Method of manufacturing a face plate for a golf club head

• US 10,183,201 B2
• Filed: 01/03/2017
• Issued: 01/22/2019
• Est. Priority Date: 03/17/2004
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Karsten Manufacturing Corporation
• Inventors: Schweigert, Bradley D.
• Primary Examiner(s): Koehler, Christopher M
• Application Number:
  US15/396,911
• Publication Number:
  US 20170106255A1
• Time in Patent Office: 749 Days
• Field of Search: 29557, 29558, 407 53, 407 54, 473329, 473345, 473349, 473346, 473342, 473330, 473331, 473332
• CPC Class Codes: A63B 53/04 Heads
• CPC Class Codes: A63B 53/0408 characterised by specific dimensions, e.g. thickness
• CPC Class Codes: A63B 53/0416 Heads having an impact surface provided by a face insert
• CPC Class Codes: A63B 53/0458 with non-uniform thickness of the impact face plate
• CPC Class Codes: A63B 53/0462 characterised by tapering thickness of the impact face plate
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: B23C 3/13 Surface milling of plates, sheets or strips
• CPC Class Codes: Y10T 29/49 Method of mechanical manufacture
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49995 Shaping one-piece blank by removing material
• CPC Class Codes: Y10T 407/1946 Face or end mill
• CPC Class Codes: Y10T 409/303752 Process
• CPC Class Codes: Y10T 83/0304 Grooving

Abstract

Golf club heads with patterned face plates described herein. Other examples, embodiments and related methods are also disclosed herein.

Claims

1. A golf club head comprising:

a face plate having a contoured rear surface, the contoured rear surface including a central thickened region having a first non-circular, elliptical outer edge surrounded by a transition region tapered from the central thickened region toward a thinner peripheral region, the transition region having a second non-circular, elliptical outer edge,

wherein the transition region comprises a frustum-like region formed by a straight edge of a lateral cutting surface associated with a cutting device where the lateral cutting surface is angled upward from about 5 to 20 degrees;

wherein the first non-circular, elliptical outer edge has a first aspect ratio, a first major axis and a first minor axis,

wherein the second non-circular, elliptical outer edge has 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,

wherein the first aspect ratio is greater than the second aspect ratio, and

wherein the central thickened region comprises a maximum thickness of the face plate and wherein the central thickened region comprises a constant thickness throughout its entirety and extends through a centerpoint of the first elliptical outer edge and the second elliptical outer edge.

2. The golf club head of claim 1, wherein the transition region decreases from the first elliptical outer edge to the second elliptical outer edge at an angle of about 13 degrees.

3. The golf club head of claim 1, wherein the predetermined distance ranges from 0.40 inch and 1.20 inches.

4. The golf club head of claim 1, wherein the first major axis is approximately 0.85 inch and the minor axis of approximately 0.35 inch.

5. The golf club head of claim 4, wherein the first aspect ratio is approximately 2.4.

6. The golf club head of claim 1, wherein the second major axis is 1.71 inches, and the second minor axis is 1.21 inches.

7. The golf club head of claim 6, wherein the second aspect ratio is 1.4.

8. The golf club head of claim 1, wherein the face plate comprises a titanium alloy.

9. A golf club head comprising:

a face plate having a contoured rear surface, the contoured rear surface including a central thickened region having a first non-circular, elliptical outer edge surrounded by a transition region tapered from the central thickened region toward a thinner peripheral region, the transition region having a second non-circular, elliptical outer edge,

wherein the transition region comprises a frustum-like region formed by a non-straight edge of a lateral cutting surface associated with a cutting device;

wherein the first non-circular, elliptical outer edge has a first aspect ratio, a first major axis and a first minor axis,

wherein the second non-circular, elliptical outer edge has 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,

wherein the predetermined distance is greater than the first major and minor axis;

wherein the first aspect ratio is greater than the second aspect ratio, and

wherein the central thickened region comprises a maximum thickness of the face plate and wherein the central thickened region comprises a constant thickness throughout its entirety and extends through a centerpoint of the first elliptical outer edge and the second elliptical outer edge.

10. The golf club head of claim 9, wherein the lateral cutting surface of the cutting tool is concave.

11. The golf club head of claim 9, wherein the lateral cutting surface of the cutting tool is convex.

12. The golf club head of claim 9, wherein the angle of the transition region, measured from the second elliptical outer edge to the first elliptical outer edge is about 13 degrees.

13. The golf club head of claim 9, wherein the first major axis ranges from 0.65 inch to 1.05 inches.

14. The golf club head of claim 9, wherein the first minor axis ranges from 0.25 inch to 0.45 inch.

15. The golf club head of claim 9, wherein the predetermined distance is constant, ranging from 0.40 inch to 1.20 inches.

16. The golf club head of claim 9, wherein the second major and minor axis are 0.86 inch greater than the first major and minor axis.

17. The golf club head of claim 9, wherein the face plate comprises a titanium alloy.