Golf club face plates with internal cell lattices and related methods

• US 8,663,027 B2
• Filed: 01/17/2012
• Issued: 03/04/2014
• 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
• Primary Examiner(s): HUNTER, ALVIN A
• Application Number:
  US13/352,086
• Publication Number:
  US 20130072321A1
• Time in Patent Office: 777 Days
• Field of Search: 473324-350
• US Class Current: 473/329
• 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 53/045 Strengthening ribs
• 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: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: B23K 20/02 by means of a press ; Diffusion bonding B23K20/001, B23K20/04 take 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: 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 method for providing a face plate for a golf club head, the method comprising:

providing an inner skin of the face plate;

providing an outer skin of the face plate;

providing a midsection of the face plate; and

bounding the midsection between the inner skin and the outer skin;

wherein;

providing the midsection comprises;

providing a plurality of midsection layers comprising a first midsection layer and a second midsection layer;

forming a first lattice pattern through the first midsection layer; and

forming a second lattice pattern through the second midsection layer;

providing the inner skin, the outer skin, and the midsection comprises;

providing each of the midsection, the inner skin, or the outer skin as separate distinct pieces;

bounding the midsection comprises;

diffusion bonding the inner skin, the midsection, and the outer skin together, including the first and second midsection layers, into a single integral piece of material that is substantially seamless between the inner skin and the midsection and between the midsection and the outer skin;

wherein after the diffusion bonding;

a midsection central area of the midsection comprises a cell lattice;

the cell lattice comprises a plurality of walls defining a plurality of cells in a hexagonal pattern;

the plurality of walls and the plurality of cells of the cell lattice are defined at least in part by the first and second lattice patterns;

the cell lattice is fully bounded between the inner and outer skins of the face plate; and

a midsection perimeter area of the midsection bounds the midsection central area and is devoid of the cell lattice;

forming the first lattice pattern through the first midsection layer comprises forming a first cutout through the first midsection layer, the first cutout configured to define a first volume portion of a first cell of the cell lattice;

forming the second lattice pattern through the second midsection layer comprises forming a second cutout through the second midsection layer, the second cutout configured to define a second volume portion of the first cell;

bounding the midsection comprises;

aligning the second midsection layer over the first midsection layer such that the first and second cutouts are centered about a first cell axis of the first cell;

bounding the midsection comprises

forming the plurality of cells in an isogrid pattern;

diffusion bonding the inner skin, the midsection, and the outer skin together comprises intermeshing interfaces between the inner skin, the midsection, and the outer skin together via a high-pressure and high-heat process;

providing the inner skin, the outer skin, and the midsection comprises;

providing the midsection, the inner skin, and the outer skin to each comprise a titanium alloy with an alpha-type crystal structure;

and

diffusion bonding the inner skin, the midsection, and the outer skin together comprises

transforming the alpha-type crystal structure of the midsection, the inner skin, and the outer skin to a beta-type crystal structure intermeshing the midsection, the inner skin, and the outer skin together;

the alpha-type crystal structure comprising a hexagonal crystal phase; and

the beta-type crystal structure comprises a body-centered cubic crystal phase.

2. A method for providing a face plate for a golf club head, the method comprising:

providing an inner skin of the face plate;

providing an outer skin of the face plate;

providing a midsection of the face plate; and

coupling the midsection between the inner skin and the outer skin such that;

an inner midsection end of the midsection is coupled to the inner skin of the face plate; and

an outer midsection end of the midsection is coupled to the outer skin of the face plate;

wherein;

providing the midsection comprises;

providing a cell lattice in the midsection, the cell lattice comprising a plurality of walls defining a plurality of cells;

prior to coupling the midsection between the inner skin and the outer skin;

the inner skin comprises a first crystal structure of an alpha-type structure;

the outer skin comprises a second crystal structure of the alpha-type structure; and

the midsection comprises a midsection crystal structure of the alpha-type structure;

and

coupling the midsection between the inner skin and the outer skin comprises;

transforming the first crystal structure, the second crystal structure, and the midsection crystal structure to a beta-type structure such that;

the midsection crystal structure is intermeshed with the first crystal structure; and

the midsection crystal structure is intermeshed with the second crystal structure.

3. The method of claim 2, wherein:

coupling the midsection comprises;

merging the inner skin, the midsection, and the outer skin together into a single integral piece of material without adhesives or fasteners.

4. The method of claim 3, wherein:

the single integral piece of material is seamless between the inner skin and the midsection and between the midsection and the outer skin.

5. The method of claim 3, wherein:

coupling the midsection comprises;

merging the inner skin, the midsection, and the outer skin together via diffusion bonding using a high-pressure and high-heat process.

6. The method of claim 2, wherein:

the midsection comprises a metallic material; and

the inner skin and the outer skin comprise the metallic material.

7. The method of claim 2, wherein:

providing the cell lattice comprises;

providing the cell lattice extended from the inner midsection end to the outer midsection end.

8. The method of claim 2, wherein:

providing the midsection comprises;

forming the cell lattice in a midsection central area of the midsection; and

providing a midsection perimeter area of the midsection bounding the midsection central area and devoid of the cell lattice.

9. The method of claim 8, further comprising:

coupling the face plate to a front end of the golf club head;

wherein coupling the face plate to the front end of the golf club head comprises;

coupling the front end of the golf club head to at least one of;

an inner skin perimeter area of the inner skin;

or an outer skin perimeter area of the outer skin;

the inner skin perimeter area and the outer skin perimeter area being coupled to the midsection perimeter area without contacting the cell lattice at the midsection central area.

10. The method of claim 2, wherein:

providing the cell lattice comprises forming one or more of the plurality of cells with at least one of a hexagonal shape, a diamond shape, a rectangular shape, a circular shape, or a triangular shape.

11. The method of claim 2, wherein:

providing the cell lattice comprises;

providing cells of a first set of the plurality of cells with a first geometric shape; and

providing cells of a second set of the plurality of cells with a second geometric shape different than the first geometric shape; and

providing the first set of the plurality of cells interspersed with the second set of the plurality of cells.

12. The method of claim 2, wherein:

providing the cell lattice comprises forming one or more subcells within one or more of the plurality of cells.

13. The method of claim 2, wherein:

forming the cell lattice comprises forming the plurality of cells in an isogrid pattern.

14. The method of claim 2, wherein:

providing the cell lattice comprises;

forming a first wall of the plurality of walls to comprise a varying wall dimension.

15. The method of claim 2, wherein:

providing the cell lattice comprises forming the plurality of cells in at least one of;

a first pattern where a density of the plurality of cells decreases towards a target strike region of the face plate;

or

a second pattern where a size of the plurality of cells decreases towards the target strike region of the face plate.

16. The method of claim 2, wherein:

providing the midsection comprises;

providing a plurality of midsection layers comprising;

a first midsection layer; and

a second midsection layer;

providing the cell lattice in the midsection comprises;

forming a first lattice pattern of the cell lattice through the first midsection layer; and

forming a second lattice pattern of the cell lattice through the second midsection layer;

and

coupling the midsection between the inner skin and the outer skin comprises;

merging the first midsection layer and the second midsection layer together integrally into a single piece of material.

17. The method of claim 16, wherein:

providing the cell lattice comprises forming a first cell of the plurality of cells;

forming the first lattice pattern through the first midsection layer comprises;

forming a first cutout through the first midsection layer, the first cutout configured to define a first volume portion of the first cell;

and

forming the second lattice pattern through the second midsection layer comprises;

forming a second cutout through the second midsection layer, the second cutout configured to define a second volume portion of the first cell.

18. The method of claim 17, wherein:

forming the second cutout comprises;

forming the second cutout to comprise a different dimension than the first cutout, the different dimension comprising at least one of;

a different radius, a different perimeter length, a different area, or a different volume.

19. The method of claim 17, wherein:

prior to merging the first midsection layer and the second midsection layer together;

forming the cell lattice comprises;

aligning the second midsection layer over the first midsection layer such that the first and second cutouts are centered about a first cell axis of the first cell.

20. The method of claim 16, wherein:

providing the cell lattice comprises forming a first cell of the plurality of cells;

forming the first lattice pattern through the first midsection layer comprises;

forming a first cutout through the first midsection layer, the first cutout configured to define a first volume portion of the first cell;

prior to merging the first midsection layer and the second midsection layer together;

forming the second lattice pattern of the cell lattice through the second midsection layer comprises;

forming a second cutout through the second midsection layer, the second cutout configured to define a second volume portion of a second cell of the cell lattice;

and

providing the cell lattice further comprises;

aligning the first midsection layer over the second midsection layer such that;

the first and second cells are offset relative to each other;

the second cell is at least partially capped by a solid portion of the first midsection layer; and

the first cell is at least partially capped by a solid portion of the second midsection layer.

21. A method for providing a face plate for a golf club head, the method comprising:

providing an inner skin of the face plate;

providing an outer skin of the face plate;

providing a midsection of the face plate; and

coupling the midsection between the inner skin and the outer skin such that;

an inner midsection end of the midsection is coupled to the inner skin of the face plate; and

an outer midsection end of the midsection is coupled to the outer skin of the face plate;

wherein;

providing the midsection comprises;

providing a cell lattice in the midsection, the cell lattice comprising a plurality of walls defining a plurality of cells;

coupling the midsection comprises;

merging the inner skin, the midsection, and the outer skin together into a single integral piece of material without adhesives or fasteners;

merging the inner skin, the midsection, and the outer skin together via diffusion bonding using a high-pressure and high-heat process; and

a metallic material of the midsection comprises a titanium alloy comprising at least approximately 8% aluminum.

22. A method for providing a face plate for a golf club head, the method comprising:

providing an inner skin of the face plate;

providing an outer skin of the face plate;

providing a midsection of the face plate; and

coupling the midsection between the inner skin and the outer skin such that;

an inner midsection end of the midsection is coupled to the inner skin of the face plate; and

an outer midsection end of the midsection is coupled to the outer skin of the face plate;

wherein;

providing the midsection comprises;

providing a cell lattice in the midsection, the cell lattice comprising a plurality of walls defining a plurality of cells;

and

providing the cell lattice comprises;

providing a plurality of cell junctions where two or more of the plurality of walls couple together; and

forming a first junction channel into a first cell junction of the plurality of cell junctions, the first junction channel extending from the inner midsection end to the outer midsection end.

23. A method for providing a face plate for a golf club head, the method comprising:

providing an inner skin of the face plate;

providing an outer skin of the face plate;

providing a midsection of the face plate; and

coupling the midsection between the inner skin and the outer skin such that;

an inner midsection end of the midsection is coupled to the inner skin of the face plate; and

an outer midsection end of the midsection is coupled to the outer skin of the face plate;

wherein;

providing the midsection comprises;

providing a cell lattice in the midsection, the cell lattice comprising a plurality of walls defining a plurality of cells;

and

providing the cell lattice comprises;

forming a first wall of the plurality of walls to comprise a transverse passageway between adjacent cells of the plurality of cells.

24. A face plate for a golf club head, the face plate comprising:

a face plate central area

a face plate perimeter area between the face plate central area and a perimeter of the face plate;

an inner skin;

an outer skin; and

a midsection comprising;

an inner midsection end coupled to the inner skin;

an outer midsection end coupled to the outer skin; and

a cell lattice comprising a plurality of walls defining a plurality of cells between the inner midsection end and the outer midsection end;

wherein;

the inner skin comprises a first crystal structure;

the outer skin comprises a second crystal structure;

the midsection comprises a plurality of midsection layers having a midsection crystal structure;

the inner skin, the outer skin, and the midsection, along with the plurality of midsection layers, comprise a single piece of material;

the midsection comprises a metallic material;

the inner skin and the outer skin comprise the metallic material;

the cell lattice is located in the face plate central area without extending into the face plate perimeter area and

the cell lattice comprises a hexagonal pattern defined by the plurality of walls;

the metallic material comprises a titanium alloy comprising at least approximately 8% aluminum;

the first, second, and midsection crystal structures comprise a beta-type structure having a body-centered cubic crystal phase; and

the cell lattice comprises an isogrid pattern defined by the plurality of walls and the plurality of cells.