US Patent 7874938 Composite articles and methods for making the same

The present disclosure pertains to composite articles, and in particular a composite face plate for a golf club-head, and methods for making the same. In certain embodiments, a composite face plate for a club-head comprises a lay-up of multiple, composite prepreg plies. The face plate can be made by first forming an oversized lay-up of multiple prepreg plies having a central portion and a sacrificial portion surrounding the central portion. The lay-up is at least partially cured in a mold under elevated pressure and heat. The lay-up is then removed from the mold and the sacrificial portion is removed from the central portion to form a composite part that is substantially free of defects.