Methods and apparatus for a golf club head with an encapsulated insert

• US 20030220156A1
• Filed: 05/21/2002
• Published: 11/27/2003
• Est. Priority Date: 05/21/2002
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Karsten Manufacturing Corporation
• Inventors: Solheim, John A.
• Granted Patent: US 6,921,343 B2
• Time in Patent Office: Days
• US Class Current: 473/340
• CPC Class Codes: A63B 53/04 Heads
• CPC Class Codes: A63B 53/0433 with special sole configurations
• CPC Class Codes: A63B 53/0487 for putters A63B53/065 takes precedence
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like

Abstract

A golf club head includes a body (formed of cast titanium, steel, bronze, or the like) with a cavity formed therein behind a front face. An insert (e.g., an elastomeric insert) is provided through an opening exposed on a surface of the body (e.g., the sole of the club head) such that the insert is substantially encapsulated within the body. The opening or openings may be configured to provide a distinct visual appearance through the use of, for example, one or more rectangular and/or circular shapes. One or more supports and/or baffles may be provided within the cavity for altering the sound and feel of the club head during impact. Furthermore, the elastomeric insert may include a plurality of bubbles configured to alter the mechanical properties of the insert. The club head may be fabricated, for example, through the use machining techniques and/or a powdered metal or investment casting process.

Claims

1. A golf club head comprising:

a body having a cavity formed therein, said body having a front face arranged for impacting a golf ball, said cavity having an interior surface opposite said front face;

an insert provided within said cavity and substantially encapsulated by said body, said insert contacting said interior surface and configured to elastically deform when said front face impacts a golf ball;

an opening on an exterior surface of said body, said opening communicating with said cavity to facilitate forming said insert within said cavity of said body.

2. The club head of claim 1, wherein said insert comprises a polymer selected from the group consisting of thermoset elastomers and thermoplastic elastomers.

3. The club head of claim 1, wherein said insert comprises an elastomer selected from the group consisting of polyurethane, silicone, natural rubber, synthetic rubber, olefinic polyester, and styrenic polyester.

4. The club head of claim 1, wherein said insert further includes a plurality of bubbles configured to modify a mechanical property of said insert.

5. The club head of claim 1, wherein said body comprises a metal selected from the group consisting of titanium, steel, bronze, and aluminum.

6. The club head of claim 1, wherein said exterior surface includes a sole of said body, and wherein said opening is provided on said sole.

7. The club head of claim 1, wherein said opening comprises at least one rectangular area.

8. The club head of claim 1, wherein said opening comprises at least one circular area.

9. The club head of claim 1, wherein said opening communicates with said cavity through one or more passageways.

10. The club head of claim 1, further comprising a plug provided within said opening.

11. The club head of claim 1, wherein said body comprises a contiguous structure consisting of a single material.

12. The club head of claim 1, further including at least one support coupled to said interior surface.

13. The club head of claim 12, wherein said at least one support comprises at least one cylindrical support.

14. The club head of claim 12, wherein said at least one support comprises at least one vertical rib.

15. The club head of claim 12, wherein said at least one support comprises at least one horizontal rib.

16. The club head of claim 1, further including a plurality of baffles within said cavity to impede the flow of said insert during impact.

17. The club head of claim 1, wherein said cavity is configured such that said interior surface and said front face are separated by a thickness, and wherein said thickness is selected to allow said insert to deform in response to said front face striking a golf ball.

18. The club head of claim 17, wherein said thickness is substantially constant.

19. The club head of claim 18, wherein said interior surface and said front face are substantially planar.

20. The club head of claim 17, wherein said thickness is approximately 20 mils to 200 mils.

21. A method for fabricating a golf club head, said method comprising the steps of:

forming a body having a cavity formed therein and an opening on an exterior surface of said body which communicates with said cavity, said cavity having an interior surface opposite a front face provided on said body; and

providing, through said opening, an insert in said cavity such that said insert contacts said interior surface.

22. The method of claim 21, wherein said step of forming a body includes the step of forming said opening on a sole of said body.

23. The method of claim 22, wherein said providing step includes the step of injecting an elastomeric material into said cavity.

24. The method of claim 21, wherein said step of forming a body includes the step of forming a cast metal body selected from the group consisting of titanium, bronze, steel, and copper.

25. The method of claim 24, wherein said step of forming a cast metal body includes the step of performing an investment casting process.

26. The method of claim 21, further including the step of forming a plug within said opening.

27. The method of claim 21, further including the step of providing at least one support within said cavity.

28. The method of claim 21, wherein said providing step includes the step of providing an elastomeric insert having a plurality of air bubbles provided therein.

36. The method of claim 21, wherein said providing step includes the step of providing an insert having a plurality of air bubbles provided therein.

29. A method for fabricating a club head, said method comprising the steps of:

a) providing a die having a club head shape formed therein, said club head shape corresponding to a body having a cavity formed therein and an opening on an exterior surface of said body which communicates with said cavity, said cavity having an interior surface opposite a front face provided on said body;

b) injecting wax into said die and forming a solidified wax pattern;

c) removing said solidified wax pattern from said die;

d) immersing said solidified wax pattern in a ceramic slurry;

e) immersing said solidified wax pattern in a sand to form a shell mold around said solidified wax pattern;

f) melting substantially all of said solidified wax pattern out of said shell mold;

g) baking said shell mold;

h) pouring molten metal into said shell mold;

i) removing said shell mold to reveal said club head;

j) providing an insert within said cavity of said club head through said opening of said body.

30. The method of claim 29, wherein said step of forming a body includes the step of forming a cast metal body selected from the group consisting of titanium, bronze, steel, and copper.

31. The method of claim 29, wherein said opening is formed on a sole of said body.

32. The method of claim 29, wherein said providing step includes the step of injecting an elastomeric material into said cavity.

33. The method of claim 32, wherein said injecting step includes the step of injecting an elastomeric material selected from the group consisting of polyurethane, silicone, natural rubber, synthetic rubber, olefinic polyester, and styrenic polyester.

34. The method of claim 29, further including the step of forming a plug within said opening.

35. The method of claim 29, further including the step of providing at least one support within said cavity.