Golf club face plates with internal cell lattices and related methods

• US 10,322,320 B2
• Filed: 01/02/2018
• Issued: 06/18/2019
• Est. Priority Date: 09/21/2011
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Karsten Manufacturing Corporation
• Inventors: Morales, Eric J., Henrikson, Erik M.
• Primary Examiner(s): Simms, Jr., John E.
• Application Number:
  US15/859,912
• Publication Number:
  US 20180117424A1
• Time in Patent Office: 532 Days
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• 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 53/042 the face insert consisting of a material different from that of the head
• CPC Class Codes: A63B 53/0425 the face insert comprising two or more different materials
• CPC Class Codes: A63B 53/0429 the face insert comprising two or more layers of material
• CPC Class Codes: A63B 53/0454 Strengthening ribs on the rear surface of the impact face plate
• 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 53/047 iron-type
• CPC Class Codes: A63B 53/0487 for putters A63B53/065 takes precedence
• CPC Class Codes: B23K 20/021 Isostatic pressure welding
• CPC Class Codes: B23K 20/023 Thermo-compression bonding
• CPC Class Codes: B23K 20/233 without ferrous layer
• CPC Class Codes: B23K 2103/14 Titanium or alloys thereof
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Embodiments of golf club face plates with internal cell lattices are presented herein. Other examples and related methods are also disclosed herein.

Claims

1. A golf club head comprising:

a face plate having;

an inner skin;

an outer skin;

a cell lattice with a plurality of walls having;

a plurality of axes extending centrally through the walls between the inner skin and the outer skin, wherein the walls extend from the axes at an angle less than or equal to approximately 45 degrees, wherein the walls intersect adjacent walls at a single, first point near the inner skin and at a single, second point near the outer skin;

a wall thickness that varies relative to position from the inner skin and the outer skin;

a plurality of cells defined by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin and having a cell width that varies relative to position from the inner skin and the outer skin; and

a plurality of apertures for removal of excess material in the cell lattice, the plurality of apertures including at least a first aperture positioned near a center of the cell lattice and additional apertures positioned around a perimeter of the cell lattice.

2. The golf club head of claim 1, wherein the wall thickness is greater near the inner skin and the outer skin than near a central region of the cell lattice and wherein the plurality of apertures are filled with a material identical to a material of the face plate.

3. The golf club head of claim 1, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches.

4. The golf club head of claim 2, wherein the maximum cell width ranges from 0.005 inches to 0.2 inches.

5. The golf club head of claim 1, wherein the thickness of the walls varies defining a plurality of hourglass shapes.

6. The golf club head of claim 1, wherein a center-to-center distance between adjacent axes ranges from 0.005 inches to 0.2 inches.

7. The golf club head of claim 1, wherein the axes are positioned radially from a center of the faceplate.

8. The golf club head of claim 1, wherein the cell lattice is selected from the group consisting of hexagonal, diamond, square, circular, circular interspersed with triangles, and cell subsets with walls.

9. The golf club head of claim 1, wherein the cell lattice is selected from the group consisting of a center, heel, and toe lattice region, a center, heel, toe, top, and bottom lattice region, and a center, top-heel, top-toe, bottom-heel, and bottom-toe lattice region.

20. The golf club head of claim 1, wherein the plurality of apertures are filled with a metallic alloy.

10. A face plate of a golf club head comprising:

a cell lattice comprising;

an inner skin;

an outer skin;

a plurality of walls having;

a plurality of axes extending centrally through the plurality of walls between the inner skin and the outer skin, wherein the plurality of walls extend from the axes at an angle less than or equal to approximately 45 degrees; and

a wall thickness that varies relative to position from the inner skin and the outer skin;

a plurality of cells defined by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin; and

a plurality of apertures for removal of excess material in the cell lattice, the plurality of apertures including at least a first aperture positioned near a center of the cell lattice and additional apertures positioned around a perimeter of the cell lattice,

wherein the plurality of apertures are positioned through the inner skin of the cell lattice or through the outer skin of the cell lattice.

11. The face plate of claim 10, wherein the wall thickness of the cell lattice is greater near the inner skin and the outer skin than near a central region of the cell lattice.

12. The face plate of claim 10, wherein a minimum wall thickness of the cell lattice ranges from 0.005 inches to 0.2 inches.

13. The face plate of claim 10, wherein a maximum cell width of the cell lattice ranges from 0.005 inches to 0.2 inches.

14. The face plate of claim 10, wherein the thickness of the plurality of walls varies defining a plurality of hourglass shapes.

15. The face plate of claim 10, wherein a center-to-center distance between adjacent axes of the cell lattice ranges from 0.005 inches to 0.2 inches.

16. The face plate of claim 10, wherein the plurality of axes of the cell lattice are positioned radially from a center of a faceplate.

17. The face plate of claim 10, wherein a diameter of the plurality of apertures ranges from approximately 0.005 inches to 0.2 inches.

18. The face plate of claim 10, wherein each of the plurality of apertures are spaced apart from the additional apertures by a distance greater than or equal to two times a diameter of the plurality of apertures.

19. The face plate of claim 10, wherein the cell lattice is selected from the group consisting of a center, heel, and toe lattice region, a center, heel, toe, top, and bottom lattice region, and a center, top-heel, top-toe, bottom-heel, and bottom-toe lattice region.