No. 12/004,590B2, U.S. Ser. No. 11/155,009B2, U.S. Ser. No. 11/952,455B2, etc. the disclosure of each of which are incorporated herein by reference.) Other foam or foaming materials understood by a person skilled in the art are contemplated herein.
“Shear thickening fluid” or “STF” as used interchangeably herein, are also known as non-Newtonian fluids and/or dilatants. STFs are generally comprised of a suspension media (typically polymer-based) and inorganic colloidal particles of relatively uniform size. Normally, the STF can flow easily when force or high velocity is not applied. Under increased stress or strain at higher velocities or with elevated pressure, the STF rapidly stiffens or solidifies in response to the increased force because of higher viscosity and/or the alignment of the spherical particles within the suspension media. Importantly, this stiffening effect is a dynamic process with a rapid “on and off rate”, making the material, housing the STF, both elastic and resilient. Exemplary shear thickening fluids may be found in U.S. Pat. No. 9,193,890, the disclosure of each are incorporated herein by reference. Variants of STFs understood by a person skilled in the art are contemplated herein.
“Injection molding method” is a well-known process in metallurgy. It generally involves a mold chamber, or cavity, corresponding to the desired shape of an article to be molded and formed between two mold portions, one of which is movable to allow removal of the article upon completion of the process. After the mold is closed, the molding composition is injected under pressure and in a molten state through a nozzle into a runner network and in turn to individual cavities through sprues and on through connecting passageways or runners and through an opening or gate into the mold cavity or cavities. Other variants of injection molding as disclosed in U.S. Pat. Nos. 4,128,613, 6,884,381, and as understood by a person skilled in the art are contemplated herein.
“Coating” refers to a layer of material applied to the surface of an object.
“Gluing” refers to the process of joining two or more materials together.
“Metal” or “metallic” refers to an electropositive chemical element.
“Amorphous”, unlike crystalline material, lacks long-range order. It is also characterized by random atomic orientation. It excludes partially crystalline and metastable crystalline metal alloys. Amorphous material comprises at least 50% amorphous phase by volume, preferably at least 80% amorphous phase by volume, and most preferably at least 90% amorphous phase by volume, and is determined by any of the following techniques: X-ray diffraction, scanning electron microscopy, transmission electron microscopy, and differential scanning calorimetry.
An “amorphous alloy” is an alloy having an amorphous content of more than 50% by volume, preferably more than 90% by volume of amorphous content, more preferably more than 95% by volume of amorphous content, and most preferably more than 99% to almost 100% by volume of amorphous content, as determined by any of the following techniques: X-ray diffraction, scanning electron microscopy, transmission electron microscopy, and differential scanning calorimetry. An alloy high in amorphicity is equivalently low in degree of crystallinity.
An “amorphous metal” is an amorphous metal material with a disordered atomic-scale structure. In contrast to most metals, which are crystalline and therefore have a highly ordered arrangement of atoms, amorphous metals are non-crystalline. Materials in which such a disordered structure is produced directly from the liquid state during cooling are sometimes referred to as “glasses.” Accordingly, amorphous metals are commonly referenced as “metallic glasses” or “glassy metals.”
Nonetheless, the manufacture of metallic glasses presents challenges that limit their viability as engineering materials. In particular, metallic glasses are typically formed by raising a metallic alloy above its melting temperature, and rapidly cooling the melt to solidify it in a way such that its crystallization is avoided, thereby forming the metallic glass. The first metallic glasses required extraordinary cooling rates, e.g., on the order of 106 K/s, and were thereby limited in the thickness with which they could be formed. Indeed, because of this limitation in thickness, metallic glasses were initially limited to applications that involved coatings. Since then, however, particular alloy compositions that are more resistant to crystallization have been developed, which can thereby form metallic glasses at much lower cooling rates and can therefore be made to be much thicker (e.g., greater than 1 mm). These thicker metallic glasses are known as ‘bulk metallic glasses’ (“BMGs”).
“Bulk-solidifying amorphous alloys,” or bulk metallic glasses (“BMG”), are a recently developed class of metallic materials. These alloys may be solidified and cooled at relatively slow rates, and they retain the amorphous, non-crystalline (i.e., glassy) state at room temperature. Amorphous alloys have many superior properties, e.g., physical properties, than their crystalline counterparts. However, if the cooling rate is not sufficiently high, crystals may form inside the alloy during cooling, so that the unique benefits of the amorphous state can be lost. For example, one challenge with the fabrication of bulk amorphous alloy parts is the partial crystallization of parts due to cither slow cooling or impurities prevalent in the raw alloy material. As a high degree of amorphicity (and, conversely, a low degree of crystallinity) is desirable in BMG parts, there is a need to develop methods for casting BMG parts having predictable and controlled amounts of amorphicity. The terms “bulk metallic glass” (“BMG”), bulk amorphous alloy (“BAA”), and bulk solidifying amorphous alloy are used interchangeably herein.
Over the past twenty years many bulk metallic glass compositions have been discovered. See, e.g., U.S. Pat. Nos. 5,288,344; 6,325,868, A. Inoue et al., Appl. Phys. Lett., Volume 71, p 464 (1997); Shen et al., Mater. Trans., JIM, Volume 42, p 2136 (2001); and Japanese patent application 2000126277 (Publ. #0.2001303218 A); and C. C. Hays et al., Physical. Review Letters, Vol. 84, p 2901, (2000), all of which are incorporated herein by reference.
In an embodiment, bulk metallic glass includes alloys containing Zr, Cu, Ni, Al, Ti, Hf, Si, B, C, P, Co, Fc, Mo, or combinations thereof. In addition to monolithic bulk metallic glasses, a number of composite bulk metallic glass materials that incorporate particulate reinforcements such as, SiC, diamond, carbon fiber and metals such as Molybdenum, or have a dendritic phase reinforcement, have also been discovered. Sec, e.g., U.S. Pat. Nos. 5,886,254; 5,567,251; 5,288,344; 5,368,659; 5,618,359; 11,407,058 and 5,735,975; the disclosures of which are incorporated herein by reference. It should be understood that in the context of the current application, any bulk metallic glass compositions as understood by a person skilled in the art may be used to form a bulk composite material as described in one or more embodiments of the disclosure.
In some embodiments of the disclosure, bulk metallic glasses are metallic glass. In an embodiment, the BMG includes BMG composites.
Problem in Existing Knowledge: Currently, the brittleness has been the critical weakness of bulk metallic glasses (BMG). Despite having tensile strengths that are often 2× of its crystalline counterparts, bulk metallic glasses have not been able to find wide acceptance due to their catastrophic failure mode. When a crack is initiated, it propagates quickly across the entire cross section.
Monolithic solid BMG structures do not work hardened, they are somewhat brittle, and thus lack the mechanism to blunt crack propagation. This can be compared to large pieces of glass that shatter suddenly when a small crack is initiated.
From
In the prior art, much effort had been put forth to increase toughness of BMG through composition variations. Although there have been slight variations in toughness between the various compositions, the basic fact of lacking a mechanism to blunt crack propagation remained the same. In addition, efforts to grow dendritic crystalline structures within the BMG structure have yielded little results. These materials exhibited extreme shrinkage during casting and often developed cracks within the BMG portion of the matrix.
Further, laminating BMG sheets, like silica glass sheets, has also been attempted. This would result in similar gains in toughness. However, this does not allow for 3-Dimensional casting and complex geometrics.
In accordance with an embodiment, the following three broad methods can be deployed to increase working toughness of bulk metallic glass.
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- i. Spreading the strain over the wider percentage of the structure.
- ii. Reducing and altering the transmission path of vibration.
- iii. Laminating BMG with crystalline alloys, plastic, or other synthetic materials that can help to blunt crack propagation and reduce vibration. (This lamination can take place where honeycombs are filled with polymers and fluids).
In an embodiment, by combining structures that can distribute and spread a given load over a wider area of the structure and allowing the entire structure to elastically stretch, net stress and elastic load applied to a specific area of BMG can be reduced.
In an embodiment, the BMG structure can be designed to fully utilize the elastic properties of BMG while maintaining a significant margin of safety in terms of material toughness and durability.
In an embodiment, certain structures can disperse strain. For example, a coil or a honeycomb structure bonded to a flat plate can help to distribute the load over a wider area. This property can be illustrated by the pulley system where the 100 kg weight is spread out by multiple pulleys. Specific load carried by each segment of the rope is divided by the number of pulleys, as shown in
In an embodiment, having the strain spread over the structure versus a localized area, greatly reduces the stress and strain experienced by a specific area. The pulley and honeycomb structure illustration in
LOAD IS DISBURSED TO THE ENTIRE COIL SPRING: In an embodiment, coil springs, where the structure can stretch and compress far beyond elastic limits of given materials, incorporating, and allowing the shape of the material itself to flex. disperse and reduce stress and strain concentration to a specific area.
In an embodiment, open cell honeycomb structure's function similar to the coil spring to distribute the load over the entire structure.
In an embodiment, a honeycomb structure flexes well beyond the 2% limit of solid BMG structures, and its shape changes to accommodate stress. The BMG structure is springy and tough. Therefore, the hitting surface could be made comprising 100% BMG material with honeycomb structure or honeycomb-like structures.
In an embodiment, other honeycomb-like structures in the material can be designed for similar advantages to traditional honeycomb designs. For example, foam structures, including foam plastics and metal foams, replicate the cellular arrangement of honeycombs and provide lightweight, high-strength, and energy-absorbing properties. Truss structures, consisting of interconnected beams or struts in a repeating pattern, offer high strength-to-weight ratios and customizable load-bearing capabilities. Lattice structures, composed of interconnected beams or nodes in a 3D framework, exhibit comparable mechanical properties to honeycombs. Grid structures, featuring interconnected rods or beams in a grid pattern, offer high stiffness and case of fabrication. Woven structures, formed by interlaced fibers or filaments, provide flexibility, durability, and formability. Tubular structures, comprising interconnected tubes, offer lightweight, flexible, and energy-absorbing properties. Corrugated structures, characterized by repeating folds or ridges, offer enhanced stiffness and strength while maintaining lightweight construction.
The honeycomb structure offers advantages due to its unique geometric configuration due to high strength-to-weight ratio, reducing weight without compromising strength. The design distributes loads, enhancing its capacity to bear heavy weights. Honeycomb structures excel in energy absorption providing impact protection. Honeycomb structures can be designed for good clastic behavior, making them advantageous for flexibility and resilience. The configuration of honeycomb cells allows these structures to deform elastically under stress and return to their original shape once the load is removed. This clastic behavior is beneficial in enhancing shock absorption, enabling mitigation impacts, reducing damage to the impact prone surface. Additionally, the clastic properties help in damping vibrations for reducing wear and tear. The flexibility and resilience of honeycomb structures make them suitable for repeated loading and unloading of golf club heads. The elastic behavior may be tailored by adjusting cell size, shape, and material, allowing precise control over the mechanical properties to meet specific requirements as designed. Furthermore, the ability to withstand cyclic loading without significant degradation in performance enhances the fatigue resistance and extends the lifespan of the hitting surface. The calibrated clastic behavior of honeycomb structures provides a balance of flexibility, strength, durability, and aesthetics making them a suitable design for resilience and structural integrity.
Arched dome portions toughen critical parts of the structure. In an embodiment, more than 25%, more than 50%, more than 60%, more than 70%, more than 80%, more than 90% or more of cells of the said structure have dome bottoms. In another embodiment, all the cells of the honeycomb structure have arched dome bottoms.
In an embodiment, BMG can be induced to exhibit ductile failure modes. Honeycomb structures utilize geometries to induce elastic buckling.
In an embodiment, the thickness of the cells of the honeycomb structure of the substrate is at least about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm or higher.
In an embodiment, the thickness of the cells of the honeycomb structure of the substrate is less than 5 mm, less than 4.5 mm, less than 4 mm, less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.5 mm, less than 1 mm, or less than 0.5 mm.
In an embodiment, distance between a cell is about 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm of more.
In an embodiment, depth of arched domed structure in Z-direction is about −1 mm, −1.5 mm, −2 mm, −2.5 mm, −3 mm, −4 mm or more.
In an embodiment, a key factor that determines strength of structure is l/t (length to thickness ratio). When l/t decreases from 50 to 2.5, the honeycomb's strength increases by two orders of magnitude: ˜1 MPa for l/t=50 (ρ*/ρs=2.3%) up to 300 MPa for l/t=2.5 (ρ*/ρs=41.0%), indicating a nonlinear relationship with density. In an embodiment, l/t ratio of 5 or less for dimensions is employed in a honeycomb structure.
In an embodiment, a ratio of length to thickness of the cells of the honeycomb structure of the substrate is less than 0.5, less than 0.45, less than 0.4, less than 0.35, less than 0.3, less than 0.25, less than 0.2 or less. In an embodiment, a ratio of length to thickness of the cells of the honeycomb structure of the substrate is less than 5, less than 4, less than 3, less than 2, less than 1, less than 0.5 or less.
In an embodiment, lack of macroscopic plasticity is considered the Achilles' heel of BMGs and has prevented wide-spread proliferation of BMGs as a structural material. However, when BMGs are used in geometries where one dimension is below about 10 times its critical crack length (˜1 mm for a medium range Zr-based BMG), they exhibit significant bending plasticity. This feature, and other size effects have been widely explored in foams to design overall plasticity. In addition to the potential for microstructural architecture design, the unusual high ratio of yield strength over modulus of BMGs suggests that a transition from plastic yielding to elastic buckling can be realized for practical l/t ratios (l: ligament length, t: ligament thickness).
Dispersion and Distribution of Strain.1. INCREASED LOAD CAPACITY—By combining honeycomb structures behind the BMG face, one can increase the load strength of the combined structure to be multiple that of a monolithic solid structure for specific weight. This structure can also be designed to fail plastically.
In an embodiment, one method to avoid brittle fracture is to make the wall sections thin enough to buckle elastically.
The strengths of the out-of-plane structures are about 5-10 times higher than for the in-plane structures.
2. ELASTIC AND TOUGH—During impact, such as with a golf ball, the striking surface of the club goes into compression, while the back structure is under tension.
In an embodiment, a honeycomb structure made of wall sections (about 0.5 mm) can easily accommodate 10% strain which far exceeds the 2% elastic limit of BMG. Honeycomb BMG structure increases compressive strength, toughness, and elasticity.
As shown in
In an embodiment, the honeycomb structure disrupts the propagation of cracks. However, the honeycomb structure disrupts the vibration and the strain of the initial crack from traveling through the structure in a single plane or line. This division of strain from a singular plane/line to multiple directions divides the level of strain that must be managed at each critical point. Thus, a crack being blunted by the honeycomb structure is observed.
According to an embodiment, from
In an embodiment, golf club head is 100% BMG material wherein the front side and the back side of the golf club head are made of the BMG material.
In another embodiment, golf club head can be a hybrid casting material wherein the front side of the golf club head can be made of Damascus steel and the back side of the golf club head can be made of BMG honeycomb structure. In the hybrid casting material, the materials are molded together to form a single piece for the advantage of the honeycomb structure to control propagation of the crack as quickly as possible.
The BMG honeycomb structure disperses the strain. It disrupts the strain going forward and behaves like a spring coil that compresses when load/stress is applied and decompresses when the load/stress is removed. The BMG honeycomb structure shares the load rather than stretching the Damascus steel. Thus, only one specific area does not experience the stress rather it is distributed over a wide area due to the presence of BMG honeycomb structure according to an embodiment.
In an embodiment, in order to overcome the cracking issue, the surface can be formed by either laminating more than one layer of BMG and or incorporating honeycomb like structures to toughen the BMG structure. According to an embodiment, a hitting surface may be 100% made of bulk metallic glass (BMG) material comprising honeycomb structure. For attaching the BMG structure to a shell, adhesives and/or screw types of attachments may be used where welding would affect the properties of amorphous alloys.
In an embodiment, the second substrate is laminated on a first substrate of the composite.
Layered Structure of BMG HoneycombAccording to an embodiment, layered honeycomb structure is made with BMG, where multiple layers of the BMG honeycomb structures are bonded together, further increases toughness of such structure.
In an embodiment, the composite layered structure of BMG structure (honeycomb) includes casting BMG material with a variety of materials together that can blunt crack propagation. For example,
In an embodiment, the BMG composite material is hot formed around 450° C. This process can be accomplished with various alloys and synthetic materials that can withstand this temperature. Another process is to mold BMG with other alloys during the injection process. Both of these steps allow BMG to bond intimately.
Composite structures can leverage the various advantages of materials (second material) being combined, such as:
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- (a) Low Density materials, such as aluminum, carbon fiber, graphene, which help to reduce the overall weight of the matrix.
- (b) Kelvar and Carbon Fiber which can increase stiffness.
- (c) Foam and corrugated structures which can increase energy absorption.
- (d) Polymers and rubber which can mold onto BMG and provide sound and vibration absorption.
In an embodiment, the second material/substrate can withstand a temperature around 450° C., around 440° C., around 430° C., around 420° C., around 410° C. or around 400° C.
In an embodiment, the second substrate could be Damascus steel.
Damascus steel has high strength and is resistant to cracking. By folding layers of steel up to 1,000,000 layers, Damascus steels maximize strength and hardness with minimal loss of toughness. Damascus steel is renowned for its unique patterned appearance and excellent strength. Traditionally, it was produced by forging layers of different types of steel together, resulting in a distinctive wavy pattern on the surface. While the traditional Damascus steel was primarily used for blades, modern versions can be found in various applications, including knives, jewelry, and even watches.
In an embodiment, the hardness of the Damascus steel may be approximately around 59 to 65 Rockwell Hardness Scale, HRC. Achieving a hardness level above 45 HRC requires careful selection of the steel alloys used in the layering process and proper heat treatment techniques. In an embodiment, the hardness of the Damascus steel may be at least 45 HRC. In an embodiment, the hardness of the Damascus steel may be at least 50 HRC. In an embodiment, the hardness of the Damascus steel may be at least 55 HRC. In an embodiment, the hardness of the Damascus steel may be in the range of 40-60 HRC.
The process of creating German Damascus steel involves forging together layers of different steel alloys to create a billet. These layers are typically composed of high-carbon steel and low-carbon steel or iron, which have contrasting properties. The high-carbon steel provides hardness and edge retention, while the low-carbon steel or iron contributes to toughness and flexibility. The layers of steel are stacked and then heated to a high temperature. Once the billet reaches the correct forging temperature, it is hammered and folded to create a homogeneous and layered structure. This folding process helps to distribute the carbon content evenly throughout the material and create the characteristic patterns seen on the surface.
After the folding and forging process, the steel billet is often twisted, manipulated, or otherwise patterned to enhance the visual appeal. The precise patterns created during this stage can vary, ranging from intricate swirls to more uniform ladder or raindrop patterns. These patterns are a result of the alternating layers of different steel alloys.
German Damascus steel is known for its visual beauty and the contrast between the light and dark layers of steel. The intricate patterns created by the layering and folding process give each piece a unique and distinctive appearance. In terms of its properties, German Damascus steel offers a combination of hardness, toughness, and corrosion resistance. The high-carbon steel layers provide excellent edge retention and hardness, while the low-carbon steel or iron layers contribute to the overall strength and durability of the material.
Stainless Damascus steel takes this concept further by incorporating stainless steel alloys into the layering process. Stainless steel is known for its corrosion resistance, making it suitable for applications where maintaining a rust-free surface is essential. By combining the aesthetics and strength of Damascus steel with the corrosion resistance of stainless steel, stainless Damascus steel offers a balance between functionality and visual appeal. One important characteristic of stainless Damascus steel is its hardness. Hardness is typically measured on the Rockwell Hardness Scale (HRC), which measures the resistance of a material to indentation or penetration. Achieving a hardness level above 45 HRC requires careful selection of the steel alloys used in the layering process and proper heat treatment techniques.
Stainless Damascus steel is created through a process called pattern welding or layering. In this process, layers of different steel alloys are forged together, and then the billet (a solid block of layered steel) is repeatedly folded, twisted, and manipulated to create the desired pattern. The number of layers and the complexity of the folding process contribute to the final visual appearance of the steel.
The specific stainless-steel alloys used in the layering process can vary depending on the manufacturer and the desired properties of the final product. Common stainless-steel alloys used in stainless Damascus steel include various grades of stainless steel such as 304, 316, or 440C. These alloys are known for their high strength, corrosion resistance, and wear resistance.
To achieve the desired hardness of 45 HRC or higher, the stainless Damascus steel undergoes heat treatment. Heat treatment involves a combination of heating, quenching, and tempering processes. Heating the steel to specific temperatures and then rapidly cooling it (quenching) helps to increase its hardness, while tempering reduces brittleness and improves toughness.
Stainless Damascus steel offers excellent hardness and corrosion resistance. The actual performance of the golf club made from this material can also depend on other factors, such as the design, geometry, and overall craftsmanship of the item. Stainless Damascus steel combines the desirable qualities of stainless steel and Damascus steel, resulting in a visually stunning material with high hardness and corrosion resistance.
German Damascus steel and Stainless Damascus steel are similar in many ways but also have notable differences:
Similarities:
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- i). Layering Technique: Both German Damascus steel and Stainless Damascus steel are created using a layering technique. Layers of different steel alloys are forged together to create a billet, which is then manipulated, folded, and patterned to achieve the desired appearance.
- ii). Visual Appeal: Both types of Damascus steel are prized for their aesthetic qualities. They exhibit unique patterns and textures on the surface, which are a result of the layering and folding process. These patterns can vary in complexity and add visual interest to the finished product.
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- iii). Steel Alloys: The main difference between German Damascus steel and Stainless Damascus steel lies in the steel alloys used in their production. German Damascus steel typically incorporates high-carbon steel and low-carbon steel or iron. The high-carbon steel provides hardness and edge retention, while the low-carbon steel or iron contributes to toughness and flexibility. On the other hand, Stainless Damascus steel combines stainless steel alloys with Damascus steel techniques. Stainless steel alloys are known for their corrosion resistance, making Stainless Damascus steel suitable for applications where rust prevention is crucial. The stainless-steel alloys used can vary but often include grades such as 304L, 316L, or 440C.
- iv). Corrosion Resistance: While both types of Damascus steel possess unique patterns, Stainless Damascus steel has the added advantage of enhanced corrosion resistance due to the incorporation of stainless-steel alloys. This makes it more suitable for applications where exposure to moisture, humidity, or corrosive environments is a concern.
- v). Hardness: German Damascus steel often prioritizes achieving high hardness levels to enhance edge retention and cutting performance. On the other hand, Stainless Damascus steel may have slightly lower hardness levels due to the inclusion of stainless-steel alloys, which can sacrifice some hardness in favor of improved corrosion resistance.
Both German Damascus steel and Stainless Damascus steel share similarities in terms of the layering technique and visual appeal, their differences lie in the steel alloys used, corrosion resistance, hardness levels, and applications. German Damascus steel emphasizes hardness and cutting performance, while Stainless Damascus steel prioritizes corrosion resistance while still offering attractive patterns. Golf club heads produced using the German Damascus steel or Stainless Damascus steel can be custom designed.
In an embodiment, the second substrate is configured to be coated, glued, or overlaid on the first substrate.
In an embodiment, polymers, crystalline alloys, carbon fibers are few examples of materials that can be sandwiched between the honeycomb structure.
In an embodiment, the bulk metallic glass (first substrate) is molded with plastic (second substrate).
In an embodiment, the bulk metallic glass is shaped with a plastic mold.
In an embodiment, the bulk metallic glass is shaped from a mold and placed on the plastic.
In an embodiment, the concept is, whether it's glue, resin, epoxy or plastic, over molding, the whole idea is, when a very specific area is experiencing strain and vibration, we want to move that away, transfer it and share that load to other areas as quickly as possible, and or reduce the amount of vibration. So, glue, resin, any of the things, they vibrate at a different frequency than liquid metal. So, when they're intimately bonded together, we find that it reduces the ultimate magnitude of the load and the vibration.
In an embodiment, bonding different materials use glue which is effective at reducing vibration.
In an embodiment it is possible to over mold plastic in sections that are 0.5 mm or less in accordance with an embodiment. This combined thickness of the metallic glass section and plastic is about 1.00 mm.
In an embodiment, the honeycomb structure is under out of plane compression and also in combination with a solid plane (either BMG or crystalline alloy).
Reduction of Vibration PropagationVibration plays a disproportionate role in BMG in terms of how strain is transmitted through the plane of the initial crack. Disrupting the linear transmission of strain and vibration increases overall toughness of BMG.
1. DISRUPTION OF VIBRATION TRAVELING THROUGH THE BODY OF THE MATERIAL—Whereas the crack or breakage in crystalline metallic structure would begin from the area of maximum strain and stop as the strain is reduced away from the focal point of the strain, metallic glass structures do not have a mechanism of work hardening and thus blunting the propagation of cracks.
Because resonance causes the amplitude of vibration to increase, the oscillations may exceed the elastic limit of the material and damage it. Even resonance produced by sound waves can cause a material to break, such as when a glass goblet is shattered by sound.
METHODS TO REDUCE GENERATION AND TRANSMISSION OF VIBRATION WAVES—When water is added to a wine glass, it slows down the vibration because the water volume in contact with the wall makes it effectively heavier and as a dampening medium absorbs some of the energy. This changes the vibrating shape of the glass cup by effectively adding mass to the walls and the resonant drops in frequency.
In accordance with an embodiment, the methods to reduce this vibration transmission will significantly alter the fracture toughness of metal glass by following at least one of the methods:
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- Polymer either between the BMG layers or inside honeycomb structures themselves.
- Water or fluids between the BMG layers or inside honeycomb structures.
- Shear thickening fluid-filled honeycomb structures.
- Layered laminate structure with materials with dissimilar harmonic frequencies.
Layered Structure of BMG Honeycomb Filled with Fluids or High-Pressure Gas.
In an embodiment, filling the empty voids created between layered BMG honeycomb structures with fluids or pressurized gas can further modify how a specific load on the structure can be distributed. Since fluids do not compress under compressive load, such a structure can be ideal for Armor type of structure, where the kinetic energy of a bullet can be quickly distributed through the armor. This reduces the kinetic energy bearing on the area of impact.
“Void” is a portion that remains unfilled in a material. It is gaps or spaces that extend in the space between the top and bottom ends. It is also defined as empty space, opening, gap, the quality of being without something.
The term “filling material” refers to a material that is used to fill a portion of the cell and/or voids or similar. The filling material could fill about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or more of the volume of a cell. In an embodiment, filling material is a noise damping material.
In an embodiment,
In an embodiment,
In an embodiment, 10% of the total cells of the structure are filled with a filling material. In an embodiment, 20% of the total cells of the structure are filled with a filling material. In an embodiment, 30% of the total cells of the structure are filled with a filling material. In an embodiment, 30% of the cells are filled with a filling material. In an embodiment, 40% of the total cells of the structure are filled with a filling material. In an embodiment, 50% of the cells are filled with a filling material. In an embodiment, 60% of the total cells of the structure are filled with a filling material. In an embodiment, 70% of the total cells of the structure are filled with a filling material. In an embodiment, 80% of the total cells of the structure are filled with a filling material. In an embodiment, 90% of the total cells of the structure are filled with a filling material. In an embodiment, almost all the cells present in the structure are filled with a filling material.
In an embodiment, the filling material not only fills the cells of the honeycomb structure but also forms a coat over the BMG honeycomb structure.
In an embodiment, the filling material only fills the cells of the honeycomb structure but does not form a coating over the honeycomb structure.
In an embodiment, filling of the material such as fluid could be accomplished after the laminates are formed. The voids left between the laminates are filled by the fluids. The filling material could fill about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or more of the volume of voids created between layered structures.
In an embodiment, a part of the cells of the honeycomb structure is at least partially filled with a filling material.
In another embodiment, the cells and/or voids can be filled with water or other fluids after the forming/molding step.
In an embodiment, the honeycomb cells are not open.
In an embodiment, the filling material comprises a polymer or a fluid.
In an embodiment, the fluid comprises a shear reducing fluid, a polymer, silicone, or an epoxy resin, or a combination thereof.
In an embodiment, the filling material is sandwiched between the first substrate and the second substrate of the composite structure.
Shear thickening fluid-filled honeycomb: “This study demonstrates the enhanced dynamic mechanical behavior of an in-plane honeycomb when they are filled with shear thickening fluid (STF). The mean crushing force of STF-filled honeycomb is about 22.97% higher than that of unfilled honeycomb at 10 m/s, and this ratio is significantly enlarged with higher compressive loading velocity (approximately 129.2% higher at 40 m/s). Moreover, due to the fluid-structure coupling effect between honeycomb and STF, it provides evenly reinforcement against plastic deformation.” (Study by Qifang Hu, Guoxing Lu, Nishar Hameed, Kwong Ming Tse).
In an embodiment, this level of impact load is very similar to what a golf club would face. Thus, filling the honeycomb with STF can increase the dynamic load capacity of golf clubs by about 130%. Since Honeycomb structure itself can load 5+ times the load of solid structures, the combined compressive loading velocity of STF filled honeycomb structure is expected to significantly increase working toughness of BMG.
In an embodiment, the substrate having a three-dimensional geometric structure comprises an injection molded substrate.
In another aspect the present disclosure relates to a method comprising taking a mold and injecting a BMG on the mold using an injection molding technique to form the BMG into a three-dimensional geometric structure having plurality of cells.
In an embodiment the second substrate comprises an alloy, a metal, a synthetic material, a polymer, or a mixture thereof.
In an embodiment, the alloy comprises a crystalline alloy.
In an embodiment, the alloy comprises steel.
In an embodiment, the polymer comprises a resin, rubber, plastic, or foam.
Noise damping materials can be incorporated with BMG to reduce vibrations and minimize the sound generated upon impact. Thermoplastic Elastomers (TPE) are commonly used due to their rubber-like properties and excellent damping characteristics. These materials can be strategically placed in specific areas of the club head or grip to absorb impact energy and provide a softer feel while damping vibrations and reducing noise.
Polyurethane (PU) foam is another versatile material that offers good damping properties. It can be used as a filler or insert in the club head to reduce vibrations and improve sound quality. Polyurethane (PU) foam effectively absorbs and disperses energy, resulting in a quieter sound upon ball contact.
In an embodiment, the metal comprises aluminum.
In an embodiment, the synthetic material comprises plastic or epoxy resin.
In an embodiment, bond plastic or resin directly enhances BMG structure to distribute strain and reduce vibration. This is done as a secondary step. We can spray coat, glue, or overmold. The challenge is to have a bonded layer that stays bonded. Key point is to quickly distribute and disperse vibration away from the point of maximum stress and vibration.
Application of the MaterialIn an embodiment, the BMG structure according to at least one embodiment as disclosed herein can be used in various equipment such as a sport equipment. Examples of sports equipment, without limitation, are golf clubs, golf balls, tennis rackets, skis and snowboards, etc. Other exemplary equipment wherein such BMG is disclosed in one or more embodiments of this disclosure could be used are: flexible hinge and foundation for flexible displays, frames and brackets for electronic devices, armor structure, energy absorbing structures, bumpers, beams, efficient springs, etc.
In an embodiment, the faceplate has BMG material as disclosed in one or more embodiments of this disclosure.
In an embodiment, golf club head has BMG material as disclosed in one or more embodiments of this disclosure.
In an embodiment,
In an embodiment, the faceplate, when hit with a ball on the finished golf club head may make a noise due to the flexing of the faceplate. In an embodiment, the hollow space of the head may have inserts which can dampen the sound. In an embodiment, the material is chosen such that the damping of the noise is peculiar and unique to each of the golf clubs made.
In an embodiment, noise damping materials can be incorporated into golf clubs to reduce vibrations and minimize the sound generated upon impact. Thermoplastic Elastomers (TPE) are commonly used due to their rubber-like properties and excellent damping characteristics. These materials can be strategically placed in specific areas of the club head or grip to absorb impact energy and provide a softer feel while damping vibrations and reducing noise.
Polyurethane (PU) foam is another versatile material that offers good damping properties. It can be used as a filler or insert in the club head to reduce vibrations and improve sound quality. Polyurethane (PU) foam effectively absorbs and disperses energy, resulting in a quieter sound upon ball contact.
In an embodiment, noise damping materials could be present in toughened BMG as discussed in at least one embodiment of the disclosure.
In an embodiment, vibration-damping inserts made from various composite materials or composite structures can also be integrated into the club head. These inserts are strategically placed to absorb and dissipate energy, contributing to a more muted sound during impact. They are often made from a combination of rubber, foam, or composites.
High-density materials, such as tungsten or high-density polymers, can be incorporated in specific areas of the club head to dampen vibrations and minimize noise. These materials effectively absorb and dissipate energy, resulting in a quieter sound upon impact.
Additionally, specialized damping films or coatings can be applied to specific components of the club head, such as the face and/or crown (crown is the upper portion of the club head). These films or coatings are designed to absorb and dissipate energy, helping to reduce vibrations and minimize noise during play.
The choice of noise damping material and its application depends on various factors, including the desired level of noise reduction, the design of the club head, and the overall performance objectives. Manufacturers carefully consider these factors to optimize the balance between sound, feel, and performance in golf clubs. By incorporating noise damping materials, golf clubs can offer a more pleasant and muted sound experience without compromising performance.
In an embodiment, the golf club head also has stainless Damascus steel. Stainless Damascus steel is a type of steel that combines the qualities of stainless steel and Damascus steel. In an embodiment, the hardness of the Stainless Damascus steel may be approximately around 59 to 65 HRC. In an embodiment, the hardness of the Stainless Damascus steel may be at least 45 HRC.
In an embodiment, the golf club head has German Damascus steel. German Damascus steel, also known as German pattern-welded steel, is a type of steel that is produced using traditional techniques similar to those used in the creation of historical Damascus steel. While the term “German Damascus steel” is often used colloquially, it is important to note that it does not refer to steel made exclusively in Germany, but rather steel made using a specific pattern-welding technique.
In an embodiment, the golf club head has a hybrid of BMG and Damascus steel.
In an embodiment, the golf club head has about 100% BMG. 100% BMG may have acceptable amount of impurities.
In an embodiment, the hollow space of the head may have inserts which can dampen the sound. These inserts may be the filing material. In an embodiment, the material is chosen such that the damping of the noise is peculiar and unique to each of the golf clubs made.
Table 1 provides test results of the Damascus Face with BMG Honeycomb support.
Table 2A and 2B provide test results of 100% BMG Honeycomb support golf club tested at two different time periods.
Both Hybrid and lob wedge (LM) irons have not been optimized for distance but for high loft and short-hitting. However, these irons should be within 5 to 10 yards of their maximum potential.
There will be a greater transfer of impact energy to the velocity of the ball as the thinner plate flexes more. Golf balls will bounce back 80% to 90% of dropped distance, indicating that approximately 15% of the energy was lost due to internal friction during the compression/decompression cycle of the golf ball as it was bouncing off a solid floor.
A golf ball coming off the face of Irons can lose 10% to 15% of potential velocity due to internal friction generated during compression and depression cycle of the polymer material. However, certain alloys such as Damascus steel and Amorphous alloys experience almost near 0% loss during the compression/decompression cycle. Thus, if a greater percentage of the energy generated and released during impact can be transferred into the Damascus Steel face, greater the effect of reducing the compression of the golf ball and thus reducing the amount of energy lost due to internal friction in the ball. In essence, the impact of a golf iron with a golf club can be described as two springs working in harmony. By allowing the more efficient spring to store more energy of the impact, less kinetic energy is lost during impact and the golf ball propels off the face of the club with greater velocity.
Steel and metal alloys will lose less than 1% of energy through internal friction of the steel ball during the compression/decompression cycle.
“Speed of ball=Mass of Club×Velocity2×% loss from internal friction”—If a club face is allowed to flex and take on more of the spring action during the compression/decompression cycle, the golf ball will come off the face of the club with greater velocity. This is exactly the reason that USGA implemented the rule of limiting Coefficient of Restitution (COR) for drivers when they observed the Liquid metal Ball bounding demonstration. The coefficient of restitution (COR) is a measure of the “bounciness” or elasticity of a golf ball. In the context of drivers, the COR refers to the rebound effect when the ball strikes the clubface. The USGA (United States Golf Association) has specific rules regarding the maximum allowable COR for drivers. According to the USGA rules, the maximum COR limit for drivers is 0.830. This means that the COR of a driver's face must not exceed 0.830 to be considered conforming to the rules of golf. The USGA imposes this limit to ensure fair play and to prevent drivers from providing an unfair advantage by generating excessive ball speed. Since the 0.830 limit can only be achieved by Titanium drivers with head size of 350 cubic centimeters (cc) to 400 cc, irons were far from approaching this limit. The case might be that average irons only can achieve around 0.780 to 0.800 COR. An ultra-thin Damascus Iron can gain up to 10% in distance without having to violate the USGA rules. As is stated clearly in this disclosure herein, a 3% gain COR can gain a 9% in distance. In addition, a larger sweet spot can contribute significantly to consistent distance gain. The COR of irons can vary depending on the design and construction of the clubhead. Irons are typically designed to provide a combination of distance, control, and feel, with an emphasis on accuracy and precision rather than maximizing ball speed. Manufacturers may employ various materials, face technologies, and designs to optimize the performance of irons within the broader guidelines and principles set forth by the USGA. According to an embodiment, the golf club comprising a Damascus steel face is configured to follow the aspects such as club dimensions, weight, and other characteristics as per USGA rules and regulations or any regulatory body related to the golf game.
According to an embodiment, the golf club comprising BMG face is configured to follow the aspects such as club dimensions, weight, and other characteristics as per USGA rules and regulations or any regulatory body related to the golf game.
The golf club faces that are thinner, maximize the “trampoline effect” or coefficient of restitution (COR). The COR is a measure of how efficiently the club face transfers energy to the golf ball upon impact, influencing the distance the ball travels. A thinner face allows for greater flexing or deflection at impact, resulting in increased ball speed and distance. According to an embodiment, the face conforms to the USGA and Royal and Ancient (R&A) regulations that limit the maximum COR value allowed for golf club faces.
In an embodiment, the golf club has Damascus steel with the amorphous honeycomb structure in the back. Without the honeycomb structure, the Damascus steel would collapse, that is, it would cave in during impact. By combining with Honeycomb structure in the back, the structure has a spring effect, it does not cave in. It's maintaining its position.
In an embodiment, pertaining to golf hitting surface application, which is out-of-plane compression, honeycomb structure, supporting a flat plane exhibit both greater load capability as well as elastic buckling. The honeycomb structure would never fail before the front plate fails catastrophically. BMG honeycomb support combines the high coefficient of restitution (energy efficiency) as well as toughness associated with crystalline alloys.
Table 3 provides a comparative test result for distance of different materials of golf head.
In an embodiment the shaping and forming methods for bulk metallic glass can include, but not limited to, additive manufacturing (AM), die casting, hot pressing and injection molding.
A number of additive manufacturing (AM) technologies have shown the ability to produce amorphous metal structures due to high cooling rates in melt pools or low processing temperatures.
Additive manufacturing (AM), also referred to as 3D printing, is a cladding layer-by-layer technique of producing three-dimensional (3D) objects directly from a digital model.
Die casting is preferred for forming large parts.
In hot pressing method, combinations of heat and pressure are used to form components.
In an embodiment, injection molding is used for producing parts by injecting molten material into a mold.
In an embodiment, the method of injection molding comprises the steps of melting, injection, cooling and ejection.
In an embodiment, the raw material such as BMG is fed into a heated barrel where it is melted. This is typically done using a screw mechanism that helps mix and transport the material. Once the material is fully melted, it is injected into a mold cavity under high pressure. The pressure ensures that the molten material fills the mold completely and conforms to its shape. After the mold is filled, the material cools and solidifies, taking the shape of the mold. The cooling time depends on the material used and the thickness of the part. Once the part has cooled sufficiently, the mold opens, and ejector pins push the finished part out of the mold.
Injection molding is a highly efficient and versatile manufacturing method that excels in producing high volumes of precise, complex parts with excellent surface finishes.
Injection molding offers several advantages such as rapid production rates, short cycle times, uniformity (the process produces consistent parts with minimal variation, which is crucial for applications requiring high quality and reliability), intricate designs, reduced waste, low labor cost, excellent surface finish and cost effectiveness for large volumes.
In an embodiment, BMG is joined with another metal, like steel or titanium or other metal by hot forming the amorphous metal.
In an embodiment, plates are joined. In an embodiment, first and second substrate are joined. In an embodiment, rivet system is used to join the plates.
In another embodiment, tools are used for bonding the second substrate (an alloy, a metal, a synthetic material, a polymer, or a mixture thereof) with a first substrate (BMG honeycomb structure).
In an embodiment the tools can include, but not limited to, nuts, bolts and rivets. Other suitable tools/methods can also be used.
Caving of steel typically refers to the process where steel structures or components experience structural failure due to various factors such as stress, fatigue, or corrosion.
In an embodiment, by combining/bonding the BMG honeycomb structure at the back of Damascus steel, a spring-like effect is obtained (stress is not concentrated at a specific area and distributed to a wider area preventing the crack propagation). Moreover, the Damascus steel is also not caving in and maintains its position.
Whereas in the absence of the BMG honeycomb structure at the back side, the Damascus steel will collapse and cave in.
In an embodiment, we could use a rivet system to put the two plates together. A process of bonding, or the interface of these two similar materials are mechanically fastened to achieve the purpose.
Welding Technologies that could be Employed in Joining a Faceplate to the Body of the Golf Club Head:
In golf club head manufacturing, as well as in various other industries, advanced face welding technologies play a crucial role in achieving high-performance products. One notable technology is the use of Electron Beam Welding (EBW). EBW utilizes a focused beam of high-energy electrons to precisely melt and fuse the materials together. This technology offers several advantages, including minimal heat-affected zones, precise control over the welding parameters, and the ability to join dissimilar materials with varying thicknesses. The result is a strong and reliable bond between the face material and the club head body, ensuring improved energy transfer and increased forgiveness on off-center hits. Another innovative welding technique employed in golf head manufacturing is Laser Welding. This technology utilizes a high-intensity laser beam to melt and join the materials. Laser Welding offers benefits such as fast processing times, high precision, and excellent control over the heat input. It allows for intricate and complex weld patterns, enabling manufacturers to optimize the face design for maximum performance. Laser Welding also provides the flexibility to work with a wide range of materials, including stainless steels, titanium alloys, and carbon composites, making it suitable for various club head constructions.
Furthermore, Advanced Resistance Spot Welding (RSW) techniques can be used to enhance the welding process in golf club head production. These technologies involve using advanced welding controls, precise electrode designs, and monitoring systems to achieve consistent and reliable welds. By carefully controlling the heat input and pressure, manufacturers can create strong bonds between the face material and the club head body, ensuring durability and performance.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, maraging steel, and BMG; and wherein a first weight of the golf club head is at most a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, BMG and/or maraging steel.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising a Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, maraging steel, and BMG; and wherein a first weight of the golf club head is at most a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, BMG and/or maraging steel.
In an embodiment, the second area of the second face comprises a honeycomb structure.
In an embodiment, it is a golf club head comprising: a shell and a first face comprising BMG attached to the shell; wherein the first face comprises a decorative pattern formed by the BMG.
In an embodiment, it is a golf club head comprising: a shell and a first face comprising Damascus Steel attached to the shell and a second area of a second face made of at least one of stainless steel, carbon steel, maraging steel, and BMG.
According to an embodiment of the golf club head, a thickness of the first face is reduced by approximately 50% when compared to that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the thickness of the first face is reduced by about 30% to 40% in a sweet spot, and approximately 60% in rest of the first face when compared to that of the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel is changed in at least one of a height and a width as compared to the second face made of at least one of stainless steel, carbon steel, BMG and maraging steel.
According to an embodiment of the golf club head, the first area of the first face comprising the Damascus Steel is increased in area approximately 15% to 25% than that of the second face made of at least one of stainless steel, carbon steel, BMG and maraging steel.
According to an embodiment of the golf club head, a width of the first face comprising the Damascus Steel is increased by approximately 10% to 15% than the second face made of at least one of stainless steel, carbon steel, BMG and maraging steel.
According to an embodiment of the golf club head, a height of the first face of the golf club head is increased approximately 5% to 25% based on a design objective than the second face made of at least one of stainless steel, carbon steel, BMG and maraging steel.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel has a larger sweet spot when compared with a sweet spot on the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to a second face made of at least one of stainless steel, carbon steel, BMG and maraging steel.
According to an embodiment of the golf club head, a weight in the first face is moved away from an impact zone.
According to an embodiment of the golf club head, the shell comprises at least one of an Al 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the golf club head, the Damascus Steel along with BMG at the back has at least 2 times the yield strength of that of another material used for the shell.
According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the Damascus Steel comprises a plurality of layers and wherein the plurality of layers thickness is reduced from an initial thickness to a final thickness in a range of approximately 100 to 1.
According to an embodiment of the golf club head, the Damascus Steel has high strength, and resistance to cracking due to reducing an effect of imperfection by confining defects within each layer of the plurality of layers when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the BMG has high strength and resistance to cracking due to reducing an effect of imperfection by confining defects within each layer of the plurality of layers when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the Damascus Steel produces high resistance to fracture strain when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the BMG produces high resistance to fracture strain when compared to at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the Damascus Steel is heat treated from an initial hardness of approximately 38 Rockwell Hardness Scale (HRC) to result in a final hardness of approximately 50 HRC to 60 HRC.
According to an embodiment, the golf club head comprising Damascus Steel has an impact toughness approximately 2 to 3 times higher when compared to a golf club head made of at least one of monolithic (single layered) stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first face further comprises Damascus Titanium.
According to an embodiment of the golf club head, the decorative pattern is customizable such that it is unique to the golf club head.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate a sweet spot on the first face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the first face comprising the Damascus Steel generates a higher golf ball speed at impact on the first face of the golf club head when compared with a second face of a golf club comprising at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a golf ball dropped from a dropping distance on the first face comprising the Damascus Steel bounces back 80% to 90% of the dropping distance. A golf ball coming off the face of Irons can lose 10% to 15% of potential velocity due to internal friction generated during compression and depression cycle of the polymer material. However, certain alloys such as Damascus steel and Amorphous alloys experience almost near 0% loss during the compression/decompression cycle. Thus, if greater percentage of the energy generated and released during impact can be transferred into the Damascus Steel face, greater the effect of reducing the compression of the golf ball and thus reducing the amount of energy lost due to internal friction in balls. In essence, the impact of golf iron with a golf club can be described as two springs working in harmony. By allowing the more efficient spring to store more energy of the impact, less kinetic energy is lost during impact and the golf ball propels off the face of the club with greater velocity
According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by approximately 3% so as to increase the speed of a golf ball coming off an impact from the first face comprising the Damascus Steel. Increasing the size of hitting face by 20% to 25% and reducing the face thickness by 30%-50% can add 1% to 2% increase in ball speed. This is achieved from greater deflection of the Damascus steel Plate due to its reduction in thickness and greater size. Based on this formula, D=Mass×V2, a 2% increase in initial ball velocity will result in a 4% increase in distance. However, for average golfers, the greater benefit could be the reduction in lost distance due to missing the sweet spot at impact and slicing the ball off the desired trajectory.
According to an embodiment of the golf club head, a net distance achieved by a golf ball coming off an impact on the first face comprising the Damascus Steel of the golf club head is greater than a net distance achieved by the golf ball coming off an impact on the second face of the golf club made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment, it is a method comprising: casting a shell of a golf club head comprising a hosel and a back; producing, by repeated rolling and forging plurality of layers, a first face of the golf club head comprising Damascus Steel; and welding the first face to the shell of the golf club head; wherein the first face comprises a decorative pattern formed by the Damascus Steel; wherein a first area of the first face comprising the Damascus Steel is larger than a second area of a second face made of at least one of stainless steel, carbon steel, BMG and maraging steel; and wherein a first weight of a first golf club head is at most a second weight of a second golf club head made of at least one of stainless steel, carbon steel, and maraging steel; wherein the method is configured for manufacturing an iron-type of the golf club head and is configured for enhanced performance.
According to an embodiment of the method, a material for the shell comprises casting stainless steel.
According to an embodiment of the method, the shell is made using investment casting.
According to an embodiment of the method, the first golf club head is heat treated to improve a grain structure.
According to an embodiment of the method, the shell comprises at least one of an Al 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the method, the plurality of layers is reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the method, each layer of the plurality of layers are selected to comprise material properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment, it is a golf club head comprising: a shell comprising a hosel and a back; and a first face comprising a Damascus Steel attached to the shell; wherein the first face comprises a decorative pattern formed by the Damascus Steel; and wherein a first weight of the golf club head is less than a second weight of a head of a golf club made of at least one of stainless steel, carbon steel, BMG and maraging steel; and wherein a first area of the first face comprising the Damascus Steel is equal to a second area of a second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, the first weight of the golf club head is approximately 20% to 25% less than the second weight of the head of the golf club made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, 40% to 60% of material weight is reduced from the first face comprising the Damascus Steel when compared to the second face made of at least one of stainless steel, carbon steel, and maraging steel.
According to an embodiment of the golf club head, a sweet spot on the first face is thicker relative to other areas surrounding the sweet spot on the first face.
According to an embodiment of the golf club head, the sweet spot comprises colored rings around the decorative pattern formed from the Damascus Steel. In an embodiment, a back side of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and/or a conspicuous finish.
According to an embodiment, disclosed is a golf club head comprising a body comprising a shell and a face; the shell comprising a hosel, a first periphery, and a back made of a non-layered material; the face comprising a Damascus Steel comprising a plurality of layers of at least a first material and a second material; the face comprising a second periphery, wherein the second periphery of the face is attached to the first periphery of the shell, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toe edge, and a sole edge of the second periphery; and a cavity formed behind the face and within the body, the cavity extending rearward from the face to the back of the shell; wherein a first thickness of a sweet spot of the face is greater than a second thickness of other areas of the face; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the golf club head is an iron type golf club head.
According to an embodiment of the golf club head, the face has a surface area of at least 60 square centimeters.
According to an embodiment of the golf club head, the first thickness of the face is in a range of 0.1 centimeters to 0.25 centimeters.
According to an embodiment of the golf club head, the second periphery of the face is attached via a welding to the first periphery of the shell.
According to an embodiment of the golf club head, the first material and the second material are selected from a group consisting of titanium, steel, Stainless steel, Amorphous Alloys, and composites thereof.
According to an embodiment of the golf club head, the shell comprises at least one of an Al 6061, a 431 stainless steel, and a 17-4PH stainless steel.
According to an embodiment of the golf club head, the sweet spot of the face is at least 10% thicker than the other areas of the face.
According to an embodiment of the golf club head, the Damascus steel comprises a stainless steel 304L and a stainless steel 316L.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the toe edge and the heel edge compared to an identically constructed club that does not contain a Damascus Steel face.
According to an embodiment of the golf club head, the sweet spot of the face is larger in a direction toward the crown edge and the sole edge compared to an identically constructed club that does not contain a Damascus Steel face.
According to an embodiment of the golf club head, the first thickness is distributed circularly along the sweet spot of the face.
According to an embodiment of the golf club head, the first thickness to the second thickness is a continuous variation in the thickness from most thick region being at the sweet spot.
According to an embodiment of the golf club head, the first thickness to the second thickness is an abrupt variation in the thickness from most thick regions at the sweet spot.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound upon impact of a golf ball based on a location where the golf ball is hit on the face.
According to an embodiment of the golf club head, the golf club head produces a distinguishing sound and is configured such that it produces audio feedback to a user of the golf club.
According to an embodiment of the golf club head, the sweet spot on the face further comprises colored rings around the decorative pattern formed from the Damascus Steel; and
wherein a back side of the face comprises a ring that marks the sweet spot, wherein the ring comprises at least one of a color and a conspicuous finish.
According to an embodiment of the golf club head, the Damascus Steel has at least 2 times yield strength of that of a material used for the shell.
According to an embodiment of the golf club head, the Damascus Steel comprises a minimum of 10.5% chromium.
According to an embodiment of the golf club head, the plurality of layers are reduced from an initial thickness to a final thickness in a range of approximately 50 to 1.
According to an embodiment of the golf club head, the golf club head is part of a golf club.
According to an embodiment of the golf club head, a frictional loss of a golf ball at impact is configured to be reduced by at least 3%.
According to an embodiment of the golf club head, each layer of the plurality of layers are selected to comprise material with properties that optimize a strength, a toughness, a corrosion resistance, and an edge retention of the face.
According to an embodiment of the golf club head, the face comprising the Damascus Steel is heat treated.
According to an embodiment of the golf club head, the decorative pattern is configured to indicate the sweet spot on the face to mark a perfect center of a hitting zone.
According to an embodiment of the golf club head, the cavity behind the face is filled with an insert configured to dampen a sound generated by the face upon hitting a golf ball.
According to an embodiment of the golf club head, the insert comprises at least one of Thermoplastic Elastomers (TPE) and Polyurethane (PU) foam.
According to an embodiment, disclosed is a method comprising casting a shell comprising a hosel, a first periphery, and a back made of a non-layered material; producing a face comprising a Damascus Steel from plurality of layers, by repeated rolling and forging, wherein the plurality of layers comprises at least a first material and a second material, and wherein the face comprises a second periphery; generating a first thickness of a sweet spot of the face greater than a second thickness of other areas of the face; attaching the second periphery to the first periphery of the shell via a welding, wherein the first periphery is attached along a boundary connecting a heel edge, a crown edge, a toc edge, and a sole edge of the second periphery; and forming a cavity behind the face and within a body, the cavity extending rearward from the face to the back of the shell; wherein the face comprises a decorative pattern formed from Damascus Steel; wherein a hardness of the face comprising the Damascus Steel on a Rockwell scale is at least 45 HRC; and wherein the method is configured for manufacturing a golf club head of an iron type.
According to an embodiment of the method, a material for the shell comprises casting stainless steel.
According to an embodiment of the method, golf club head is heat treated to improve a grain structure.
According to an embodiment of the method, the shell comprises at least one of an Aluminum Alloy (Al) 6061, a 431 stainless steel, and 17-4PH stainless steel.
In an embodiment, the golf club head is made of 100% BMG.
The descriptions of the one or more embodiments are for purposes of illustration but are not exhaustive or limiting to the embodiments described herein. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the embodiments described. The terminology used herein best explains the principles of the embodiments, the practical application and/or technical improvement over technologies found in the marketplace, and/or enable others of ordinary skill in the art to understand the embodiments described herein.
The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The embodiments described are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims
1. A sport equipment, comprising: a golf club comprising a golf club head comprising a first substrate comprising bulk metallic glass (BMG) having one or more layers, wherein at least one layer of the said substrate comprises a three-dimensional geometric structure having cells, wherein a part of cells has an arched dome structure.
2. The sport equipment of claim 1, wherein the three-dimensional geometric structure comprises a honeycomb structure.
3. The sport equipment of claim 2, wherein thickness of a wall of the cells of the honeycomb structure is at least 0.5 mm.
4. The sport equipment of claim 1, wherein the BMG comprises a BMG composite.
5. The sport equipment of claim 4, wherein the said composite comprises a second substrate comprising an alloy, a metal, a synthetic material, a polymer, or a mixture thereof.
6-9. (canceled)
10. The sport equipment of claim 5, wherein the second substrate is configured to withstand a temperature of around 450° C.
11. (canceled)
12. The sport equipment of claim 2, wherein a part of the cells of the honeycomb structure is at least partially filled with a filling material.
13. The sport equipment of claim 12, wherein the filling material comprises a polymer or a fluid.
14. The sport equipment of claim 13, wherein the fluid comprises a shear reducing fluid, a polymer, silicone, or an epoxy resin, or a combination thereof.
15-16. (canceled)
17. The sport equipment of claim 1, wherein the three-dimensional geometric structure comprises an injection molded structure.
18. (canceled)
19. The sport equipment of claim 2, wherein a ratio of length to thickness of the cells of the honeycomb structure is less than 0.5.
20-21. (canceled)
22. A method comprising taking a mold and injecting a first substrate comprising a bulk metallic glass (BMG) on the mold using an injection molding technique to mold into a three-dimensional geometric structure having plurality of cells.
23. The method of claim 22, wherein the three-dimensional geometric structure comprises a honeycomb structure.
24. The method of claim 23, wherein a part of cells of the honeycomb structure have arched dome structure.
25. The method of claim 22, wherein the first substrate further comprises a metal, a crystalline alloy, a fully amorphous alloy or a partially amorphous alloy.
26. (canceled)
27. The method of claim 22, further comprising adding a second substrate.
28. (canceled)
29. The method of claim 27, wherein the second substrate is configured to withstand a temperature of about 400° C. or more.
30-34. (canceled)
35. The method of claim 27, further comprising adding a fluid between the first substrate and the second substrate.
36-41. (canceled)
42. The method of claim 23, wherein a ratio of length to thickness of the cells of the honeycomb structure is less than 0.5.
43. The method of claim 22, wherein thickness of a wall of a cell is at least 0.5 mm.
44-45. (canceled)
Type: Application
Filed: Oct 8, 2024
Publication Date: Apr 9, 2026
Inventor: James KANG (Las Vegas, NV)
Application Number: 18/909,218
