U.S. patent application number 11/344596 was filed with the patent office on 2007-08-02 for golf clubs and golf club heads including cellular structure metals and other materials.
This patent application is currently assigned to Nike, Inc.. Invention is credited to David N. Franklin, Abhishek Gupta, David Soong-hua Lee, Gary G. Tavares.
Application Number | 20070178988 11/344596 |
Document ID | / |
Family ID | 37946433 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070178988 |
Kind Code |
A1 |
Tavares; Gary G. ; et
al. |
August 2, 2007 |
Golf clubs and golf club heads including cellular structure metals
and other materials
Abstract
Golf club heads include: (a) a body member constructed, at least
in part, from cellular structure material; (b) a ball striking face
engaged or integrally formed with the body member; and/or (c) a
shaft member engaged with the body member. Weight savings realized
through the use of lightweight cellular structure materials allows
additional weight to be placed at other desired locations in the
club head structure. By adjusting and selectively placing weight in
the club head structure, the club head's moment of inertia, center
of gravity, and/or stability characteristics may be favorably
affected and/or the resulting ball flight may be influenced and/or
customized to a specific individual golfer, to provide a more
controlled, consistent, and/or straight ball flight.
Inventors: |
Tavares; Gary G.; (Azle,
TX) ; Franklin; David N.; (Granbury, TX) ;
Gupta; Abhishek; (Columbus, OH) ; Lee; David
Soong-hua; (La Mirada, CA) |
Correspondence
Address: |
BANNER & WITCOFF, LTD.
1100 13th STREET, N.W., SUITE 1200
WASHINGTON
DC
20005-4051
US
|
Assignee: |
Nike, Inc.
Beaverton
OR
|
Family ID: |
37946433 |
Appl. No.: |
11/344596 |
Filed: |
February 1, 2006 |
Current U.S.
Class: |
473/334 ;
473/340; 473/345; 473/349; 473/350 |
Current CPC
Class: |
A63B 53/04 20130101;
A63B 53/047 20130101; A63B 60/00 20151001; A63B 53/0433 20200801;
A63B 60/02 20151001; A63B 2209/00 20130101 |
Class at
Publication: |
473/334 ;
473/345; 473/349; 473/340; 473/350 |
International
Class: |
A63B 53/00 20060101
A63B053/00 |
Claims
1. A golf club head, comprising: a club head body member
constructed, at least in part, from a cellular structure metal
material; and a ball striking face engaged or integrally formed
with the club head body member.
2. A golf club head according to claim 1, wherein the club head
body member includes a shell defining an interior chamber, wherein
at least a portion of the shell is constructed from the cellular
structure metal material.
3. A golf club head according to claim 2, further comprising: a
weight member provided at least partially within the shell.
4. A golf club head according to claim 1, further comprising: a
weight member engaged with the club head body member.
5. A golf club head according to claim 1, wherein the cellular
structure metal material forms a major portion of the club head
body member.
6. A golf club head according to claim 1, wherein the club head
body member forms a putter head structure.
7. A golf club head according to claim 1, wherein the club head
body member forms an iron golf club head structure.
8. A golf club head according to claim 1, wherein the club head
body member forms a wood golf club head structure.
9. A golf club head according to claim 1, wherein the club head
body member forms a driver head structure.
10. A golf club head according to claim 1, wherein the ball
striking face includes a metal face member engaged with the
cellular structure metal material of the club head body member.
11. A golf club head according to claim 1, wherein the ball
striking face is integrally formed with the cellular structure
metal material of the club head body member.
12. A golf club head according to claim 1, wherein at least a
portion of the cellular structure metal material includes a
polymeric filling.
13. A golf club head according to claim 1, wherein the club head
body member includes at least a first body member including the
cellular structure metal material and a second body member engaged
with the first body member.
14. A golf club head according to claim 13, wherein the second body
member includes a second cellular structure metal material.
15. A golf club head according to claim 1, further comprising: a
club head weighting system engaged with the club head body
member.
16. A golf club head according to claim 15, wherein at least a
portion of the club head weighting system is selectively removable
from the golf club head.
17. A golf club head according to claim 15, wherein at least a
portion of the club head weighting system is movably mounted with
respect to the club head body member.
18. A golf club, comprising: a club head body member constructed,
at least in part, from a cellular structure metal material; and a
shaft member engaged with the club head body member.
19. A golf club according to claim 18, wherein the club head body
member includes a ball striking face integrally formed with the
cellular structure metal material.
20. A golf club according to claim 18, further comprising: a grip
member engaged with the shaft member.
21. (canceled)
22. A golf club according to claim 18, further comprising: a weight
member engaged with the club head body member.
23. A golf club according to claim 18, wherein the cellular
structure metal material forms a major portion of the club head
body member.
24. A golf club according to claim 18, wherein the club head body
member forms a putter head structure.
25. A golf club according to claim 18, wherein the club head body
member forms an iron golf club structure.
26. A golf club according to claim 18, wherein the club head body
member forms a wood golf club head structure.
27. A golf club according to claim 18, wherein the club head body
member forms a driver head structure.
28. A golf club according to claim 18, further comprising: a ball
striking face including a metal face member engaged with the
cellular structure metal material.
29. A golf club according to claim 18, wherein at least a portion
of the cellular structure metal material includes a polymeric
filling.
30-32. (canceled)
33. A method of forming a golf club head, comprising: forming a
club head body member, at least in part, from a cellular structure
metal material; and providing a ball striking face on the club head
body member.
34. (canceled)
35. A method according to claim 33, further comprising: engaging a
weight member with the club head body member.
36. A method according to claim 33, wherein the club head body
member is formed as a putter head structure.
37. A method according to claim 33, wherein the club head body
member is formed as an iron golf club head structure.
38. (canceled)
39. A method according to claim 33, wherein the club head body
member is formed as a wood golf club head structure.
40. A method according to claim 33, wherein the club head body
member is formed as a driver head structure.
41-46. (canceled)
47. A method of forming a golf club, comprising: forming a club
head body member, at least in part, from a cellular structure metal
material; and engaging a shaft member with the club head body
member.
48-49. (canceled)
50. A method according to claim 47, further comprising: engaging a
weight member with the club head body member.
51. A method according to claim 47, wherein the club head body
member is formed as a putter head structure.
52. A method according to claim 47, wherein the club head body
member is formed as an iron golf club structure.
53. A method according to claim 47, wherein the club head body
member is formed as a wood golf club head structure.
54. A method according to claim 47, wherein the club head body
member is formed as a driver head structure.
55-59. (canceled)
Description
RELATED APPLICATION DATA
[0001] Aspects of the invention described in this patent
application relate to and/or may be used in conjunction with at
least some of the aspects of the inventions described in: (a) U.S.
patent application Ser. No. 10/707,599 filed Dec. 23, 2003 (now
U.S. Patent Publication No. 2005-0137024A1 published Jun. 23, 2005)
and entitled "A Golf Club Head Having a Bridge Member and a Weight
Positioning System;" (b) U.S. patent application Ser. No.
10/666,346 filed Sep. 19, 2003 (now U.S. Pat. No. 6,923,732 issued
Aug. 2, 2005) and entitled "Golf Club Head Having a Bridge Member;"
(c) U.S. patent application Ser. No. 10/934,742 filed Sep. 7, 2004
and entitled "Structure of a Golf Club Head or Other Ball Striking
Device;" and/or (d) U.S. patent application Ser. No. 11/125,327
filed May 10, 2005 and entitled "Golf Clubs and Golf Club Heads."
Each of the above-identified patents, publications, and
applications is entirely incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to golf clubs and golf club
heads and to methods for making such structures.
BACKGROUND
[0003] Various golf club heads have been designed to improve a
golfer's accuracy by assisting the golfer in squaring the club head
face at impact with a golf ball. A number of golf club heads
position weight of the golf club head in order to alter the
location of the club head's center of gravity and/or to increase
the club head's moment of inertia (e.g., resistance to twisting).
The location of the center of gravity of the golf club head and its
moment of inertia are factors that, at least in part, determine
whether a golf ball is propelled in the intended direction. When
the center of gravity is positioned behind the point of engagement
on the contact surface and the club head is square to the intended
target line, the golf ball follows a generally straight route. When
the center of gravity is spaced to a side of the point of
engagement and/or the club head is not square at impact, however,
the golf ball may follow a route that curves left or right or
simply fly to the left or right, ball flights that often are
referred to as "draws," "fades," "hooks," "slices," "pulls," or
"blocks." Similarly, when the center of gravity of the club head is
spaced above or below the point of engagement with the ball, the
route of the golf ball may exhibit more boring or climbing
trajectories, respectively.
[0004] Golf club heads, such as cavity back club heads, assist the
golfer by locating much of the weight of the golf club head around
the golf club head perimeter. Generally, these golf club heads are
more forgiving than non-cavity golf club heads thereby allowing a
golf ball to be struck somewhat off center or miss-hit, while still
providing relatively good distance and accuracy. Cavity back club
heads have helped the average golfer reduce mis-hits and improve
scoring.
[0005] While golf club technology has improved in recent years,
there is room in the art for still further advances and
improvements in golf club technology.
SUMMARY OF THE INVENTION
[0006] This invention relates to golf club heads and golf clubs
including such golf club heads, such as putters, irons (including
all types of wedges), hybrid type clubs, fairway woods, drivers,
and the like. Golf clubs and golf club heads according to at least
some example aspects of this invention may include: (a) a club head
body member constructed, at least in part, from a cellular
structure metal or other material; (b) a ball striking face engaged
or integrally formed with the club head body member; and/or (c) a
shaft member engaged with the club head body member. Optionally, if
desired, the club head body member may be of a multi-piece
construction, and any one or more of these multiple pieces may be
formed from a cellular structure metal or other material without
departing from this invention. Weight savings realized through the
use of lightweight cellular structure metal or other materials as
part of a club head structure according to at least some examples
of this invention allow additional weight to be placed at other
desired locations in the club head structure, such as around the
club head perimeter, toward the rear and/or bottom of the club head
structure, toward the heel and/or toe edges of the club head
structure, etc. In some example structures, weight members may be
selectively placed at and/or moved to different locations in the
club head structure to enable customization of the club head's
weighting, e.g., for better use by a particular golfer or a golfer
having particular swing characteristics. By adjusting and
selectively placing weight in the club head structure, the club
head's center of gravity, moment of inertia, and/or stability
characteristics may be favorably affected and/or the resulting ball
flight, when struck by the club head, may be influenced to assist
in providing a more controlled, more consistent, and/or straighter
ball flight.
[0007] Additional aspects of this invention relate to methods of
making and/or using golf club heads and golf clubs that include
cellular structure metal or other materials forming at least a
portion of the club head structure. Such methods may include
engaging one or more weight members with the club head structure,
moving the weight member(s) with respect to the club head
structure, and/or removing the weight member(s) from the club head
structure and replacing them with different weight members (e.g.,
of different mass).
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention is illustrated by way of example and
not limited in the accompanying figures, in which like reference
numerals indicate similar elements throughout, and in which:
[0009] FIG. 1 illustrates an example cellular structure metal
material that may be used in golf club head manufacture in
accordance with at least some examples of this invention;
[0010] FIG. 2 illustrates an example cellular structure metal
material including a surface element that may be used in golf club
head manufacture in accordance with at least some examples of this
invention;
[0011] FIGS. 3A through 3E illustrate an example of a putter
structure that incorporates a cellular structure metal material in
accordance with some examples of this invention;
[0012] FIGS. 4A and 4B illustrate an additional example of a putter
structure that incorporates a cellular structure metal material in
accordance with some examples of this invention;
[0013] FIG. 5 illustrates another example of a putter structure
that incorporates a cellular structure metal material in accordance
with some examples of this invention;
[0014] FIGS. 6A through 11 illustrate examples of iron type golf
club head structures that incorporate cellular structure metal
materials in accordance with some examples of this invention;
[0015] FIGS. 12A through 13B illustrate examples of wood type golf
club head structures that incorporate cellular structure metal
materials in accordance with some examples of this invention;
and
[0016] FIG. 14 illustrates an example face plate member of a golf
club structure that includes cellular structure metal materials in
accordance with at least some examples of this invention.
DETAILED DESCRIPTION
[0017] The following description and the accompanying figures
disclose features of golf clubs and golf club heads in accordance
with the present invention (e.g., woods, irons, hybrids, putters,
etc.).
I. General Description of Aspects of the Invention
[0018] Aspects of this invention relate to golf club heads and golf
clubs including such golf club heads. Golf club heads according to
at least some example aspects of this invention may include: (a) a
club head body member constructed, at least in part, from a
cellular structure material (e.g., a cellular structured metal
materials (also called "metal foam" materials, including cellular
structured alloys, amorphous metal or alloy materials, etc.),
semi-metal materials, ceramic materials, glass materials, polymer
materials (e.g., polyurethanes, etc.), rubber materials, etc.); and
(b) a ball striking face engaged or integrally formed with the club
head body member. Optionally, if desired, the club head body member
may be of a multi-piece construction, and any one or more of these
multiple pieces may be formed from a cellular structure material
without departing from this invention.
[0019] Any desired type of golf club head may be constructed
including cellular structure materials, including, for example,
putters, irons (including all types of wedges), hybrid type clubs,
fairway woods, drivers, and the like. Moreover, any desired portion
or amount of the club head structure may be made from the cellular
structure material without departing from the invention, such as
the entire club head body (e.g., including a solid body, a body
shell, etc.), the ball striking face member, a crown portion, a
body ribbon portion, a sole portion, etc. As some more specific
examples, if desired, a major portion of the overall club head body
(e.g., a majority of its volume and/or surface area) may be
provided as cellular structure material.
[0020] The use of cellular structure materials as part of a golf
club head structure can be advantageous, at least in part, because
of the relative lightweight nature of these materials. The weight
savings realized through the use of cellular structure materials
(e.g., cellular structure metals including amorphous metals and
alloys, etc.) for at least a portion of the club head body member
allows club designers, club fitters, users, and the like to
position weight (e.g., weight members (optionally movable,
removable, or otherwise customizable weight members) and weighting
systems, etc.) at desired locations within the overall club head
structure. As examples, if desired, club heads may be provided with
one or more weight members housed at least partially within a shell
or enclosure of the club head body member, attached to the club
head body member, movably and/or removably mounted to and/or at
least partially within the club head body member, etc. If desired,
suitable receptacles may be formed in the club head body member for
permanently, movably, and/or removably engaging with and/or
attaching one or more weight members with the club head body
member.
[0021] Various ways of providing the ball striking face on the club
head body member may be used without departing from this invention.
For example, if desired, the ball striking face may be provided as
a metal (or other material) face plate member engaged with the
cellular structure material of the club head body member, e.g., by
welding, soldering, brazing, adhesives, casting, forging, etc. As
another example, if desired, the ball striking face may be provided
as an integral part of the cellular structure material making up
the club head body member, e.g., by integrally forming a solid
metal face (or other material) on the cellular structure material
body; by at least partially filling, impregnating, or coating the
cellular structure material body with a metal and/or polymeric
material, such as an epoxy, the material making up the cellular
structure material, a different material, a different cellular
structure material, etc.; etc.
[0022] Additional aspects of this invention relate to golf clubs.
Golf clubs according to at least some examples of this invention
may include: (a) a club head body member constructed, at least in
part, from a cellular structure material (e.g., cellular structured
metal materials (also called "metal foam" materials, including
cellular structured alloys, amorphous metal or alloy materials,
etc.), cellular structured semi-metal materials, cellular
structured ceramic materials, cellular structured glass materials,
cellular structured polymeric materials (e.g., polyurethane foams),
cellular structured rubber materials, etc.); and (b) a shaft member
engaged with the club head body member. The shaft member may or may
not be directly engaged with the cellular structure material. The
club head body member further may include a ball striking face
engaged or integrally formed with the cellular structure material
or other portion of the club head body member structure.
Additionally, golf clubs in accordance with at least some examples
of this invention may include a grip member engaged with the shaft
member. Golf clubs in accordance with at least some examples of
this invention may be formed as putters, irons (including all types
of wedges), hybrid type clubs, fairway woods, drivers, and the
like, optionally with an additional weighting system, e.g., with
one or more permanent, fixed, movable, removable, or otherwise
customizable and/or selectable weight members.
[0023] Still additional aspects of this invention relate to methods
of forming golf club heads, e.g., of the various types described
above. Such methods may include, for example: (a) forming a club
head body member, at least in part, from a cellular structure
material; and (b) providing a ball striking face on or as part of
the club head body member. Optionally, if desired, the club head
body member may be formed as a multi-piece construction, and any
one or more of these multiple pieces may be formed from a cellular
structure material without departing from this invention. As a more
specific example, if desired, separate face plate members, sole
plate members, crown members, body ribbon members, and the like may
be constructed from the cellular structure material and/or attached
to the cellular structure material portion of the club head body
member without departing from this invention.
[0024] Yet additional aspects of this invention relate to methods
of forming golf clubs. Such methods may include, for example: (a)
forming a club head body member, at least in part, from a cellular
structure material; and (b) engaging a shaft member with the club
head body member (e.g., directly with the cellular structure
material, partially with the cellular structure material, with a
part of the club head material not made from cellular structure
material, etc). Any of the various types and variations on the club
head body member, the methods of making it, and the structures and
methods for weighting it, as described above, may be used in making
golf club structures without departing from these aspects of the
invention. Moreover, methods according to at least some examples of
these aspects of the invention further may include: (c) forming a
ball striking face on the club head body member (e.g., on at least
a portion of the cellular structure material, on another portion of
the club head body member, etc.), and/or (d) engaging a grip member
with the shaft member.
[0025] Given the general description of aspects of the invention
provided above, more detailed descriptions of various specific
examples of golf clubs and golf club head structures according to
the invention are provided below.
II. Detailed Description of Example Golf Club Heads and Golf Club
Structures According to the Invention
[0026] A. Cellular Structure Materials
[0027] FIG. 1 generally illustrates a block of a cellular structure
material 100 (e.g., a cellular structure metal (which includes
within its scope, unless otherwise noted, individual metals,
alloys, amorphous metals, amorphous alloys, and/or combinations
thereof), etc.) that may be used in golf club head construction in
accordance with at least some examples of this invention. Cellular
structure metal materials, as are known in the art, may include a
metallic base member 102 with numerous cells or voids 104 formed
therein (also called "pores" in this specification). As is known,
cellular structure materials (also called "cellular foams") may
have a density as low as 10%, 5%, 3%, or lower, based on the
density of the same base metal material without the cellular
structure, and they may have an open cellular structure or a closed
cellular structure. Regarding the other end of the spectrum,
cellular metal or other materials used in accordance with some
examples of this invention may have a density as high as 50%, 75%,
85%, or even 90% or higher, based on the density of the same base
metal material without the cellular or foam structure. Nonetheless,
despite the reduced amount of structural materials, weight,
density, and the presence of openings in the cellular material
structure, the resulting materials maintain very desirable physical
properties (e.g., strength, rigidity, deformation resistance or
return, etc.). Any desired pore size range may be used in the
cellular structure materials without departing from this invention.
Also, any degree or percentage of weight density may be used in
golf club head structures without departing from the invention,
e.g., provided the resulting club head structures and/or portions
thereof have adequate strength and other suitable physical
properties, e.g., when the club head strikes a ball and/or is
otherwise used in the manner intended for the club structure.
Suitability of a specific cellular structure metal or other
material for use in a golf club structure can be readily determined
through routine experimentation.
[0028] If desired, cellular structure materials, including cellular
structure metal materials, additionally or alternatively may be
used in other parts of the golf club structure without departing
from the invention, such as in the hosel area, in the shaft, in the
grip, etc.
[0029] While any desired type of metal or other material may be
used as the base member 102 without departing from the invention,
more specific examples of suitable metal materials include
aluminum, titanium, nickel, copper, zinc, carbon, zirconium,
tungsten, lead, molybdenum, and/or combinations and alloys thereof
(such as nickel-aluminum alloys, pewter, brass, etc.). Also, any
desired method of making the cellular structure material may be
used without departing from the invention, including conventional
ways that are known and used by commercial vendors of cellular
structure materials, such as: ALM (Applied Lightweight Materials)
GmbH of Saarbrucken, Germany; Alulight International GmbH of
Ranshofen, Austria; Cymat Corporation of Mississauga, Ontario,
Canada; ERG Materials and Aerospace Corporation of Oakland, Calif.;
Foamtech Co., Ltd. of Seoul, Korea; FiberNide Ltd. of Ontario,
Canada; Gleich GmbH of Kaltenkirchen, Germany; Hutte
Klein-Reichenbach Ges.m.b.H of Schwarzenau, Austria; Inco Ltd. of
Toronto, Ontario, Canada; Korea Metalfoam of Choenan, Korea;
Mitsubishi Materials Corporation of Okegawa-shi, Japan; M-Pore GmbH
of Dresden, Germany; Porvair Advanced Materials of Hendersonville,
N.C.; Recemat International B.V. of the Netherlands; Reade Advanced
Materials of Providence, R.I.; Spectra-Mat, Inc. of Watsonville,
Calif.; SAS Solea of Boussens, France; and Ultramet Corporation of
Pacoima, Calif. Note also, for example, the various materials and
methods of making them described in U.S. Pat. Nos. 6,932,146;
6,866,084; 6,840,301, 6,706,239; 6,592,787; 5,951,791; 5,700,363;
and 4,957,543, which patents are entirely incorporated herein by
reference. Furthermore, the cellular structure materials may be
produced into structures used in golf club heads or other golf club
parts (such as shafts, hosels, etc.) in any desired manner,
including through conventional machining, grinding, forging,
casting, molding, and/or other processing techniques known and used
in the golf club art, optionally before, during, and/or after the
cellular forming process has been completed.
[0030] Cellular structured metal materials that may be used in
accordance with at least some examples of this invention include
individual metals as well as alloys, combinations of metals,
combinations of metals with other materials, etc. In at least some
examples of this invention, the cellular structure material may
include an amorphous metal or alloy material, such as those
produced by and/or available from LiquidMetal Technologies, Inc. of
Lake Forest, Calif. Such amorphous metal materials (including metal
alloys) and their formation into various structures are known, for
example, as described in U.S. Pat. Nos. 6,446,558; 6,771,490;
6,818,078; 6,843,496; 6,875,293; and 6,887,586, and the documents
cited therein. Each of these patents is entirely incorporated
herein by reference. These amorphous metal materials may be formed
into cellular metal (or foamed) structures in various ways, e.g.,
by at least some of the various processes described in the
preceding paragraph.
[0031] As generally illustrated in FIG. 1, if desired, the pores
104 may be generally formed throughout the three dimensional
structure of the base member 102 (e.g., a metal alloy base). One or
more porous surfaces (such as surface 106) may remain exposed when
the cellular structure material 100 is formed into at least a
portion of the golf club structure. Alternatively, if desired, one
or more of the porous surfaces may be covered or enclosed, e.g.,
before, during, or after the cellular structure material 100 is
formed into a portion of a golf club structure. FIG. 2 illustrates
an example cellular structure material 200 in which the cells or
pores 104 of the base member 102 are enclosed in or covered by a
layer of material 202, e.g., coated, impregnated, filled, and/or
overlaid with one or more layers of material the same as or
different from the base material 102. In this manner, an exposed
surface of the material or the resulting club structure will not
include open voids or pores, thereby presenting a smooth,
consistent surface and/or appearance to the club structure. This
type of filled structure also may be referred to herein as a
"cellular structure material composite." The fill layer 202 may
have any desired thickness, e.g., from 10 Angstroms to 4 cm or even
more, or even a varying thickness. The fill layer 202 also may
directly follow the shape or contours of the underlying base member
102 (if any), or it may provide an independent exterior or exposed
shape from that of the underlying base member 102. The fill layer
202 itself also may be porous or non-porous without departing from
the invention.
[0032] The layer 202 may be formed on the cellular structure base
member 102 in any desired manner and at any desired time in the
cellular structure material and/or club making process without
departing from this invention. Additionally, the layer 202 may be
made from any desired material without departing from the
invention. As more specific examples, if desired, the layer 202 may
be integrally formed with the cellular structure base member 102,
e.g., as a thin, solid sheet of the same metal material as that
making up the cellular structure base member 102 (e.g., layer 202
may be a thin aluminum layer integrally formed as a one piece
construction with a cellular aluminum base member 102, etc.), it
may be formed of a different metal material, etc. If desired, a
molten metal material (the same as or different from the base
member 102) may be used to fill all or some of the exterior pores
104 and/or provide a smooth exterior surface. As additional
examples, if desired, layer 202 may be a separate piece of material
engaged with the base member 102 in any desired manner, such as by
adhesives, cements, welding, soldering, brazing, or other bonding
or fusing techniques, or via mechanical connectors. As still
additional examples, if desired, layer 202 may constitute a
polymeric material coating, such as an epoxy, a polyethylene,
polyurethane, polystyrene; a glass coating; a ceramic coating; a
rubber coating; or the like, that is coated over (and optionally
into at least some of the voids 104 and/or at least partially
filling at least some of the voids 104) and/or forms a solid layer
atop the metal base member 102. As still additional examples, if
desired, some or all of the voids or pores 104 of the overall metal
base member 102 may be filled or at least partially filled with a
polymeric material, such as the various polymeric materials
described above (e.g., the polymeric material may be provided to
fill or impregnate the pores 104 at least at or near one or more
exterior surfaces 106 of the cellular structure material 100 so as
to provide a smooth finish at the various surfaces, etc.). Of
course, still other ways of providing a smooth exterior surface
(e.g., including a smooth ball striking exterior surface), if
desired, may be provided without departing from the invention.
Coating, impregnating, and/or filling a cellular structure base
material 102 with polymeric or metal (or other) material may take
place at any desired time in the cellular structure material and/or
club production process without departing from this invention
(e.g., before, during, or after foaming; before, during, or after
club head production; before, during, or after shaft formation or
attachment; etc.).
[0033] The cellular structure materials may have any desired pore
sizes, pore size distributions, multiple pore size distributions,
or no readily discernable pore size distribution without departing
from this invention. Additionally, if desired, a given golf club
head structure and/or individual component may contain multiple
different cellular structure materials, e.g., different portions of
the club made of different materials (e.g., different metals),
different portions of the club having different densities or pore
distributions, etc. (generically called "multiple cellular
structure materials" herein), a different fill material in the
pores at different locations, etc.
[0034] In view of the above description of the cellular structure
materials, more specific examples of golf club structures including
such materials are provided below.
[0035] B. Example Putter Structures
[0036] One example aspect of this invention relates to putter
structures that include one or more parts made, at least in part,
from cellular structure metal or other materials, e.g., aluminum,
nickel, titanium, or other cellular materials. Cellular structure
raw materials and/or cellular structure parts for use in the club
structure may be obtained, for example, from one or more of the
various vendors identified above.
[0037] FIGS. 3A through 3E illustrate examples of parts for a
putter structure 300 that may be made from a cellular structure
material (e.g., a cellular structure metal material) in accordance
with at least some examples of this invention. The first structural
member 302 (also called a "body member" in this specification), as
illustrated in FIG. 3A, includes a first surface 304 that faces a
golf ball (or other ball) when the club head is used. The body
member 302 in this illustrated example essentially is rectangular
cubic shaped such that a second surface 306 is located opposite the
first surface 304. Of course, a wide variety of sizes, shapes, and
orientations of body member 302 and/or other putter head designs
may be used without departing from the invention.
[0038] The second surface 306 of this example body member structure
302 has an opening 308 defined therein. Opening 308 in this example
structure extends completely through the body member 302, from the
second surface 306 to the first surface 304. In other examples, if
desired, the opening 308 need not extend all of the way through the
club head portion of body member 302. For example, if desired, the
opening 308 could begin at surface 306 and extend part way through
the club head portion of body member 302 but terminate before it
reaches the first surface 304. As another example, if desired, the
opening 308 may be provided in the top surface 310 or another
surface of the club head portion of the body member 302 without
departing from the invention, optionally with or without an opening
provided in the front surface 304. As still another example, if
desired, in some structures, no opening will be required (e.g., the
insert member 350, as described in more detail in conjunction with
FIG. 3B, may be integrally formed with or attached to the body
member 302 in some manner).
[0039] The body member 302 of this example structure further
includes a base member 312 that extends in a direction behind the
club head face and away from the first surface 304 and the second
surface 306. The base member 312 may take on a wide variety of
different structures and shapes without departing from the
invention. In the illustrated example, the base member 312 includes
a lowered flat region 314 immediately adjacent the opening 308 to
provide easy access to the opening 308 (for reasons that will
become more apparent in the description to follow). From the
lowered flat region 314, the base member 312 forms an angled
portion 316 that extends back away from the club head portion of
the body member 302 and upward, and then the base member 312 of
this example structure further provides a handle or shaft mounting
system 318. Any suitable or desired manner of mounting a shaft or
handle to the club head body member 302 may be used without
departing from the invention, including conventional manners known
and used in the art. For example, a shaft may be screwed or
threaded into a suitable receptacle region 318 on the base member
312, it may be secured via adhesives, mechanical connectors, and/or
the like.
[0040] The base member 312 of this example structure extends back
further and provides a securing region 320. The securing region 320
is used in this example structure to secure the body member 302 to
another portion of the overall club head structure 300, as will be
described in more detail below.
[0041] The base member 312 may be included as part of the club head
portion of the body member 302 in any suitable or desired manner
without departing from the invention. For example, the entire
structure 302 may be a unitary, one-piece construction, e.g.,
formed by casting, forging, molding, machining, etc. As another
example, the base member 312 may be welded, soldered, press fit,
inserted into, adhesively applied to, and/or otherwise attached to
the club head portion of the body member 302. The base member 312
and the club head portion of the body member 302 may be made from
any suitable or desired material without departing from the
invention, including conventional materials known and used in the
art. Examples of suitable materials include: aluminum, titanium,
nickel, steel, brass, pewter, carbon fiber, polymers, glasses,
ceramics, rubber, etc. Also, if desired, the base member 312 and/or
the club head portion 302 may be constructed from a cellular
structure material, including cellular structure metal materials,
as described above, optionally with a coating or other layer to
provide a smooth exterior or at least the ball striking
surface.
[0042] The base member 312 also may be attached to or otherwise
included as part of the club head portion of the body member 302 at
any desired position or location without departing from the
invention. In this illustrated example, the base member 312 extends
from the bottom center of the club head, below opening 308.
Alternatively, if desired, as additional examples, the base member
312 may extend from the top of the club head (e.g., above opening
308), from the top surface 310, from along one or both sides of the
opening 308, from the side and/or bottom surfaces of the club head
portion, and/or from any other desired location without departing
from the invention. As another example, if desired, the base member
312 may extend from and/or be included as part of the insert
portion 350, which is described in more detail below in conjunction
with FIG. 3B. In still other examples, if desired, no base member
312 is required in the overall body member structure 302 and/or the
overall putter structure.
[0043] Notably, the base member 312 in this example has a very open
or "truss-like" structure, with open areas 322 defined in it at
various locations. These open areas 322, along with the potential
construction of all or some portion of the body member 302 from a
cellular structure material, help reduce the overall weight of the
body member 302, which allows additional weight to be distributed
elsewhere in the overall club head structure, while still
maintaining an overall strong and stable structure and avoiding an
excessively heavy structure. The material(s) making up the body
member 302, including the base member 312, also may be selected so
as to avoid creating an excessively heavy club head structure. The
potential re-distribution of weight in the overall club head
structure and its advantageous effects on the club head's moment of
inertia, center of gravity, and/or other characteristics will be
described in more detail below.
[0044] FIG. 3B illustrates an example of a second piece of a putter
head in accordance with at least some examples of this invention.
This second member 350 (also called an "insert member" in this
specification) includes an insert portion 352 that is sized and
shaped so as to be received in the opening 308 defined in the body
member 302 (e.g., press or friction fit into the opening 308,
adhesively engaged within the opening 308, etc.). This example
insert member 350 further includes a body portion 354 that extends
in a direction away from the insert portion 352. The insert portion
352 and the body portion 354 may be of a unitary, one-piece
construction, or alternatively, if desired, the insert portion 352
may be separate from and engaged with the body portion 354 in any
desired manner without departing from the invention, such as via
welding, soldering, brazing, adhesives, mechanical connectors,
inserts, press fitting, and the like. Moreover, the insert member
350, optionally including the insert portion 352 and the body
portion 354, may be formed of any suitable or desired materials
without departing from the invention, including conventional
materials known and used in the art. As more specific examples, the
various portions of insert member 350 may be constructed from one
or more of: aluminum, titanium, steel, brass, pewter, nickel,
carbon fiber, polymers, glasses, ceramics, rubbers, etc. If
desired, in at least some examples of this invention, at least some
portion(s) of the insert member 350 (e.g., the insert portion 352
and/or the body portion 354), or even all of it, may be constructed
from a cellular structure material (optionally a cellular structure
material such as a cellular structure metal material that displays
a smooth exterior surface, e.g., due to filling, coating,
impregnating, or layering, as described above).
[0045] The insert member 350, including the insert portion 352
and/or the body portion 354, may take on any desired shape or form
without departing from the invention. In at least some examples of
the invention, the body portion 354 will be constructed and shaped
so as to form an open area 356 (or another central area of reduced
mass). In this illustrated example, the body portion 354 is
generally triangular shaped including a base side 358 and two side
arms 360 and 362, wherein the open area 356 is defined between the
base side 358 and the side arms 360 and 362. The base side 358, in
this example, extends in a direction parallel to (or substantially
parallel to) a front surface 364 of the insert portion 352 (and it
will extend parallel to (or substantially parallel to) the front
surface 304 of base member 302, when the insert member 350 is
joined with base member 302). Of course, any desired arm lengths,
arm widths, arm thicknesses, base side lengths, base side
thicknesses, relative arm angles, and the like may be used in the
insert member 350 without departing from the invention. Also,
shapes other than the generally triangular shape shown in FIG. 3B
may be used for the insert member 350 without departing from the
invention, such as rectangular shaped, elliptical-shaped,
round-shaped, trapezoidal-shaped, etc.
[0046] The open area 356 helps reduce the overall weight of the
insert member 350. To further reduce the weight of the insert
member 350, if necessary or desired, interior portions of its
structure (e.g., its arms 360 and 362 or base side 358) may be
hollowed out, formed into an open or "truss-like" structure (e.g.,
similar to the structure for the base member 312 shown in FIG. 3A)
and/or formed from a cellular structure material. As still another
example, the insert portion 352 is shown in FIG. 3B as including
two cut out or hollowed out regions 352a and 352b, which may extend
completely through the insert portion 352 (if desired, these
hollowed out regions 352a and 352b could partially extend through
the insert portion 352). Of course, such cut out or hollowed out
regions may be provided along the side arms 360 and 362 and/or
along the base side 358 without departing from the invention. Also,
if desired, the material(s) for constructing the insert member 352
may be selected so as to control the overall weight of the device
(e.g., lightweight aluminum or titanium materials, etc.).
[0047] The cut out or hollowed out regions 352a and 352b (if any),
as well as the open area 356 (if any) and the open structure 322 of
the base member 312, as well as the structure of the materials used
to make up at least some of these elements (e.g., lightweight
materials made from, for example, aluminum, titanium, nickel,
polymers, glasses, ceramics, rubbers, etc.), help reduce the
overall weight of the entire club head. The reduced weight enables
club makers and designers to apply additional weight at other
selected locations in the overall club head structure without
excessively increasing the club head's total weight. Weight
distribution and control of this type allows one to change and/or
control the swing characteristics of the overall club head (e.g.,
increase the club head's moment of inertia, etc.). Any desired way
of redistributing and/or weighting the club head 300 may be used
without departing from the invention. For example, the insert
member 350 may include receptacles 366 and 368 for receiving
weighted members 370 and 372, respectively, such as weighted
inserts including lead, tungsten, or other heavy metals or
materials. If desired, the weighted members 370 and 372 may be
removably mounted to the insert member 350, e.g., by removable
adhesives, threads, turnbuckles, clamps, clasps, set screws, or
other mechanical connections, so that the weighted members 370 and
372 may be easily removed from their receptacles 366 and 368,
interchanged for other weighted members, etc. This feature enables
customization of the swing characteristics of the overall club head
to better suit an individual user's swing characteristics,
preferences, and the like.
[0048] The receptacles 366 and 368 (and hence the weighted inserts
370 and 372) may be provided at any desired location on the overall
club head structure 300 without departing from the invention. In at
least some examples of the invention, as illustrated in FIGS. 3B
and 3E, the receptacles 366 and 368 are located on the insert
member 350, and even more particularly, on the body portion 354 of
the insert member 350, e.g., at locations remote from the insert
portion 352 and/or away from the center of the ball striking
surface. Using the triangular shaped body portion 354 shown in FIG.
3B, the weighted member receptacles 366 and 368 (and hence the
weighted members 370 and 372 themselves) may be located at the
corner regions of the triangular shaped body portion 354, generally
at the locations where the base side 358 meets each of the side
arms 360 and 362. This arrangement provides the weighted members
370 and 372 behind the ball striking face and toward the club
head's heel and toe, which increases the club head's moment of
inertia characteristics (e.g., its resistance to twisting during a
swing and/or during contact with a ball).
[0049] FIGS. 3C and 3D illustrate different perspective views of an
example overall putter structure 300 including the body member 302
and the insert member 350 as illustrated in FIGS. 3A and 3B. As
shown in FIG. 3C, the insert portion 352 of the insert member 350
fits into the opening 308 provided in the back surface 306 of the
body member 302. The flattened region 314 and the angled region 316
of the base member 312 provide sufficient room to allow insertion
of the insert portion 352 into the opening 308. The insert member
350 and the body member 302 may be secured together at the insert
portion 352/opening 308 location, if desired, in any desired manner
without departing from the invention, including in conventional
manners known in the art, such as via welding, adhesives,
mechanical connections, spring-loaded detents or other mechanical
engaging systems, other bonding techniques, other fusing
techniques, or the like. If desired, the insert member 350 and the
body member 302 may be secured together in a removable manner
(e.g., via bolts, nuts, screws, set screws, clamps, clasps, or
other mechanical connectors) without departing from the invention
so that different parts of the overall putter structure 300 can be
interchanged, e.g., by a user, a club repair person, by a club
fitter, etc., e.g., to allow changes to the club's swing
characteristics, to customize the club head 300 to a user's
preferences, to change the club head 300 based on play conditions
(e.g., fast greens v. slow greens, wet conditions v. dry
conditions, etc.), etc. As another example, the insert member 350
and the body member 302 may be press fitted together at the insert
portion 352/opening 308 (e.g., sized and shaped so as to tightly
fit together) and/or mechanical attachments may be used to hold the
pieces together, without permanently fixing the insert portion 352
into the opening 308. FIGS. 3C and 3D further illustrate a shaft or
handle 380 mounted to the base member 312 at the shaft mounting
region 318. If desired, the shaft or handle 380 may be made, at
least in part, from a cellular structure material.
[0050] Additional features present in structures according to at
least some examples of the invention are shown in FIGS. 3C and 3D.
As shown in these figures, the body member 302 and the insert
member 350 may be secured to one another at a location where the
base member 312 meets the body portion 354 of the insert member
350. While any manner of securing these members 302 and 350
together may be used without departing from the invention, in the
illustrated example, one or more bolts, screws, rivets, or other
connectors 382 pass through securing region 320 of body member 302
and through securing region 374 of insert member 350 (see also
FIGS. 3A and 3B). Alternatively (or additionally), if desired, the
base member 312 of the body member 302 may be secured to the body
portion 354 of the insert member 350 at the securing region 320 by
adhesives, welding, soldering, set screws, clamps, clasps,
spring-loaded detent mechanisms, other mechanical connectors,
and/or in any other desired manner without departing from the
invention, including in conventional manners known and used in the
art.
[0051] As further illustrated by FIG. 3D, the opening 308 in this
example structure extends all of the way through the body member
302, ending at the front surface 304 of the body member 302.
Accordingly, when the insert member 350 is inserted into the
opening 308 in this example structure, the front face 364 of the
insert member 350 is exposed through the front surface 304 of the
body member 302. In the illustrated example, the front surfaces 304
and 364 of the body member 302 and the insert member 350,
respectively, are flush or substantially flush with one another in
the final club head structure 300, and these surfaces 304 and 364
together form the ball striking surface of this example putter
structure 300.
[0052] FIG. 3E illustrates an overhead view of the club head
structure 300 of FIGS. 3A through 3D. Various "hidden" features of
the insert member 350 in this view are shown in broken lines to
help provide a more complete picture of the club head structure 300
according to this example of the invention.
[0053] As generally described above, the combination of the use of
lightweight materials (such as the cellular structure materials for
at least portions of the insert member 350, the base member 302,
and/or the shaft member 380) and/or the open areas in the club head
structure (e.g., areas 322, 352a, 352b, 356, and the like) reduce
the mass of the overall club head structure 300 and allow the club
designer or manufacturer to place that mass at other locations in
the design (e.g., using permanent weights, removable weighted
members 370 and 372, etc.) and thereby change and/or control the
swing characteristics of the club. In the example illustrated in
FIGS. 3A through 3E, much of this mass is redistributed at the
outer regions of the club head 300, behind the ball striking face
and toward the club head's heel and toe (e.g., at the external
corners or external perimeter of the triangular shaped insert
member's body portion 354, between arms 360 and 362 and the base
member 358). Using additional weighting of a club head, e.g., of
the type illustrated in FIGS. 3A through 3E, the overall club head
design (i.e., the combination of body member 302, insert member
350, and any weighted inserts) may be structured and weighted so
that the club head will have a high moment of inertia, e.g., at
least 10,000 g/cm.sup.2 about the center of the ball striking face
304 and 364. The moment of inertia provides a measure of a club
head's resistance to twisting, e.g., both during a swing and/or
during contact with an object to be hit (e.g., such as a golf
ball). A twisted or twisting club head, either during a swing or
during contact, will tend to send a ball off-line, with undesired
spin, and/or miss the club's desired ball contact location, e.g.,
resulting in a loss of distance or a mis-directed hit. Therefore,
the high moment of inertia associated with club head structures
according to at least some examples of the invention may help
prevent club head twisting and/or mis-hits.
[0054] Of course, many variations in the design of the various
parts of a putter structure are possible without departing from the
invention. For example, if desired, the connection between the base
side 358 of the insert member 350 and the base member 312 can be
omitted, and thus the base member 312 need not extend all the way
to the base side 358. Also, if desired, any of the open areas 322,
352a, 352b, and/or 356 may be omitted, may be covered, and/or may
be made larger or smaller without departing from the invention.
[0055] FIGS. 4A and 4B provide perspective views of another example
putter structure 400 in accordance with this invention. In this
example, a body member 402 provides a ball striking portion 404 and
a base member 406 extending away from the ball striking portion 404
(and toward the rear of the club structure 400). An opening 408 is
defined in the rear surface 410 of the ball striking portion 404,
and this opening 408 extends from the rear surface 410 through to
the front surface 412, which faces the ball during use. If desired,
of course, the opening 408 could begin at rear surface 410 and
extend part way through the ball striking portion 404 of body
member 402 and terminate before it reaches the front surface 412.
As another example, if desired, the opening 408 may be provided in
another surface of the ball striking portion 404, or not at all,
without departing from the invention. Also, if desired, the ball
striking portion 404 may take on any desired form (and is not
limited to a generally cubic rectangular form in all examples of
the invention).
[0056] The base member 406 of this example structure 400 includes a
flattened portion 414 and an angled portion 416 to allow room for
insertion of an insert member 450 into the opening 408, which will
be described in more detail below. A shaft or handle receptacle 418
is provided along the angled portion 416 of the base member 406, in
an off-set manner. Of course, this shaft or handle receptacle 418,
or other shaft mounting means, may be provided at any desired
location or in any desired orientation without departing from the
invention. Additionally or alternatively, the shaft or handle may
be mounted to the putter structure 400 at any desired location on
the structure 400 (including on the insert member 450 or on both
the body member 402 and the insert member 450) without departing
from the invention.
[0057] Insert member 450 includes an insert portion 452 and a body
portion 454. The insert portion 452 is inserted into the opening
408 of the body member 402, and the body portion 454 extends in a
direction rearward and away from the ball striking portion 404. In
this example, the base member 406 of the body member 402 does not
attach to the body portion 454 of the insert member 450, although
the body member 402 may be attached to the insert member 450 at the
insert portion 452/opening 408 interface (e.g., using adhesives,
welding, set screws, bolts, clamps, clasps, other mechanical
connectors, a tight friction fit, press fitting, etc.). Optionally,
the body member 402 and the insert member 450 may be removably
attached to one another such that repairs may be made, the swing
characteristics of the overall club head 400 may be changed, etc.,
e.g., by interchanging body members 402 and insert members 450.
This feature may allow users or club fitters to freely customize
the club by interchanging body members 402 and/or insert members
450, e.g., to suit their swing characteristics or preferences, to
match play conditions (e.g., fast greens v. slow greens, wet
conditions v. dry conditions, etc.), etc.
[0058] In this illustrated example, the body portion 454 of insert
member 450 is generally triangular shaped, with two side arms 456
and 458 and a base side 460. The body portion 454 has a reduced
weight area, in this example embodied as an open area 462 defined
in the body portion. Also, if desired, all or at least some
portions of the insert member 450 (and/or the body member 402) may
be constructed from a cellular structure material (e.g., a cellular
structure metal, semi-metal, amorphous metal, polymer, rubber,
ceramic, etc.), to further reduce the weight of the main body
portion(s) of the overall club head structure 400. Additional
weighted areas 464 and 466 may be provided at the corner regions of
the triangular base structure (i.e., where the base side 460 meets
the two side arms 456 and 458), to thereby re-distribute weight
(e.g., saved via use of the cellular structure material and/or open
area 462 structures) to the rear, heel, and toe regions of the club
head structure 400. Rather than providing selectively removable
weighted members (like those shown in FIGS. 3B and 3E), in this
example structure 400, the weighted areas 464 and 466 are provided
by not extending the open area 462 all the way to the corners of
the triangular structure (e.g., at least some of the metal,
cellular structure material, polymeric, or other structural
material of the body portion 454 is left at the areas of the body
portion remote from the ball striking portion 404, and optionally,
these areas 464 and 466 may be made from and/or constructed to
include a denser or weighted material, such as lead or tungsten
materials). If desired, additional weights may be fitted and
received in the weighted areas 464 and 466, optionally in a
selectively removable manner, without departing from the invention.
The additional weights, if present, may be in the form of metal or
weighted inserts (e.g., lead, tungsten, etc.), weighted adhesive
(e.g., lead tape), or any other form without departing from the
invention.
[0059] As shown in FIG. 4A, the front surface 468 of the insert
member 450 is exposed through the opening 408 and forms at least a
part of the ball striking surface of the putter structure 400.
While the front surface 468 of the insert member 450 and the front
surface 412 of the body member 402 are shown flush (or
substantially flush) in this illustrated example (and together form
the overall ball striking face of the putter structure 400), if
desired, these surfaces need not be flush. For example, if desired,
the front surface 468 of the insert member 450 may extend out of
the opening 408 and in front of the front surface 412 of the body
member 402 (e.g., such that the front surface 468 exclusively forms
the ball striking face of the putter structure 400). Various sizes
and/or shapes of front surface 468 exposed through the opening 408
(if any) may be used without departing from the invention.
[0060] The putter structure 400 of this example includes additional
features. For example, as illustrated, the base side 460 is curved
and provides an indicia area 470. These features provide an
interesting aesthetic design to the club head 400. If desired, a
club maker, manufacturer, or another may provide a logo, model
name, model number, owner's name, and/or other indicia or data in
the indicia area 470.
[0061] The putter structure 400 of FIGS. 4A and 4B also differs
from the examples illustrated in FIGS. 3A through 3E in that the
base member 406 of the body member 402 extends from the top area of
the ball striking head 404, rather than the bottom area. Thus, the
flattened area 414 of the base member 406 extends away from the
ball striking surface 412 and the insert member 450 fits underneath
the base member 406. This structure 400 also provides the angled
portion 416 and the handle mount 418 extending in different
directions as compared to the structures described above in
conjunction with FIGS. 3A through 3E. Of course, the base member
406 may be provided at other locations, including beneath opening
408, along side opening 408, and/or elsewhere, without departing
from the invention. Numerous other structural modifications and the
like are possible without departing from the invention. Also, if
desired, the overall putter head structure 400 may be formed as a
one piece construction without departing from the invention.
[0062] FIG. 5 illustrates another example of a putter structure 500
according to some example aspects of this invention. In this
example structure, the putter head 500 includes a ball striking
front surface 502 and a body member 504 extending in a direction
away from the ball striking surface 502. Putter heads of this
general design may have a moment of inertia about a center of the
ball striking surface 502 of at least 20,000 g/cm.sup.2, and in at
least some examples the moment of inertia will be at least 25,000
g/cm.sup.2, and even at least 28,000 g/cm.sup.2 in some
examples.
[0063] As with the various examples described above, the material
that makes up all or at least some portions of the golf club head
500 may help provide the desirable moment of inertia
characteristics described above. For example, all or at least some
of the body portion 504 may be made of a lightweight material, such
as a lightweight polymeric material (e.g., a polyamide or nylon
material, a polymeric cellular structured material, etc.), a
lightweight metal material (e.g., such as a cellular structure
aluminum, titanium, and/or nickel material), or the like. In at
least some examples, the body portion 504 and the ball striking
portion 506 of the club head (e.g., the portion of the club head
including the ball striking surface 502) may be integrally formed
as a unitary, one-piece construction, e.g., from a cellular
structure material as described above. If desired, however, the
body portion 504 may be designed as an insert that fits into one or
more openings provided in the ball striking portion 506, as
described above in more detail in conjunction with FIGS. 3A through
4B. As still another option, the body portion 504 may be attached
to a separate ball striking portion 506 in any desired manner
without departing from the invention (e.g., using adhesives,
mechanical connectors, welding, etc.). If desired, the ball
striking portion 506 may be made of a different material as
compared to the body portion 504 without departing from this
invention (e.g., each made from different cellular structure
materials, etc.).
[0064] The ball striking front surface 502 may take on various
forms without departing from the invention. For example, the ball
striking surface 502 may be integrally formed as simply the
front-most surface of the ball striking portion 506. As another
alternative, if desired, the ball striking surface 502 may be a
metal plate, polymeric coating, or other material that is attached
to or formed on the front of the ball striking portion 506, e.g.,
using adhesives, screws, mechanical connectors, coating technology,
etc. As still another option, the ball striking surface 502 and/or
the ball striking portion 506 may be integrally formed as a
unitary, one-piece construction with the remainder of the body
portion 504 without departing from the invention. As yet another
option, at least a portion of the ball striking surface 502 may be
provided as an insert portion attached to or formed as part of the
body member 504 (or another structural member) that is inserted
into an opening defined in the ball striking portion 506, e.g., as
generally described above in connection with FIGS. 3A through 4B.
Other ways of providing the ball striking surface 502 may be
utilized without departing from this invention.
[0065] Additional features of the structure of the club head 500
may help produce the favorable moment of inertia characteristics
described above. For example, the body member 504 may be designed
so as to extend behind and outside the ball striking surface 502.
For example, side arms 508 and 510 of the body member 504 may
extend back and outside of the ball striking portion 506. The body
member 504 further may include a base member 512 that extends
behind the ball striking portion 506, in a manner parallel to (or
essentially parallel to) the ball striking surface 502. Thus, the
overall club head structure 500 may have a generally trapezoidal or
triangular appearance (e.g., depending on the location where the
arms 508 and 510 meet the ball striking portion 506), with an
optionally open area 514 defined in its center. The arms 508 and
510 are illustrated as being shorter than the ball striking portion
506 (into and out of the page of FIG. 5), and the base member 512
has an even thinner portion 516. These reduced sizes, as well as
the open area 514, help reduce the overall weight of the body
member 504 (and optionally make that weight available for
redistribution elsewhere in the club head structure 500, as will be
described in more detail below). If desired, the arms 508 and 510
and/or the base member 512 may be hollowed out and/or produced in a
"truss-like" manner and/or formed at least partially from a
cellular structure material, to further reduce their weight (and to
further make that weight available for redistribution
elsewhere).
[0066] In at least some examples of the invention, the club head
500 may be relatively large sized, e.g., at or near the limits
permitted by current USGA regulations and guidelines. Currently,
the USGA guidelines limit putter head designs to: (a) a maximum
overall width (e.g., dimension "A" in FIG. 5) of seven inches
(A.ltoreq.7 inches); (b) a maximum overall depth (e.g., dimension
"C" in FIG. 5) of less than dimension "A" (A>C); (c) a minimum
face width (e.g., dimension "B" in FIG. 5) of at least 2/3 of
dimension "C" and at least 1/2 of dimension "A" (B.gtoreq.2/3 C and
B.gtoreq.1/2 A); and (d) a maximum overall height (e.g., into and
out of the page of FIG. 5) of 2.5 inches.
[0067] In this illustrated example, the body member 504 includes a
pair of weighted member receptacles 518 and 520 located behind the
ball striking surface 502 and at least partially outside of this
surface 502 (e.g., toward the club head's heel and toe directions).
More specifically, at least some portions of the weighted member
receptacles 518 and 520 are located outside of a plane oriented
perpendicular to the ball striking surface 502 and located at the
respective ends 502a and 502b of the ball striking surface 502 (see
planes P.sub.1 and P.sub.2 in FIG. 5). If desired, in at least some
examples, the entire weighted member receptacles 518 and 520 may be
located outside of these planes without departing from the
invention. Weighted members 522 and 524 (e.g., lead, tungsten, or
other heavy material inserts) may be provided in the receptacles
518 and 520, respectively, to provide extra weighting behind and
generally at the outer perimeter or at the heel and toe portions of
the club head structure 500. Thus, at least some portions (or all)
of the weighted members 522 and 524 also are located outside of the
planes P.sub.1 and P.sub.2 described above.
[0068] The example structure 500 illustrated in FIG. 5 further
includes a base portion 526 extending away from the ball striking
surface 502 and toward the rear of the club head structure 500.
This base portion 526 may be provided at the very center of the
ball striking surface 502, and thereby may act as an alignment aid
for the putter head structure 500 (e.g., identifying the desired
ball contact location of the club head). The base portion 526 may
extend from and/or attach to the ball striking portion 506 and/or
the body portion 504 in any desired manner without departing from
the invention. For example, the base portion 526 may be attached to
one or more of the body portion 504, the ball striking surface 502,
and/or the ball striking portion 506, e.g., via adhesives, welding,
soldering, mechanical connectors, and the like. As another example,
the base portion 526 may be integrally formed as a unitary
one-piece construction with the body portion 504, the ball striking
surface 502, and/or the ball striking portion 506, optionally made
from the same materials as one or more of these elements, without
departing from the invention. If desired, the base portion 526 may
be formed, at least in part, from a cellular structure
material.
[0069] The club head structure 500 further may include a shaft
mounting member 528 (e.g., a hosel member) to which a shaft 530 is
mounted, e.g., in any desired manner, including in conventional
manners known and used in the art. Any desired type of shaft 530
may be used without departing from the invention, including shafts
530 of conventional design and made of conventional materials as
are known and used in the art. Alternatively, if desired, either or
both of the shaft mounting member 528 and the shaft 530 may be made
from a cellular structure material.
[0070] C. Example Iron Type Golf Club Structures
[0071] Putters are not the only types of golf clubs that can take
advantage of the weight saving properties of cellular structure
materials. These lightweight materials also can be used, for
example, in iron type golf club structures. Referring to FIGS. 6A
through 6C, a golf club 600 in accordance with at least some
examples of this invention is illustrated. This example golf club
600 includes a shaft 602 and a golf club head 604. The golf club
head 604 of FIGS. 6A through 6C may be representative of any iron
or hybrid type golf club head. The shaft 602 of golf club 600 may
be made of various materials, such as one or more of steel,
titanium, graphite, or composite materials, as well as combinations
thereof, including materials that are conventionally known and used
in the art. As another example, if desired, the shaft 602 may be
made, at least in part, from a cellular structure material.
Additionally, the shaft 602 may be attached to the club head 604 in
any desired manner, including in conventional manners known and
used in the art (e.g., via adhesives or cements at a hosel element
612 (which itself may be made from a cellular structure material),
via threads or other mechanical connectors, etc.). A grip element
(not shown) may be positioned on the shaft 602 to provide a golfer
with a slip resistant surface with which to grasp golf club shaft
602. The grip element may be attached to the shaft 602 in any
desired manner, including in conventional manners known and used in
the art (e.g., via adhesives or cements, mechanical connectors,
etc.).
[0072] As shown in FIG. 6A, the golf club head 604 includes a body
member 606 that includes a heel portion 608 and a toe portion 610.
The heel portion 608 is attached to and/or extends from a hosel 612
(e.g., as a unitary or integral one-piece construction) for
connecting the shaft 602 of FIG. 6A to the golf club head 604. The
body member 606 also includes a top portion 614 and a sole portion
616. A striking face 618 is provided between the top portion 614
and the sole portion 616, and between the toe 610 and the heel 608.
The striking face 618 provides a contact area for engaging and
propelling a golf ball in an intended direction. The striking face
618 may include grooves 620 (e.g., generally horizontal grooves 620
extending across the face 618 in the illustrated example) for the
removal of water and grass from the striking face 618 during a ball
strike. Of course, any number of grooves and desired groove pattern
may be provided (or even no groove pattern, if desired), without
departing from this invention.
[0073] The body member 606 of the golf club head 604 may be
constructed from a wide variety of different materials, including
materials known and used in the art, such as steel, titanium,
aluminum, nickel, tungsten, graphite, polymers, or composites, or
combinations thereof. Advantageously, at least some portion of the
club head structure (e.g., a major body portion thereof) will be
formed from a cellular structure material. Also, the club head 604
may be made from any number of independent pieces and/or by any
construction technique, including, for example, casting, forging,
and/or other methods known and used in the art.
[0074] FIG. 6B illustrates a rear view of a golf club head 604 in
accordance with at least some examples of this invention. This
example golf club head 604 includes a rear face 624 positioned
opposite the striking face 618. The rear face 624 forms or defines
a first rear cavity 626 having a relatively large opening. A bridge
member 628 extends across the first rear cavity 626, and this
bridge member 628 may connect the heel portion 608 of the club head
604 to the toe portion 610. Bridge member 628 also may extend
across the first rear cavity 626 in other directions and may be
connected at various other locations on a golf club head structure
without departing from the invention, as shown, for example, in
U.S. Pat. No. 6,450,897 issued on Sep. 17, 2002 to John T. Stites,
et al., which patent is entirely incorporated herein by reference.
Bridge member 628 may have any desired shape, such as rectangular,
oval, triangular, trapezoidal, square, or other symmetrical or
asymmetrical shapes. Bridge member 628 also may have a uniform or
non-uniform width or thickness throughout its length.
[0075] Bridge member 628 may be connected to the toe portion 610
and/or the heel portion 608 (or other portion(s)) of the club head
604 in any desired manner, including through the use of mechanical
connectors (such as rivets or screws 630), fusing techniques (such
as welding, soldering, brazing, etc.), bonding techniques (such as
adhesives or cements), etc. Those skilled in the art will recognize
that bridge member 628 may be connected to the toe portion 610
and/or the heel portion 608 using fewer or additional connection
points or elements than shown in FIG. 6B and/or through numerous
other connection means and/or techniques without departing from the
present invention. As still additional examples, if desired, bridge
member 628 may be formed with the golf club head 604 in a single
casting and/or as a single unitary element, thereby making the
bridge member 628 a one piece construction with the golf club head
604.
[0076] In the golf club head structure 604 according to this
illustrated example of the invention, a second rear cavity 632 is
provided below the bridge member 628, as shown in FIG. 6B. With
reference to FIG. 6C, a cross-sectional view of an example golf
club head 604 is illustrated. As shown, in this arrangement, a
major body portion 640 of the club head 604 is formed from a
cellular structure material, e.g., made from foamed aluminum,
titanium, nickel, etc. A face plate 642 is formed on and/or
overlays the cellular structure material 640, to provide a solid,
consistent surface through which the ball is struck. The face plate
642 may be integrated with the major body portion 640 in any
desired manner, e.g., fabricated as a one piece construction;
welded, brazed, or soldered thereto; bonded thereto with cements or
adhesives, etc.; coated or filled therein (e.g., as a molten metal
or polymer coating or filling, etc.); etc. Also, the face plate 642
may be made from the same or a different material as compared with
the material of the major body portion 640.
[0077] The illustrated example arrangement in FIG. 6C shows an
optional wall 634 extending from the sole portion 616 of the club
head 604 to the bridge member 628. The wall 634, at least in part,
creates or defines the second rear cavity 632, which includes an
opening positioned below bridge member 628 in this club head
structure 604. The wall 634 may be formed so as to include a front
surface (facing outward, toward second cavity 632), a back surface
(facing inward, toward first cavity 626), a top surface, and a
bottom surface. If desired, a space may exist between the back
surface of wall 634 and the rear face 624 of the golf club head
604. Additionally, if desired, additional elements, such as
weighted members, plastic members, a fluid filled bladder, a
pressurized bladder, or the like, may be provided in the cavity 626
between the bridge member 628 and/or wall member 634 and the rear
wall 624 of the club head, e.g., to change the sound, vibrational
response, swing feel, and/or other feel characteristics of the club
head 606.
[0078] The wall 634, when present, may be integrally formed with
the club head 604 and/or the bridge member 628, e.g., to provide
additional support and stiffness to the bridge member 628. Wall 634
may be linear, curved, or otherwise shaped, e.g., depending upon
the shape of bridge member 628, the shape of the club head 604,
desired aesthetics, etc. Like the club head 604, the wall 634
and/or the bridge member 628 may be made from a wide variety of
materials, such as stainless steels, titanium, graphite, plastics,
polymeric materials, composite materials, combinations thereof,
and/or other materials conventionally used in golf club head
manufacture. Also, the club head 604, the wall 634, and the bridge
member 628 may be made from the same or different materials without
departing from this invention. The additional support and stiffness
to bridge member 628 provided by the wall 634, if any, may help
prevent or reduce deformation of bridge member 628 upon contact
with a golf ball. In addition, if desired, the wall 634 may provide
at least some vibration damping effect upon impact of striking face
618 with a golf ball. The wall 634 also may be used as a weighting
member for the club head 604.
[0079] The wall 634, if any, may be secured in the club head
structure 604 (e.g., to the bridge member 628 and/or to other
portions of the club head 604) in any desired manner without
departing from this invention. As some more specific examples, the
front surface and/or the bottom surface of wall 634 may be secured
to the bridge member 628 and/or the sole portion 616, respectively,
using an adhesive or cement. Optionally, if desired, the wall 634
may fit into grooves or recessed areas provided in the surfaces of
the bridge member 628 and/or the sole portion 616. Those skilled in
the art will recognize that numerous other ways exist to attach the
wall 634 to the bridge member 628 and sole portion 616 (or to other
portions of the club head structure 604) without departing from
this invention. These numerous other ways of attachment are
contemplated and fall within the scope of the present
invention.
[0080] During the game of golf, an individual holds and swings the
golf club 600 such that club head 604 traverses a generally arcuate
path and impacts a golf ball. A portion of the inertia of the golf
club 600, and particularly the inertia of the golf club head 604,
then is transferred to the golf ball to propel the golf ball. The
position of a center of gravity of the club head 604 during the
ball strike has an influence upon the ball's flight, e.g., whether
the golf ball curves right, curves left, or follows a generally
straight route, as well as the extent of the curvature. The golf
ball will follow a generally straight route when the club head
604's center of gravity is positioned directly behind the point of
engagement of the ball with the striking face 618. When the club
head 604's center of gravity is spaced to one side of this point of
engagement with the ball, however, the golf ball may follow a route
that curves left or right. The position of the center of gravity of
golf club head 604 during contact with a ball also will influence
whether the golf ball exhibits a low, boring trajectory or a high,
climbing trajectory, depending upon whether the center of gravity
is spaced above or below the point of engagement of the ball on
striking face 618.
[0081] Although the concepts behind utilizing a golf club 600 to
propel a golf ball toward an intended target appear relatively
simple, the actual practice of propelling the golf ball in an
intended manner can be quite difficult. The golf ball may, for
example, consistently curve right when, in fact, the individual
intends to propel the golf ball along a substantially straight
route. Many conventional golf club heads have a center of gravity
located at the striking face. However, changing the position of the
center of gravity of the golf club head 604 for different golf
clubs may assist many golfers in squaring the club head face 618
upon impact with a golf ball and better propelling the ball along
its intended path. The use of cellular structure materials for at
least some portions of the golf club head 604 or other portions of
the golf club structure (such as hosel 612 or shaft 602) can assist
in club design by enabling club designers and manufacturers to
selectively place weight and move the center of gravity to
positions so as to better affect the ball flight. For example,
positioning the center of gravity of the club head 604 away from
the striking face 618 and toward the rear of the golf club head 604
may better conform to the play characteristics, style, and
preferences of many golfers. Accordingly, golfers may be able to
correct or modify the route of a golf ball by using the golf club
head 604 of the present invention as the center of gravity of golf
club head 604 is repositioned with respect to striking face 618 as
compared to other golf club heads.
[0082] The center of gravity of golf club head 604, also referred
to herein as its "center of mass," is defined as an equilibrium
point. More specifically, the center of gravity of golf club head
604 is a point at which the entire weight of golf club head 604 may
be considered as concentrated so that, if supported at that point,
the club head 604 would remain in static equilibrium in any
position. The location of the center of gravity of golf club head
604 may be changed by altering the weight distribution of the golf
club head 604, e.g., by making a major portion 640 the body 604 of
a lightweight cellular structure material and positioning
additional weight away from the striking face 618. Altering the
weight distribution of golf club head 604 in accordance with at
least some examples of this invention (such as the examples
illustrated in FIGS. 6A through 6C) may be accomplished, at least
in part, with the use of weighted bridge members 628, weighted
walls 634, and optionally independent weight elements (as will be
described in more detail in conjunction with FIG. 7-11).
[0083] As more specific examples, bridge member 628 may be used to
increase the weight of the back of the golf club head 604, e.g.,
relative to the striking face 618. This increase in weight toward
the rear of golf club head 604 alters the position of the center of
gravity of golf club head 604. By moving the center of gravity
lower and toward the rear of the golf club head 604, the golf club
600 will tend to have an increased loft upon impact with a golf
ball. In addition, the shape, location, and weight distribution of
bridge member 628 also may influence the location of the center of
gravity of golf club head 604. For example, on longer iron clubs
(e.g., zero through five iron and/or hybrid clubs), it may be
desirable for at least some golfers to have the center of gravity
lower than on the corresponding shorter iron clubs (e.g., six iron
through various wedges). On the longer iron or hybrid clubs, a
lower center of gravity typically will assist a golfer in obtaining
additional loft and lift on their golf shots. Therefore, in
accordance with at least some examples of this invention, the
bridge member 628 for longer iron clubs or hybrid type may be
positioned lower on the rear of the golf club head body 604 as
compared to the bridge member 628 position on a shorter iron
club.
[0084] The lowering of the center of gravity of the golf club head
604 also may be accomplished, at least in part, through the use of
wall 634 or other weight elements. The wall 634 or other elements
also may be used to increase the weight of the back of the golf
club head 604 relative to the striking face 618. This increase in
weight to the back of golf club head 604 at the low position on the
club head 604 lowers the center of gravity of the club head 604,
thus generally allowing the golf club head 604 to propel a golf
ball with a higher trajectory. In addition, as noted above, wall
634 (and/or other weight members) may be used to increase the
support of bridge member 628 and may prevent or reduce deformation
of bridge member 628 upon contact with a golf ball. This added
support may tend to somewhat increase the distance that the golf
ball travels after impact with the club head 604.
[0085] FIGS. 7-9 illustrate additional examples of iron type golf
club heads that may include cellular structure materials (e.g.,
making up some or all of the major portion of the club head body)
and additional weighting members, e.g., to allow club designers,
club fitters, users, and the like to modify the weighting and
center of gravity characteristics of a golf club head. Such
modifications may be used to alter typical ball flight
characteristics, e.g., to provide a fade or draw bias to the club,
to help correct a persistent slice or hook, etc. The basic club
head designs of FIGS. 7-9 are similar to those shown in FIGS. 6A
through 6C (e.g., with a perimeter weighted head 604, one or more
rear cavities 626 and/or 632, a bridge member 628, and an optional
wall member 632, etc.), with major portions of the club head bodies
formed from a cellular structure material and a ball striking face
plate 642 formed or otherwise provided thereon. In these example
iron structures, however, additional weighting members are provided
with the bridge member 628, to help further move and control the
club head 604 center of gravity with respect to the ball striking
face of the club head.
[0086] In the example structure shown in FIG. 7, additional weight
is provided to the club head structure 700 via one or more weight
elements 702 that are attached to the bridge member 628. As shown,
these weight elements 702 may be attached at a variety of
predetermined mounting positions 704a, 704b, and/or 704c provided
on the bridge member 628. Positioning weight member 702 at position
704a on the bridge 628 generally causes the toe portion of the club
head 700 to slightly lag behind the heel portion during a swing,
promoting a more open club face during a ball strike, and providing
a fade bias to the club (e.g., to help correct the ball flight for
golfers that tend to hook the ball). Positioning weight member 702
at position 704b on the bridge 628 generally causes the center of
gravity of the club head 604 to move rearward with respect to the
ball striking face without providing the club head 604 with a bias
toward a draw or fade ball flight. Positioning weight member 702 at
position 704c on the bridge 628 generally causes the toe portion of
the club head 700 to move slightly ahead of the heel portion during
a swing, promoting a more closed club face during a ball strike,
and providing a draw bias to the club (e.g., to help correct the
ball flight for golfers that tend to slice the ball). By making at
least some portion of the club head 700 (e.g., a major portion of
the club head 700) from a cellular structure material, additional
weight can be included in the bridge 628 and/or weighting member
702 without adversely increasing the club head's total weight, to
potentially enable additional control over ball flight
characteristics.
[0087] Of course, any way of fixing the weight member 702 to the
bridge member 628 (or other portion of the club head structure 700)
may be used without departing from the invention, including screws,
rivets, set screws, spring loaded detent mechanisms, or other
mechanical connectors; adhesives, cements, or other bonding
techniques; welding, soldering, brazing, or other fusing
techniques; and the like. Advantageously, the weight member 702 may
be removably attached to the bridge member 628 or other portion of
the club head structure 700, e.g., to enable removal of and/or
changes in the weight member position 704a, 704b, and 704c, for
example, by a user, a club fitter, a manufacturer, a sales person,
etc. Removal weight members of this type are known and used in the
art.
[0088] FIG. 8 illustrates an example club head structure 800
similar to that illustrated in FIG. 7, but with a different type of
weighting member 802. In this example structure, one or more weight
members 802 are positionable at various predetermined mounting
positions 704a, 704b, and/or 704c like the example illustrated in
FIG. 7. Therefore, the location of the center of gravity of the
club head 800 can be controlled and changed in the heel-to-toe
direction of the club head 800 in the same manner as it can be
changed and controlled in the example structure 700 of FIG. 7, as
described above. In this example structure 800, however, the weight
member 802 is irregularly shaped and weighted (e.g., elliptically
shaped and heavier at its bottom, in the illustrated example) so
that the location of its center of gravity (and thus the overall
location of the center of gravity of the golf club head 800) also
can be controlled in the club head's vertical direction. For
example, by orienting the weight member 802 as shown in FIG. 8
(with the heavier bulk of the weight member 802 directed downward),
the center of gravity of the weight member 802 (and thus the entire
club head 800 center of gravity) is located somewhat downward or at
a relatively low position with respect to the club head ball
striking face. This arrangement generally allows users to propel
golf balls with a higher trajectory (and biases the club to provide
a higher trajectory to help golfers with a tendency to have trouble
getting the ball airborne). By rotating the weight member 802 about
its mounting position (e.g., position 702b, in the illustrated
example), the bulk of the weighting member 802 (and thus its center
of gravity) can be raised with respect to the ball striking face,
and thus the center of gravity of the overall club head 800 can be
raised with respect to the club head face. A higher center of
gravity arrangement generally allows users to propel golf balls
with a lower trajectory (and biases the club to provide a lower
trajectory to help golfers with a tendency to hit very high shots).
By making at least some portion of the club head 800 (e.g., a major
portion of the club head 800) from a cellular structure material,
additional weight can be included in the bridge 628 and/or
weighting member 802 without adversely impacting the club head's
overall weight, to potentially enable additional control over ball
flight characteristics.
[0089] FIG. 9 illustrates an example club head structure 900 that
includes an additional weighting member 902 that has even more
versatile weighting characteristics as compared to the example
structures shown in FIGS. 7 and 8. More specifically, in this
example structure 900, the weighting member 902 is mounted on a
rail or slide mechanism 904 provided as part of the bridge member
628 structure. By loosening the screw 906 or other clamping
mechanism, the weight member 902 may be freely movable and
positionable along the slide mechanism 904, to thereby allow
control of the location of the center of gravity of the club head
in the heel-to-toe direction, as generally described above in
conjunction with the structures of FIGS. 7 and 8. However, by
providing the rail or slide mechanism 904, the weight member 902
can be positioned at any location along the bridge member 628, not
limited to the predetermined mounting positions 704a, 704b, and/or
704c shown in FIGS. 7 and 8.
[0090] Additionally or alternatively, if desired, the weight member
902 may be designed so that the center of gravity location of the
club head 900 also can be altered in the vertical direction, e.g.,
using an elliptical and/or irregular weight member of the type
described above in conjunction with FIG. 8. By making at least some
portion of the club head 900 (e.g., a major portion of the club
head 900) from a cellular structure material, additional weight can
be included in the bridge 628 and weighting member 902 without
adversely impacting the overall club head weight, to potentially
enable additional control over ball flight characteristics.
[0091] The weight member 902 may be secured to the bridge member
628 in any desired manner without departing from the invention,
e.g., removably or movably secured by a screw, set screw, clamp,
clasp, etc. Additionally, in this example structure 900 (as with
the other example structures described above), any number of weight
members, mounting positions, mounting rails, or the like may be
provided without departing from the invention.
[0092] While the bridge member 628 advantageously assists in
positioning weight back and/or low in an overall club head
structure, aspects of the present invention can be used in any
desired iron type club head design without departing from the
invention. For example, cellular structure material can be used to
form all or at least some portion of iron type golf club heads
formed as perimeter weighted irons without a bridge member, blade
type irons, hybrid type irons, and the like. FIGS. 10A and 10B
illustrate an example club head structure 1000 formed as a blade
type iron. In this illustrated example structure 1000, a major
portion of the club head body 1002 is formed from a cellular
structure material, and a ball striking face 1004 is integrally
formed, adhered, or otherwise provided on the major portion of the
club head body 1002. If desired, all or at least some of the
exterior surface of the cellular structure club head body may be
formed so that the pores are coated or filled (e.g., with metal or
polymer) to thereby provide a smooth overall appearance and/or
smooth consistent ball striking surface.
[0093] In this illustrated example structure 1000, the rear 1006 of
the club head body 1002 includes plural weight members 1008. Of
course, any number of weight members 1008 may be included in the
club head body 1002 without departing from the invention, and these
weight members 1008 may be provided at various different positions
on the club head structure 1002. Moreover, if desired, every weight
member 1008 need not have the same mass and/or size, to enable
additional control over the center of gravity characteristics of
the overall club head structure 1002.
[0094] In this illustrated example, the weight members 1008 are
removably mounted in weight member receptacles 1010 provided in the
club head structure 1002. Of course, any way of mounting the weight
members 1008 in the receptacles 1010 may be provided without
departing from the invention. As examples, the weight members 1008
may include threads that engage with mating threads provided in the
receptacle, to enable easy removal and/or repositioning of the
weight members 1008 in the overall club head structure 1002. Of
course, other connection techniques may be used without departing
from the invention, such as other mechanical connections, clamping,
or clasping structures, spring-loaded detent mechanisms, and the
like. Also, if desired, any shaped weight members may be provided
in the club head structure 1000 without departing from the
invention.
[0095] Alternatively, if desired, the additional weight may be
permanently and/or integrally provided as part of the club head
structure without departing from the invention. FIG. 11 illustrates
an example of such a club head structure 1100. As shown in this
example, a major portion of the club head structure 1102 is formed
from a cellular structure material, and a ball striking face 1104
is formed or otherwise provided on this material, e.g., in one of
the various manners described above. The lower perimeter and/or
rear of the club head 1102 in this example structure 1100 includes
a weighted region 1106 permanently included as part of the club
head structure 1102. Any manner of providing the weighted region
1106 may be used without departing from the invention. For example,
the weighted region 1106 may be provided by fixing a weight into an
opening (e.g., a hole, slot, groove, or compartment, etc.) defined
in the club head 1102. As another example, if desired, the weighted
region 1106 may be provided by integrally fixing a weighted
material (e.g., tungsten or lead containing material) to the
material of the club head structure 1102 and then forming that
material into the club head structure 1102 (e.g., machining it,
etc.) in a manner such that the weighted material is located at the
final desired position in the club head structure 1102 (i.e., at
the weighted region 1106). As still other examples, if desired, the
weighted region 1106 may be provided by not foaming and/or
providing a markedly reduced degree of foaming of the material of
the major portion of the club head structure 1102 at the desired
weighted region location 1106 and/or by filling the pores at the
weighted region location 1106 with a relatively heavy or dense
material, such as lead or tungsten. Other ways of forming the
weighted region 1106 are possible without departing from the
invention. The material forming the weighted region 1106 may be
visible from the exterior of the club head structure 1102, it may
be concealed within the material of the club head structure 1102,
or it may be continuous with the club head structure 1102. Also, if
desired, the exterior surface of the body member may be made
smooth, e.g., by filling, coating, or covering the exposed pores
(if any) with a metal or polymer material.
[0096] D. Example Wood Type Golf Club Structures
[0097] Aspects of this invention are not limited to use with
putters, irons, and/or hybrid iron type golf clubs and golf club
heads. FIGS. 12A and 12B illustrate an example of a golf club 1200
in accordance with at least some examples of this invention.
Notably, the overall golf club structure 1200 of this example
includes a golf club head 1202, a hosel region 1204, a shaft member
1206 received in and/or inserted into and/or through the hosel
region 1204, and a grip or handle member (not shown) attached to
the shaft member 1206. Optionally, if desired, the hosel region
1204 may be eliminated and the shaft member 1206 may be directly
inserted into and/or otherwise attached to the head member 1202
(e.g., through an opening provided in the top and optionally bottom
of the club head 1202).
[0098] The shaft member 1206 may be received in, engaged with,
and/or attached to the club head 1202 in any suitable or desired
manner, including in conventional manners known and used in the
art, without departing from the invention. As more specific
examples, the shaft member 1206 may be engaged with the club head
1202 via the hosel member 1204 or directly with the club head
structure 1202, e.g., via adhesives, cements, welding, soldering,
mechanical connectors (such as threads, retaining elements, or the
like), through a shaft-receiving sleeve or element extending into
the club head body 1202, etc. The shaft member 1206 also may be
made from any suitable or desired materials, including conventional
materials known and used in the art, such as graphite based
materials, composite materials, steel materials (including
stainless steel), aluminum materials, other metal alloy materials,
polymeric materials, combinations of various materials, and the
like. If desired, either or both of the shaft member 1206 and the
hosel member 1204 (when present) may be made from a cellular
structure material.
[0099] The grip or handle member (not shown) may be attached to,
engaged with, and/or extend from the shaft member 1206 in any
suitable or desired manner, including in conventional manners known
and used in the art, e.g., using adhesives or cements; via welding,
soldering, adhesives, or the like; via mechanical connectors (such
as threads, retaining elements, etc.); and/or in any other desired
manner. As another example, if desired, the grip or handle member
may be integrally formed as a unitary, one-piece construction with
the shaft member 1206. Additionally, any desired grip or handle
member materials may be used without departing from this invention,
including rubber materials, leather materials, rubber or other
materials including cord or other fabric material embedded therein,
polymeric materials, metal materials, and the like. The grip or
handle member also may be made, at least in part, from a cellular
structure material.
[0100] The club head 1202 itself also may be constructed in any
suitable or desired manner and/or from any suitable or desired
materials without departing from this invention, including in
conventional manners and/or from conventional materials known and
used in the art. For example, in the example structure shown in
FIGS. 12A and 12B, the club head 1202 includes a sole member 1202a,
a face member 1202b, at least one body member 1202c, and a crown
member 1202d. The body member(s) 1202c may be formed, for example,
as bands or ribbons of material (e.g., optionally generally
U-shaped bands or ribbons) that extend around from one side of the
face member 1202b to its other side and form at least a portion of
the perimeter of the middle of the golf club head body 1202 (e.g.,
such that the overall club head structure 1202 defines an at least
partially hollow interior chamber (e.g., into which the shaft
member 1206 may be inserted and/or secured)). Any of the individual
portions of the club head structure 1202 described above may be
made from multiple independent pieces, and/or two or more of these
individual portions may be integrally formed together, e.g., as
unitary, one-piece constructions, without departing from this
invention (e.g., the sole and/or crown members additionally may
form at least some portions of the club head body and/or face
members, etc). As other options, if desired, the overall club head
structure 1202 may be comprised of a single, one-piece construction
or the face member 1202b may attach to a one piece club head body,
etc.
[0101] The various individual parts that make up a club head
structure 1202, if made from multiple pieces, may be engaged and/or
held together in any suitable or desired manner, including in
conventional manners known and used in the art. For example, the
various parts of the club head structure 1202 may be joined and/or
fixed together (directly or indirectly through intermediate
members) by adhesives, cements, welding, soldering, or other
bonding or fusing techniques; by mechanical connectors (such as
threads, screws, nuts, bolts, or other connectors); and the like.
If desired, the side edges of various parts of the club head
structure 1202 (e.g., the edges where sole member 1202a, face
member 1202b, body members 1202c, and/or crown member 1202d contact
and join to one another) may include one or more raised ribs, tabs,
ledges, or other engagement elements that fit into or onto
corresponding grooves, slots, surfaces, ledges, or openings
provided in or on the facing side edges to which they are joined.
Cements, adhesives, mechanical connectors, or the like may be used
in combination with the raised rib/groove or other connecting
structures described above to further help secure the various parts
of the club head structure 1202 to one another.
[0102] In at least some examples of the invention, the materials
making up at least some of the various portions of the club
structure 1200 (e.g., the sole 1202a, the face plate 1202b, the
body member(s) 1202c, the crown 1202d, the hosel 1204, the shaft
1206, etc.) may be formed from a cellular structure material, e.g.,
like the various materials described above. If desired, two or more
of these parts may be integrally formed as a one-piece construction
(e.g., if desired, the sole 1202a, the body member 1202c, and/or
the crown 1202d may be integrally formed as one piece with a
separate face plate member engaged therewith). Also, any desired
materials may be used for the club head body 1202 without departing
from the invention, including, for example, aluminum, nickel,
titanium, steel, polymers, glasses, ceramics, rubbers, and/or
combinations thereof. When at least some portion of the club head
structure 1202 is formed from a cellular structure material, if
desired, the shell wall thickness may be made somewhat larger than
the shell members of many conventional club heads.
[0103] The weight savings produced through the use of cellular
structure material, e.g., for at least some portion of the club
head body 1202, allows club manufacturers, club fitters, users, and
the like to position one or more additional weight members 1208 at
other locations in the club head structure 1202, e.g., to affect
the center of gravity, moment of inertia, and/or ball flight
characteristics of the club 1200. For example, placing weighted
members 1208 low and toward the rear of the club head structure
1202 lowers the center of gravity of the club head 1202 and helps
users get golf shots airborne when using the club. As generally
described above in conjunction with FIGS. 6A through 11, the mass
and location(s) of the weighted members 1208 may be selected so as
to control the position of the center of gravity of the club head
1202, e.g., in the heel-to-toe direction and/or the vertical
direction (e.g., to bias the club head to provide draw, fade, high,
or low shots, and/or to help users correct for sliced, hooked, low,
or high shot tendencies, respectively).
[0104] The weighted member(s) 1208 may be engaged with the club
head 1202 in any desired manner without departing from the
invention, including in the various manners described above in
conjunction with FIGS. 1-11 and/or in various manners known and
used in the art. In the illustrated example of FIGS. 12A and 12B,
the weighted members 1208 are removably attached to receptacles
1210 provided in and extending into the club head 1202 via a
threaded arrangement. Of course, other attaching and/or locking
configurations may be used without departing from this invention,
such as clamps, clasps, spring-loaded detents, turnbuckles, other
mechanical connectors, or the like. Alternatively, if desired, one
or more of the weighted members 1208 may be permanently fixed to
and/or within the club head 1202 without departing from the
invention, e.g., via bonding or fusing techniques. The weighted
members 1208 need not be visible from the club head exterior
(optionally, if desired, access to the club head interior (e.g., to
change and/or re-position weighted members 1208) may be
provided).
[0105] FIGS. 13A and 13B show another example of a wood-type golf
club structure 1300 according to the invention. In this example
structure 1300, the golf club includes a golf club head 1302, a
hosel region 1304, a shaft member 1306, and a handle member (not
shown), as generally described above in conjunction with the
example structure 1200 of FIGS. 12A and 12B. In this example
structure 1300, all or at least some portion (e.g., a major
portion) of the club head body 1302 is constructed as a one piece
element, and this element is constructed from a cellular structure
material, such as the various cellular structure metal, polymers,
and/or other materials described above. If desired, the club head
body 1302 may be formed from multiple pieces of cellular structure
material engaged with one another, optionally of different
materials, e.g., via adhesives, cements, welding, or other bonding
or fusing techniques. As still additional examples, if desired,
only some portion of the club head body 1302 may be formed from a
cellular structure material (e.g., the bottom, rear, and/or front
portions), while other portions of the club head body (e.g., the
upper crown portion) may be formed from shell members and/or other
separate, non-cellular pieces of material.
[0106] Also, in this illustrated example structure, a weighted
member 1308 is provided within the interior of the club head body
1302, e.g., in an interior recess or chamber defined in the club
head body. Of course, other ways of providing one or more weighted
members 1308 in the club head structure 1302 may be provided
without departing from the invention, including the various ways
described above in conjunction with FIGS. 12A and 12B. As still
another alternative, if desired, the weighted member(s) 1308 may be
integrally formed with the club head body structure 1302, e.g., by
forming the cellular structure material to include a weighted
region (e.g., a denser cellular region); by not foaming the metal
or other material in the weighted region; by machining a material,
including a foam portion, into a golf club head structure and to
include a non-foamed and/or increased weight region in the desired
location(s); to include a weighted coating or filler in the foam
pores at the weighted region, etc.
[0107] The dimensions and/or other characteristics of a wood-type
golf club head structure according to examples of the invention may
vary significantly without departing from the invention. Moreover,
any desired type of wood-type golf club head structure may be
provided, such as drivers, fairway woods, wood-type hybrid clubs,
chipping clubs, and the like. Any desired loft angles, head
weights, lie angles, etc., also may be used without departing from
the invention, e.g., if the club is designed as a 2-wood, 3-wood,
4-wood, 5-wood, 7-wood, 9-wood, 11-wood, etc.; to suit a user's
preferences and/or swing characteristics; to provide the desired
launch angle, carry distance, and/or other characteristics for the
club; etc. Additionally, various different shaft characteristics
(such as stiffness, flex point, kick point, etc.) may be used to
further allow change and control over the club's and the club
head's feel and characteristics.
[0108] E. Example Ball Striking Plate Structures
[0109] FIG. 14 illustrates another example golf club structure 1400
that includes cellular structure material in accordance with at
least some examples of this invention. In this example, the
cellular structure material is provided as part of a club head 1402
face plate member 1404. More specifically, as illustrated in FIG.
14, the face plate member 1404 is attached to a club head body
1406, which may be of any design and/or made of any type of
material, including conventional designs and conventional materials
known and used in the art (a wood-type club head body, in this
example). The face plate member 1404 includes a base member 1404a
formed of a cellular structure material and a ball striking plate
member 1404b, which directly contacts the ball in use. By use of
cellular structure materials in the face plate member 1404, a
thicker face plate can be provided without adversely affecting the
club head's overall weight or strength, and the use of a thicker
face plate allows better manufacturer control over the coefficient
of restitution (and potentially other characteristics) of the club
head face member 1404. Of course, face plate members of the type
illustrated in FIG. 14 may be used on any type of club head,
including woods, irons, hybrid type clubs, putters, etc.
[0110] The face plate member 1404 may be constructed in any desired
manner without departing from this invention. For example, if
desired, the face plate base member 1404a may be engaged with a
separate ball striking member 1404b, e.g., by bonding techniques
(cements, adhesives, etc.) or fusing techniques (welding, brazing,
soldering, etc.). As additional examples, if desired, the ball
striking member 1404b may be integrally formed as part of the
cellular structure base member 1404a, e.g., via conventional metal
foam manufacturing techniques. As still another example, if
desired, the ball striking member 1404b may be formed by coating or
filling open cells or pores of an exterior surface of a cellular
structure material (e.g., for the base member 1404a) with a molten
metal material, a polymeric material (such as an epoxy, etc.), or
the like, to thereby provide a smooth ball striking surface 1404b
for the face plate 1404. Other ways of forming the face plate
member 1404, at least in part as a cellular structure material, may
be provided without departing from this invention.
III. Conclusion
[0111] Golf club heads in accordance with examples of the present
invention may be incorporated into a set, e.g., sets including one
or more of woods, irons, hybrid type golf clubs, and/or putters. As
a more specific example, aspects of the present invention may be
used to provide a club set with increasing numbered woods and/or
iron golf clubs, such as a driver and/or two or more of fairway
woods, hybrid type clubs, a zero iron, a one iron, a two iron, a
three iron, a four iron, a five iron, a six iron, a seven iron, an
eight iron, a nine iron, a ten iron, a pitching wedge, a lob wedge,
a gap wedge, a sand wedge, putters, etc. With at least some
examples of the present invention, a golfer, a club designer,
and/or a club fitter may select and/or modify the position of the
center of gravity for each golf club to meet the player's unique
requirements, skill, or playing style. For each club in the set,
the bridge member, weight member(s), and/or other features of the
club head may progressively change to alter the center of gravity
of one club member with respect to the others in the set, to make
the center of gravity better suited for use of the particular club,
optionally customized for use by a specific golfer.
[0112] As is readily apparent from the above description, this
invention may be used to include cellular structure materials,
having a wide variety of potential properties, in a wide variety of
different locations, in a golf club structure (e.g., as part of the
head, striking face, hosel, shaft, grip, etc.). The cellular
structure material may be used on the club head exterior, on the
interior, on both, and the cellular structure may be visible,
partially visible, filled, partially filled, hidden, partially
hidden, etc. When a golf club product in accordance with at least
some examples of this invention includes multiple cellular
structure metals or other materials, either or both cellular
structure materials optionally may be filled, skinned, partially
filled, or partially skinned, optionally with the same or different
fill or skin materials, including filled or skinned with a
different cellular structure metal or other material. The skin or
filling material may have a variety of thicknesses and/or a wide
variety of potential properties. Different cellular structures and
properties also may be obtained by varying the pore properties of a
given cellular structure material (e.g., by varying pore density,
pore distribution, pore size distribution, etc.).
[0113] As an additional example of a specific club head
construction, if desired, a club head may be provided that
includes: (a) a relatively thick skin of a high density material
(e.g., a tungsten material) applied toward the back of a club head
structure, e.g., a tungsten skin over a cellular structure material
such as a metal or composite of tungsten, steel, etc., and
[0114] (b) a thinner skin of a less dense material (e.g., aluminum
or titanium) over a relatively light cellular structure material
(e.g., an aluminum or steel cellular structure) applied toward the
middle and/or front of a club head structure. These materials may
be integrated into a single club head structure (e.g., a putter
structure). Such an arrangement may be used to produce a putter
having a relatively high moment of inertia as compared with a
unitary putter body of the same design without the use of cellular
structure materials. Also, the use of different cellular structure
materials and/or fill materials may be used to vary a wide range of
properties in the final product, such as yield strength, Young's
modulus, grain size of the materials, etc.
[0115] The present invention is described above and in the
accompanying drawings with reference to a variety of example
structures, features, elements, and combinations of structures,
features, and elements. The purpose served by the disclosure,
however, is to provide examples of the various features and
concepts related to the invention, not to limit the scope of the
invention. One skilled in the relevant art will recognize that
numerous variations and modifications may be made to the
embodiments described above without departing from the scope of the
present invention, as defined by the appended claims. For example,
the various features and concepts described above in conjunction
with FIGS. 1-14 may be used individually and/or in any combination
or subcombination without departing from this invention.
* * * * *