Method of forming golf club head with multi-material face using spray deposition

Abstract

A metal wood golf club with a striking face portion made from more than one material is disclosed. More specifically, due to the unique construction of the striking face portion having multiple materials, the present invention utilizes bonding spray deposition process to achieve the desirable bond between the more than one materials used to form the striking face. The striking face portion is formed by creating a chip insert type material utilizing the spray deposition process that is made from a secondary material that is different from the remainder of the striking face portion substantially near a geometric center of the striking face portion; wherein the secondary material has a higher Young's modulus than the remainder of the striking face portion.

What is claimed is: 
     
         1 . A method of manufacturing a golf club head striking face comprising:
 providing a backing layer, said backing layer forming an interior surface of said striking face, said backing layer comprising a cavity substantially near a geometric center of said striking face, said backing layer formed from a first material;   forming a chip insert in said cavity via a thermal spray deposition process, said chip insert formed from a second material;   adhering an outer layer to said backing layer and said chip insert, said outer layer forming an external surface of said striking face, said outer layer formed from said first material;   wherein said second material has a young's modulus higher than the young's modulus of said first material.   
     
     
         2 . The method of  claim 1 , wherein said first material is titanium and said second material is steel. 
     
     
         3 . The method of  claim 1 , wherein adhering an outer layer to said backing layer and said chip insert comprises a thermal spray deposition process. 
     
     
         4 . The method of  claim 1 , wherein said thermal spray deposition process comprises a plasma spraying process. 
     
     
         5 . The method of  claim 1 , wherein said chip insert is at least 1 mm thick. 
     
     
         6 . The method of  claim 5 , wherein said chip insert is at least 1.25 mm thick. 
     
     
         7 . The method of  claim 6 , wherein said chip insert is at least 1.5 mm thick. 
     
     
         8 . A method of manufacturing a golf club head striking face comprising:
 providing a backing layer, said backing layer forming an interior surface of said striking face, said backing layer comprising a cavity substantially near a geometric center of said striking face, said backing layer formed from a first material;   forming a chip insert in said cavity via a thermal spray deposition process, said chip insert formed from a second material;   forming an outer layer of said striking face via a thermal spray deposition process, said outer layer forming an external surface of said striking face;   wherein said second material has a young's modulus higher than the young's modulus of said first material.   
     
     
         9 . The method of  claim 8 , wherein said outer layer is formed from said first material. 
     
     
         10 . The method of  claim 9 , wherein said first material is titanium and said second material is steel. 
     
     
         11 . The method of  claim 8 , wherein said thermal spray deposition process comprises a plasma spraying process. 
     
     
         12 . The method of  claim 8 , wherein said chip insert is at least 1 mm thick. 
     
     
         13 . The method of  claim 12 , wherein said chip insert is at least 1.25 mm thick. 
     
     
         14 . The method of  claim 13 , wherein said chip insert is at least 1.5 mm thick. 
     
     
         15 . A method of manufacturing a golf club head striking face comprising:
 providing a backing layer, said backing layer forming an interior surface of said striking face, said backing layer formed from a first material;   forming an outer layer of said striking face via a thermal spray deposition process, said outer layer forming an external surface of said striking face, said outer layer formed from said first material.   
     
     
         16 . The method of  claim 15 , wherein said backing layer comprises a cavity substantially near a geometric center of said striking face, and wherein said method further comprises forming a chip insert in said cavity via a thermal spray deposition process, said chip insert formed from a second material, wherein said second material has a young's modulus higher than the young's modulus of said first material. 
     
     
         17 . The method of  claim 16 , wherein said first material is titanium and said second material is steel. 
     
     
         18 . The method of  claim 16 , wherein said thermal spray deposition process comprises a plasma spraying process. 
     
     
         19 . The method of  claim 15 , wherein said chip insert is at least 1 mm thick. 
     
     
         20 . The method of  claim 19 , wherein said chip insert is at least 1.25 mm thick.