U.S. patent application number 11/854998 was filed with the patent office on 2008-01-03 for method of manufacturing a golf club face.
Invention is credited to Bradley D. Schweigert.
Application Number | 20080004133 11/854998 |
Document ID | / |
Family ID | 34523334 |
Filed Date | 2008-01-03 |
United States Patent
Application |
20080004133 |
Kind Code |
A1 |
Schweigert; Bradley D. |
January 3, 2008 |
METHOD OF MANUFACTURING A GOLF CLUB FACE
Abstract
Embodiments of methods of manufacturing a face plate for a golf
cub are generally described herein. In one exemplary embodiment, a
method for manufacturing a golf club face plate comprises:
providing a face plate material, and milling the face plate
material in an elliptical pattern to form a central region
comprising, a first elliptical outer edge and a transition region
extending from the first elliptical outer edge to a second
elliptical outer edge. In this exemplary embodiment, each point
along the second elliptical outer edge is displaced outward from
the first elliptical outer edge by a predetermined distance. Other
embodiments herein may be described and claimed.
Inventors: |
Schweigert; Bradley D.;
(Anthem, AZ) |
Correspondence
Address: |
KARSTEN MANUFACTURING CORPORATION
LEGAL DEPARTMENT
2201 WEST DESERT COVE
PHOENIX
AZ
85029
US
|
Family ID: |
34523334 |
Appl. No.: |
11/854998 |
Filed: |
September 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10803837 |
Mar 17, 2004 |
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11854998 |
Sep 13, 2007 |
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Current U.S.
Class: |
473/342 ; 29/428;
83/875 |
Current CPC
Class: |
A63B 53/0408 20200801;
Y10T 409/303752 20150115; A63B 53/0458 20200801; Y10T 29/49826
20150115; Y10T 83/0304 20150401; Y10T 407/1946 20150115; B23C 3/13
20130101; Y10T 29/49 20150115; A63B 53/04 20130101; A63B 53/0462
20200801; Y10T 29/49995 20150115; A63B 53/0416 20200801; A63B
53/0466 20130101; A63B 60/00 20151001 |
Class at
Publication: |
473/342 ;
029/428; 083/875 |
International
Class: |
A63B 53/04 20060101
A63B053/04 |
Claims
1. A method for manufacturing a golf club face plate comprising:
providing a face plate material; milling the face plate material in
an elliptical pattern to form: a central region comprising a first
elliptical outer edge; and a transition region extending from the
first elliptical outer edge to a second elliptical outer edge;
wherein: each point along the second elliptical outer edge is
displaced outward from the first elliptical outer edge by a
predetermined distance.
2. The method of claim 1, wherein the central region comprises a
thickness substantially similar to a thickness of the face plate
material.
3. The method of claim 1, wherein the central region comprises a
thickness of about 0.13 inches to about 0.18 inches.
4. The method of claim 1, wherein the predetermined distance is
about 0.40 inches to about 1.20 inches.
5. The method of claim 1, wherein milling the face plate material
comprises using an end mill to mill the face plate material.
6. The method of claim 1, wherein the central region comprises a
major axis of about 0.65 inches to about 1.05 inches.
7. The method of claim 1, wherein the central region comprises a
minor axis of about 0.25 inches to about 0.45 inches.
8. The method of claim 1, wherein an aspect ratio of the central
region is about 1.4 to about 4.2.
9. The method of claim 1, wherein an aspect ratio of the second
elliptical outer edge is less than an aspect ratio of the central
region.
10. The method of claim 1, wherein milling the face plate material
comprises using a cutting tool comprising a first cutting surface
and a second cutting surface different from the first cutting
surface.
11. The method of claim 10, wherein the second cutting surface
comprises a perpendicular configuration to a rotating axis of the
cutting tool.
12. The method of claim 10, wherein the first cutting surface
creates an angle with respect to the second cutting surface of
about 5 degrees to about 20 degrees.
13. The method of claim 1, wherein the transition region comprises
a non-linear transition between the first elliptical outer edge and
the second elliptical outer edge.
14. The method of claim 1, wherein the transition region comprises
a non-linear transition having a convex configuration.
15. The method of claim 1, wherein the transition region comprises
a non-linear transition having a concave configuration.
16. The method of claim 1, wherein the transition region comprises
a frustrum-like region.
17. The method of claim 1, wherein milling the face plate material
further comprises milling the face place material in a single
elliptical orbit.
18. A method for manufacturing a golf club head: providing a golf
club head shell comprising an opening to receive a faceplate;
providing a faceplate; and coupling the faceplate to the opening;
wherein, providing a faceplate further comprises: milling a face
plate material in an elliptical pattern to form: a central region
comprising a first elliptical outer edge; and a transition region
tapering from the first elliptical outer edge to a second
elliptical outer edge; wherein: cross-section profiles of the
transition region from the first elliptical outer edge to the
second elliptical outer edge are substantially similar when the
cross sectional profiles are taken along perpendicular directions
that are collinear with a major axis and a minor axis of the second
elliptical outer edge.
19. The method of claim 18, wherein: the central region comprises a
major axis of about 0.65 inches to about 1.05 inches; the central
region comprises a minor axis of about 0.25 inches to about 0.45
inches; an aspect ratio of the central region is about 1.4 to about
4.2; and a thickness of the central region is about 0.13 inches to
about 0.18 inches.
20. The method of claim 18, wherein the transition region comprises
a convex configuration.
21. The method of claim 18, wherein the transition region comprises
a concave configuration.
22. A method for manufacturing a golf club: providing a golf club
head comprising a faceplate; and coupling the golf club head to a
shaft; wherein, the faceplate comprises: a first region comprising
a first elliptical outer edge comprising a first aspect ratio, a
first major axis, and a first minor axis; and a second region
extending from the first elliptical outer edge to a second
elliptical outer edge, comprising a second aspect ratio, a second
major axis, and a second minor axis, the second major axis being
equal to the first major axis plus a predetermined distance, and
the second minor axis being equal to the first minor axis plus the
predetermined distance.
23. The method of claim 22, wherein: the first and second major
axes are collinear with each other; and the first and second minor
axes are collinear with each other.
24. The method of claim 22, wherein: the first major axis is about
0.65 inches to about 1.05 inches; the first minor axes is about
0.25 inches to about 0.45 inches; and the aspect ratio of the first
region is about 1.4 to about 4.2.
25. The method of claim 22, wherein the second region comprises a
non-linear transition from the first elliptical outer edge to the
second elliptical outer edge.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, incorporates by
reference, and is a divisional application of prior application
Ser. No. 10/803,837 filed Mar. 17, 2004 originally titled, Method
of Manufacturing a Golf Club Face.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to golf clubs and, in
particular, to so-called metal wood drivers.
[0003] Recent developments in golf club design have included
improvements in drivers, which are clubs used primarily to strike a
golf ball resting on a golf tee. These improvements have resulted
in drivers with club heads consisting of a hollow shell usually
made of metal, such as steel, aluminum, or titanium. These hollow
shells have relatively thin walls including a thin front wall that
is used to impact the golf ball. In order to prevent the front wall
of these hollow shells from permanently deforming or cracking upon
ball impact, it has become necessary to reinforce the front wall.
One example of a golf club head consisting of a hollow metal shell
with a reinforced front wall is disclosed in U.S. Pat. No.
4,511,145 to Schmidt. The club head disclosed in the Schmidt patent
has an arched ridge extending between the heel and toe ends of the
front wall. The arched ridge design of the Schmidt provides
adequate reinforcement for drivers of moderate head volume,
however, in an effort to obtain better and better performance from
these hollow metal wood drivers, golf club manufacturers have
increased the head volume from the moderate volume of 200 cc's to
over 400 cc's during the past decade. As head size increases, less
and less material is available to reinforce the front wall of the
club face within acceptable weight limitations (i.e., around 200
grams mass). Consequently, more exotic materials such as forged or
cold rolled titanium faces welded to a cast titanium body have been
utilized in these super-oversized drivers. The rear surfaces of the
front walls of these super-oversized drivers must be carefully
contoured to provide adequate structural strength with a minimum
amount of material.
[0004] The most critical region to reinforce, is, of course, the
ideal ball impact point of the front wall. Because most golfer's
swings vary somewhat from impact to impact, the reinforced region
of the front wall must be distributed around the ideal impact
point. However, since variations in a golfer's swing tend to be
more in the heel and toe direction, rather than up or down, the
distribution of hits tends to be within a horizontal, elliptical
region rather than a circular region centered around the center of
the club face. Accordingly, an elliptical, rather than a purely
circular reinforcement is preferable. One example of a golf club
head having a face with a contoured rear surface is U.S. Pat. No.
6,354,962 to Galloway, et al. The club head disclosed in Galloway
has a face plate reinforced with elliptical regions that are formed
as part of the forging process of the face plate. For clubs in
which the club face is machined from a wrought alloy sheet or other
sheet material, forming an elliptical reinforced region presents
special problems. The face cannot be machined properly on a lathe
because the lathe will produce only a circular reinforced region.
One manufacturer is known to use an end mill that makes multiple
elliptical passes to machine the reinforced region of the golf club
face. This operation is, however, time consuming and unnecessarily
costly.
SUMMARY OF THE INVENTION
[0005] According to the present invention, a golf club head is
manufactured by removing a portion of the rear surface of a face
plate to form a central thickened region surrounded by a transition
region that tapers to a thinner peripheral region. According to the
illustrative embodiment, the face plate is a rolled sheet titanium
alloy between 0.130 and 0.180 inches thick, a portion of the
transition region of which is machined away to leave the central
thickened region and to form the transition region and the thinner
peripheral region. Rather than forming the rear surface contour of
the face plate by making multiple passes with an end mill, however,
the central portion, the transition region and the peripheral
region are formed in a single elliptical pass with a special
cutting tool. The cutting tool, or "form cutter" has a conical
lateral cutting surface, which forms the transition region and the
peripheral region in a single operation. Use of this form cutter to
machine the transition region and peripheral region in a single
operation yields greater uniformity in the rear surface contour of
the face plate and saves substantial time and money over prior art
multiple pass machining operations.
BRIEF DESCRIPTION OF THE DRAWING
[0006] The present invention will be better understood from a
reading of the following detailed description, taken in conjunction
with the accompanying drawing figures in which like references
designate like elements, and in which:
[0007] FIG. 1 is a partially cut-away rear perspective view of a
golf club incorporating features of the present invention;
[0008] FIG. 2 is a rear cross-sectional view of the golf club of
FIG. 1;
[0009] FIG. 3 is a cross-sectional view of the golf club of FIG. 2
taken along line 3-3;
[0010] FIG. 4 is a cross-sectional view of the golf club of FIG. 2
taken along line 4-4;
[0011] FIG. 5 is a side view of a machining step in the method of
forming golf club head in FIG. 2;
[0012] FIG. 6 is a side view of an alternative cutting tool used in
the machining step of FIG. 5; and
[0013] FIG. 7 is a side view of another alternative cutting tool
used in the machining step of FIG. 5.
DETAILED DESCRIPTION
[0014] The drawing figures are intended to illustrate the general
manner of construction and are not necessarily to scale. In the
description and the in the drawing figures, specific illustrative
examples are shown and herein described in detail. It should be
understood, however, that the drawing figures and detailed
description are not intended to limit the invention to the
particular form disclosed but are merely illustrative and intended
to teach one of ordinary skill how to make and/or use the invention
claimed herein and for setting forth the best mode for carrying out
the invention.
[0015] Referring to FIG. 1, a golf club 10 includes a head 12, a
hosel 14 and a shaft 16. Head 12 includes a hollow body 18 made of
a metal material such as titanium. Hollow body 18 is formed as a
shell 20, which may be assembled from a series of forged pieces
but, in the illustrative embodiment, comprises a titanium
investment casting. A face plate 22 is attached by conventional
means such as plasma or electron beam welding to a corresponding
opening 23 in shell 20 to form hollow body 18. Face plate 22 may be
a conventional forged blank but, in the illustrative embodiment,
comprises a rolled sheet titanium blank that is machined prior to
welding to shell 20 as described more fully hereinafter.
[0016] As noted hereinbefore, because a golfer's swing tends to
vary more in the heel-toe direction than it does up or down, the
inventor of the present invention determined that the most
efficient reinforcement would be an elliptical thickened region
oriented so that the major axis of the reinforced region was
substantially horizontal when the club is held in its normal
position for addressing the ball. Accordingly, face plate 22
includes a central thickened region 24 that is substantially
elliptical in shape with its major axis 26 oriented horizontal when
the club is held in its normal address position. In the
illustrative embodiment, central thickened region 24 is between
0.130 and 0.180 inches in thickness. Central thickened region 24 is
surrounded by a transition region 28 that tapers from the central
thickened region 24 to a peripheral region 30, which in the
illustrative embodiment is 0.080 to 0.120 inches thick. Transition
region 28 is also elliptical, however, for reasons that are
explained more fully hereinafter, the major axis and minor axis of
transition region 28 are a fixed amount larger than the respective
major and minor axis of central thickened region 24. Accordingly,
the aspect ratio of transition region 28 is lower than the aspect
ratio of central thickened region 24 (in other words, transition
region 28 is a "fatter" ellipse than central thickened region
24).
[0017] With reference to FIGS. 2-5, prior to assembly of face plate
22 to shell 20, the rear contours of face plate 20 are formed by a
machining operation shown schematically in FIG. 5. The process
begins with a blank face plate 32, which in the illustrative
embodiment comprises a blank stamped from a rolled sheet of
titanium alloy. The blank face plate 32 has a thickness equal to
the final thickness of the central thickened region 24 of the
finished face plate 22, which as noted hereinbefore is from 0.130
to 0.180 inches in thickness. The rear surface of blank face plate
32 is machined by using a cutting tool 34 to remove a portion
thereof. The tip of cutting tool 34 has a lateral cutting surface
36 and a lower cutting surface 38. Lower cutting surface 38 is
perpendicular to the axis 40 of cutting tool 34. Lateral cutting
surface 36 is angled upward with respect to lower cutting surface
38 by an angle 42 of from about 5 to 20 degrees, but preferably
about 13 degrees such that lateral cutting surface 36 defines a
generally inverted conical frustum surface of revolution 44 as
cutting tool 34 is rotated about its axis 40. Lateral cutting
surface 36 may have straight edges as shown in FIG. 5, or may have
edges 36b that are concave downward as in the cutting tool 34b
shown in FIG. 6, or may have edges 36c that are convex downward as
in the cutting tool 34c shown in FIG. 7. yielding a conical frustum
surface of revolution (and corresponding transition regions) having
correspondingly curved sides.
[0018] As can be seen from FIG. 5, as the lower cutting surface 38
and lateral cutting surface 36 are brought into contact with rear
surface 46 of blank face plate 32, lower cutting surface 38 and
lateral cutting surface 36 cooperate to cut a tapered transition
region 28 and a flat perimeter region 30 simultaneously in a single
pass, thus obviating the need to make multiple passes with an end
mill as in the prior art. With particular reference to FIGS. 2-4,
the major axis 26 of central thickened region 24 is from 0.65 to
1.05 inches in length. The minor axis 48 of central thickened
region 24 is 0.25 to 0.45 inches in length. Accordingly, the aspect
ratio of central thickened region 24 is between 1.4 and 4.2. In the
illustrative embodiment, major axis 26 is approximately 0.85 inches
and minor axis 48 is approximately 0.35 inches yielding an aspect
ratio of approximately 2.4.
[0019] Major axis 50 and minor axis 52 of transition region 28 are
a fixed amount "6" greater than the respective major and minor axes
of central thickened region 24, wherein the 6 value can be chosen
from a range of about 0.40 inches to about 1.20 inches. In the
illustrative example, the major axis 50 and minor axis 52 are
approximately 0.86 inches greater than the respective major and
minor axes of central thickened region 24. Thus, major axis 50 in
the illustrative embodiment is approximately 1.71 inches in length
and minor axis 52 of transition region 28 is approximately 1.21
inches in length. Thus, the aspect ratio of transition region 28 is
approximately 1.4 as opposed to the 2.4 aspect ratio of central
thickened region 24. The high aspect ratio central raised portion
surrounded by the lower aspect ratio transition region provides
optimum distribution of material for improved performance and
reliability.
[0020] Although certain illustrative embodiments and methods have
been disclosed herein, it will be apparent from the foregoing
disclosure to those skilled in the art that variations and
modifications of such embodiments and methods may be made without
departing from the spirit and scope of the invention. Accordingly,
it is intended that the invention should be limited only to extent
required by the appended claims and the rules and principals of
applicable law.
* * * * *