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

• US 7,914,394 B2
• Filed: 10/13/2008
• Issued: 03/29/2011
• 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:
  US12/250,366
• Publication Number:
  US 20100093461A1
• Time in Patent Office: 897 Days
• Field of Search: 473324-350
• US Class Current: 473/332
• CPC Class Codes: A63B 53/0458 with non-uniform 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: A63B 60/52 with slits
• 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 with a back face and a face opposite the back face;

wherein;

the back face comprises a first cavity-set with one or more first-cavities extending through a surface of the back face;

at least a first cavity of the one or more first cavities comprises;

a parabolic inner surface; and

a substantially circular outer perimeter at the surface of the back face;

the face comprises a first groove-set with one or more grooves; and

a subset of the one or more first-cavities is aligned substantially parallel relative to a groove of the first groove-set.

2. The club head of claim 1, wherein:

the first cavity is devoid of parallel sidewalls.

3. The club head of claim 1, wherein:

The one or more first-cavities are offset to lie in-between the one or more grooves.

4. The club head of claim 1, wherein:

a symmetry axis of at least the first cavity is substantially perpendicular to the back face.

5. The club head of claim 1, wherein:

the club head comprises a loft plane;

a symmetry axis of at least the first cavity is;

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

slanted non-perpendicularly to the loft plane of the club head.

6. The club head of claim 1, wherein:

the back face further comprises a plurality of ribs between the one or more first-cavities; and

the plurality of ribs are at least one of;

substantially perpendicular to the back face;

substantially parallel to an axis of impact;

or

slanted relative to a loft plane of the club head.

7. The club head of claim 1, wherein:

the first cavity further comprises a diameter configured to continuously vary from the back face towards the face of the strike portion.

8. The club head of claim 1, wherein:

an angle between a symmetry axis of the first cavity and a loft plane of the club head is between approximately 90 and 150 degrees.

9. The club head of claim 1, wherein:

the one or more first-cavities are arranged in a substantially arcuate pattern relative to each other at the back face of the strike portion.

10. The club head of claim 1, wherein:

the parabolic inner surface comprises multiple parabolic sections.

11. The club head of claim 1, wherein:

the parabolic inner surface comprises;

a parabolic cross-sectional profile, located between the back face and a face of the strike portion, and parallel to a symmetry axis of the first cavity.

12. The club head of claim 1, further comprising:

an iron club head body; and

a single piece comprising;

the back face of the strike portion; and

a sole integral with at least the back face of the strike portion and comprising a sole topside plane;

wherein;

the back face comprises a plurality of cavity levels;

the plurality of cavity levels comprise a lowermost cavity level located closer to the sole than any other cavity level of the plurality of cavity levels;

the one or more first-cavities comprise one or more lowermost cavities located at the lowermost cavity level; and

each of the at least one or more lowermost cavities comprises a symmetry axis that is non-intersecting with the sole topside plane.

13. The club head of claim 1, wherein:

the club head comprises a loft plane; and

a symmetry axis of at least the first cavity is;

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

slanted non-perpendicularly to the loft plane of the club head.

14. The club head of claim 1, wherein:

the parabolic inner surface comprises multiple parabolic sections.

15. A club head comprising:

a strike portion with a back face;

wherein;

the back face comprises;

a first cavity-set with one or more first-cavities extending through a surface of the back face; and

a second cavity-set with one or more second-cavities;

at least a first cavity of the one or more first cavities comprises;

a parabolic inner surface; and

a substantially circular outer perimeter at the surface of the back face;

the one or more second-cavities are at least one of;

deeper than the first-cavities;

more concentrated than the first-cavities;

or

larger in diameter at the back face than the first-cavities;

and

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

16. The club head of claim 15, wherein:

the one or more second-cavities are deeper than the first-cavities.

17. The club head of claim 15, wherein:

the one or more second-cavities are more concentrated than the first-cavities.

18. The club head of claim 15, wherein:

the one or more second-cavities are larger in diameter at the back face than the first-cavities.

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

providing a strike portion with a front face and a back face; and

forming a plurality of parabolic cavities into the back face;

wherein forming the plurality of parabolic cavities comprises;

forming a first parabolic cavity of the plurality of parabolic cavities to comprise;

a parabolic inner surface extending through a surface of the back face; and

a substantially circular outer perimeter at the surface of the back face; and

forming the plurality of parabolic cavities with decreasing depths towards a center of the strike portion.

20. The method of claim 19, wherein:

providing the strike portion comprises;

forming a plurality of furrows at the front face of the strike portion.

21. The method of claim 20, wherein:

forming the plurality of parabolic cavities comprises;

arranging the plurality of parabolic cavities to interleave between the plurality of furrows.

22. The method of claim 20, wherein:

forming the plurality of parabolic cavities comprises;

arranging the plurality of parabolic cavities substantially parallel to and interleaved with the plurality of furrows.

23. The method of claim 19, wherein:

forming the plurality of parabolic cavities comprises at least one of;

a casting process;

a drilling process;

or

a forging process.

24. The method of claim 19, wherein:

forming the plurality of parabolic cavities comprises;

aligning one or more symmetry axes of the plurality of parabolic cavities to be slanted non-perpendicularly relative to a loft plane of the club head.

25. The method of claim 19, further comprising:

providing the club head to comprise an iron club head body; and

providing a sole formed integrally with at least the back face of the strike portion;

wherein forming the plurality of parabolic cavities comprises;

forming one or more first parabolic cavities located closer to the sole than any other parabolic cavity of the plurality of parabolic cavities; and

aligning a symmetry axis of each of the one or more first parabolic cavities to forego intersecting with a topside plane of the sole.

26. The method of claim 19, wherein:

forming the plurality of parabolic cavities comprises;

arranging the plurality of parabolic cavities in a substantially concentric arcuate pattern along the back face of the strike portion.

27. The method claim 19, wherein:

forming the plurality of parabolic cavities occurs simultaneously with providing the strike portion.

28. A method of manufacturing a club head, the method comprising:

providing a strike portion with a front face and a back face; and

forming a plurality of parabolic cavities into the back face;

wherein forming the plurality of parabolic cavities comprises;

forming a first parabolic cavity of the plurality of parabolic cavities to comprise;

a parabolic inner surface extending through a surface of the back face; and

a substantially circular outer perimeter at the surface of the back face; and

forming the plurality of parabolic cavities in decreasing concentration toward a center of the strike portion.

29. A method of manufacturing a club head, the method comprising:

providing a strike portion with a front face and a back face; and

forming a plurality of parabolic cavities into the back face;

wherein forming the plurality of parabolic cavities comprises;

forming a first parabolic cavity of the plurality of parabolic cavities to comprise;

a parabolic inner surface extending through a surface of the back face; and

a substantially circular outer perimeter at the surface of the back face; and

forming the plurality of parabolic cavities with decreasing sizes toward a center of the strike portion.