Golf club head and face insert with electroformed fine-grained materials

Abstract

A face insert for a golf club head comprises an electroform that is securely connected to a substrate. The electroform is comprised of fine-grained materials having an average grain size that is in the range of 2 nm to 5000 nm, a yield strength that is in the range of 200 MPa to 2,750 MPa, a hardness that is in the range of 100 Vickers to 2,000 Vickers, a thickness that is in the range from 30 microns to 5 cm, and a modulus of resilience that is in the range from 0.25 MPa to 25 MPa.

1 . A face insert for a golf club head, comprising:
 a substrate; and   an electroform securely connected to said substrate, said electroform comprising a fine-grained metallic material having an average grain size that is in the range of 2 nm to 5000 nm, a yield strength that is in the range of 200 MPa to 2,750 MPa, a hardness that is in the range of 100 Vickers to 2,000 Vickers, a thickness that is in the range from 30 microns to 1 cm, and a modulus of resilience that is in the range from 0.25 MPa to 25 MPa.   
     
     
         2 . The face insert of  claim 1 , further comprising a plurality of formations defined in a front face of said electroform. 
     
     
         3 . The face insert of  claim 2 , wherein said formations include a plurality of parallel grooves. 
     
     
         4 . The face insert of  claim 2 , wherein said formations include a plurality of texture lines. 
     
     
         5 . The face insert of  claim 2 , wherein said formations include a plurality of protrusions each having a width in the range of 0.5 to 100 microns, a height in the range of 0.5 to 100 microns and a spacing between protrusions in the range of 0.2 to 100 microns. 
     
     
         6 . The face insert of  claim 1 , wherein said substrate comprises a metallic material. 
     
     
         7 . The face insert of  claim 1 , wherein said substrate comprises a polymeric material. 
     
     
         8 . The face insert of  claim 1 , wherein said substrate comprises a reinforced polymeric material. 
     
     
         9 . The face insert of  claim 1 , wherein at least one of said substrate and said electroform includes a connecting structure for connecting said face insert to a body of the golf club head. 
     
     
         10 . A golf club head comprising a body and a face insert as claimed in  claim 1  that is securely connected to said body. 
     
     
         11 . A golf club head comprising:
 a body; and   a face insert that is securely connected to said body, said face insert including:
 a substrate; and 
 an electroform securely connected to said substrate, said electroform comprising a fine-grained metallic material having an average grain size that is in the range of 2 nm to 5000 nm, a yield strength that is in the range of 200 MPa to 2,750 MPa, a hardness that is in the range of 100 Vickers to 2,000 Vickers, a thickness that is in the range from 30 microns to 1 cm, and a modulus of resilience that is in the range from 0.25 MPa to 25 MPa. 
   
     
     
         12 . The golf club head of  claim 11 , further comprising a plurality of formations defined in a front face of said electroform. 
     
     
         13 . The golf club head of  claim 12 , wherein said formations include a plurality of parallel grooves. 
     
     
         14 . The golf club head of  claim 12 , wherein said formations include a plurality texture lines. 
     
     
         15 . The golf club head of  claim 11 , wherein said formations include a plurality of protrusions each having a planar or rounded upper surface, a width in the range of 0.5 to 100 microns, a height in the range of 0.5 to 100 microns and a spacing between protrusions in the range of 0.2 to 100 microns. 
     
     
         16 . The golf club head of  claim 11 , wherein said substrate comprises a metallic material. 
     
     
         17 . The golf club head of  claim 11 , wherein said substrate comprises a polymeric material. 
     
     
         18 . The golf club head of  claim 11 , wherein said substrate comprises a reinforced polymeric material. 
     
     
         19 . A golf club comprising a golf club head as claimed in  claim 11  mounted to a shaft having a grip disposed at one end. 
     
     
         20 . A golf club head comprising:
 a body having a support surface; and   an electroform securely connected to said support surface, said electroform comprising a fine-grained metallic material having an average grain size that is in the range of 2 nm to 5000 nm, a yield strength that is in the range of 200 MPa to 2,750 MPa, a hardness that is in the range of 100 Vickers to 2,000 Vickers, a thickness that is in the range from 30 microns to 1 cm, and a modulus of resilience that is in the range from 0.25 MPa to 25 MPa.