Club heads with contoured back faces and methods of manufacturing the same

• US 7,794,335 B2
• Filed: 10/13/2008
• Issued: 09/14/2010
• Est. Priority Date: 10/13/2008
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Karsten Manufacturing Corporation
• Inventors: Petersen, David L., Noble, Randall B., Cole, Eric V.
• Primary Examiner(s): Hunter; Alvin A
• Application Number:
  US12/250,395
• Publication Number:
  US 20100093459A1
• Time in Patent Office: 701 Days
• Field of Search: 473324-350
• US Class Current: 473/342
• CPC Class Codes: A63B 53/04 Heads
• CPC Class Codes: A63B 53/0445 Details of grooves or the like on the impact surface
• CPC Class Codes: A63B 53/047 iron-type
• CPC Class Codes: A63B 53/0475 with one or more enclosed cavities
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: A63B 60/52 with slits
• 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

Abstract

Embodiments of club heads with contoured back faces and methods of manufacturing the same are described herein. Other embodiments and related methods are also disclosed herein

Claims

1. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the first trench-set further comprises;

a second trench substantially parallel to the first trench; and

a first rib set comprising one or more ribs;

the one or more ribs having at least a first rib;

at least the first rib of the first rib set comprises;

one or more narrow portions with a first thickness; and

one or more thick portions with a second thickness greater than the first thickness;

the first rib is located between the first and second trenches;

the strike face comprises a first groove and a second groove;

at least two ribs of the first rib set are positioned substantially parallel and opposite to the first and second grooves; and

two of the one or more trenches are interleaved with the first and second grooves.

2. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the first trench-set further comprises;

a second trench substantially parallel to the first trench; and

a first rib set comprising one or more ribs;

the one or more ribs having a first rib;

at least the first rib of the first rib set comprises;

one or more narrow portions with a first thickness; and

one or more thick portions with a second thickness greater than the first thickness;

the first rib is located between the first and second trenches;

the strike face comprises a first groove; and

at least a first one of the one or more thick portions of at least some of the one or more ribs is positioned substantially opposite to the first groove.

3. The club head of claim 2, wherein:

the first rib comprises a body that is at least one of;

slanted relative to the back face;

or

substantially parallel to an axis of impact of the club head.

4. The club head of claim 2, wherein:

the strike face comprises a first groove;

the first trench-set is substantially parallel to the first groove.

5. The club head of claim 2, wherein:

the strike face comprises a first groove;

the first trench-set is substantially perpendicular to the first groove.

6. The club head of claim 2, wherein:

the strike face comprises a first groove;

the first trench-set is diagonal relative to the first groove.

7. The club head of claim 2, wherein:

the first trench-set comprises concentric trenches relative to a center of the strike portion.

8. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head; and

at least a first one of the one or more first shallow or deep portions comprises a parabolic shape.

9. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the strike face comprises a first groove; and

at least a first one of the one or more shallow portions of some of the one or more trenches of the first trench-set are positioned substantially opposite to the first groove.

10. The club head of claim 9, wherein:

the one or more first shallow portions alternate with the one or more first deep portions along a length of the first trench.

11. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the first trench-set further comprises a second trench;

the second trench comprises;

a second shallow portion set; and

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to a plane of the back face;

the second shallow portion set is shallower than the first shallow portion set relative to the plane;

the second deep portion set is shallower than the first deep portion set relative to the plane;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

12. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the first trench-set further comprises a second trench;

the second trench comprises;

a second shallow portion set; and

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to a plane of the back face;

the second shallow portion set is narrower than the first shallow portion set;

the second deep portion set is narrower than the first deep portion set;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

13. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

at least the first trench of the one or more trenches comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the back face further comprises a second trench-set of one or more trenches;

the one or more trenches of the first trench-set are spaced apart from each other by a first distance;

the one or more trenches of the second trench-set are spaced apart from each other by a second distance;

the second distance is greater than the first distance; and

the second trench-set is positioned closer to a center of the strike portion than the first trench-set.

14. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head;

the first trench further comprises;

a second shallow portion set; and

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to a plane of the back face;

the second shallow portion set is shallower than the first shallow portion set relative to the plane;

the second deep portion set is shallower than the first deep portion set relative to the plane;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

15. A club head, comprising:

a strike portion comprising a back face and a strike face opposite the back face;

wherein;

the back face comprises a first trench set;

the first trench-set comprises a first trench of one or more trenches;

the first trench comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a loft plane of the club head; and

the first trench further comprises;

a second shallow portion set; and

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to a plane of the back face;

the second shallow portion set is narrower than the first shallow portion set;

the second deep portion set is narrower than the first deep portion set;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

16. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face;

forming in the back face a first trench-set comprising a first trench;

forming a second trench of the first trench-set substantially parallel to the first trench, and a first rib of the first trench-set between the first and second trenches; and

forming a first groove into the strike face;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face; and

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench;

the first rib comprises;

one or more narrow portions with a first thickness;

one or more thick portions with a second thickness greater than the first thickness; and

a body that is at least one of;

substantially perpendicular to the back face;

complementary to a loft angle of the strike face;

or

substantially parallel to an axis of impact of the club head;

at least a portion of the one or more thick portions is substantially opposite the first groove.

17. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face; and

forming in the back face a first trench-set comprising a first trench;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

forming in the back face the first trench-set further comprises;

forming a parabolic surface on at least one of the first shallow portion set or the first deep portion set of the first trench.

18. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face;

forming in the back face a first trench-set comprising a first trench; and

forming a first groove into the strike face;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

forming in the back face the first trench-set further comprises;

forming at least a portion of the first shallow portion set of the first trench substantially opposite the first groove.

19. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face; and

forming in the back face a first trench-set comprising a first trench;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench;

forming in the back face the first trench-set further comprises forming a second trench of the first trench-set;

at least one of the first or second trenches comprises;

a second shallow portion set;

or

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to a back face plane;

the second shallow portion set is at least one of shallower or narrower than the first shallow portion set;

the second deep portion set is at least one of shallower or narrower than the first deep portion set;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

20. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face;

forming in the back face a first trench-set comprising a first trench; and

forming on the back face a second trench-set positioned closer to a center of the strike portion than the first trench-set;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

trenches of the second trench-set are further spaced apart from each other than trenches of the first trench-set.

21. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face;

forming in the back face a first trench-set comprising a first trench; and

forming a first groove onto the strike face;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

forming the first trench-set further comprises at least one of;

forming trenches substantially parallel to the first groove;

forming trenches substantially perpendicular to the first groove;

forming trenches substantially diagonal to the first groove;

or

forming concentric trenches relative to a center of the strike portion.

22. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face; and

forming in the back face a first trench-set comprising a first trench;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

forming the first trench-set comprises;

milling the first trench onto the back face with a parabolic end-mill.

23. A method for manufacturing a club head, the method comprising:

providing a strike portion comprising a back face and a strike face opposite the back face; and

forming in the back face a first trench-set comprising a first trench;

wherein;

the first trench comprises;

a first shallow portion set; and

a first deep portion set;

the first shallow portion set is shallower than the first deep portion set relative to a surface of the back face;

shallow portions of the first shallow portion set alternate with deep portions of the first deep portion set along a length of the first trench; and

forming on the back face the first trench-set occurs simultaneously with providing the strike portion.

24. A club comprising:

a club shaft;

a club head coupled to the shaft; and

a strike portion coupled to the club head, the strike portion comprising;

a strike face with a first groove;

a back face opposite the strike face; and

a first trench-set at the back face;

wherein;

the first trench-set comprises;

a first trench of one or more trenches;

a second trench of the one or more trenches; and

a first rib between the first and second trenches;

at least the first trench of the one or more trenches comprises;

a first shallow portion set with one or more first shallow portions; and

a first deep portion set with one or more first deep portions;

the first shallow portion set is shallower than the first deep portion set relative to a plane of the back face;

the one or more first shallow portions alternate with the one or more first deep portions along a length of the first trench;

the first rib comprises;

one or more narrow portions with a first thickness;

one or more thick portions with a second thickness greater than the first thickness; and

a rib body that is at least one of;

substantially perpendicular to the back face;

slanted relative to a loft plane of the club head;

or

substantially parallel to an axis of impact of the club head;

the first trench-set is at least one of;

substantially parallel to the first groove;

substantially perpendicular to the first groove;

diagonal relative to the first groove;

or

concentric relative to a center of the strike portion;

at least one of the first trench or the second trench comprises;

a second shallow portion set;

or

a second deep portion set;

the second shallow portion set is shallower than the second deep portion set relative to the plane of the back face;

the second shallow portion set is at least one of shallower or narrower than the first shallow portion set;

the second deep portion set is at least one of shallower or narrower than the first deep portion set;

at least a part of the second shallow portion set is positioned closer to a center of the strike portion than a part of the first shallow portion set; and

at least a part of the second deep portion set is positioned closer to the center of the strike portion than a part of the first deep portion set.

25. The club of claim 24, further comprising:

a second trench-set at the back face;

wherein;

the second trench-set is positioned closer to a center of the strike portion than the first trench-set;

trenches of the second trench-set are further spaced apart from each other than trenches of the first trench-set; and

at least one of the first or second trench-sets comprises a portion with a parabolic inner surface.