Methods of forming golf club heads

• US 9,802,372 B2
• Filed: 07/25/2014
• Issued: 10/31/2017
• Est. Priority Date: 04/05/2007
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Karsten Manufacturing Corporation
• Inventors: Stites, John T., Tavares, Gary G., Waatti, Todd A.
• Primary Examiner(s): JOHNSON, CHRISTINA ANN
• Assistant Examiner(s): Ameen, Mohammad M
• Application Number:
  US14/340,822
• Publication Number:
  US 20140333005A1
• Time in Patent Office: 1,194 Days
• Field of Search: None
• CPC Class Codes: A63B 2053/0491 with added weights, e.g. changeable, replaceable
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 53/04 Heads
• 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 53/0433 with special sole configurations
• CPC Class Codes: A63B 53/0437 with special crown configurations
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: A63B 53/0487 for putters A63B53/065 takes precedence
• CPC Class Codes: A63B 60/02 Ballast means for adjusting the centre of mass A63B60/24, A63B60/54 take precedence
• CPC Class Codes: B29C 41/04 Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B29C 70/681 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29K 2101/00 Use of unspecified macromolecular compounds as moulding material use of unspecified rubbers B29K2021/00
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29L 2031/5227 Clubs

Abstract

Wood-type golf clubs and/or golf club heads include: (a) a golf club head base member including a face member having a ball striking face; and (b) a polymeric body member engaged with the golf club head base member, wherein the polymeric body member is formed via a rotational molding process (or other centrifugal force inducing molding process) and/or engaged with the golf club head base member via a rotational molding process (or other centrifugal force inducing molding process). The polymeric body member forms at least a portion of a crown member of the club head in some structures.

Claims

1. A method of forming a golf club head, comprising:

placing a golf club head base member in a mold, wherein the golf club head base member includes at least a first opening and a second opening formed therein, wherein the first opening and the second opening are separated by a portion of the golf club head base member;

introducing a polymer material for forming a portion of a golf club body member to at least a portion of the mold; and

engaging the polymer material with the golf club head base member in the mold including molding the polymer material and embedding the portion of the golf club head base member separating the first opening and the second opening within the polymer material forming the portion of the golf club body member.

2. A method according to claim 1, wherein the golf club head base member includes a face portion and an aft portion, and wherein the portion of the golf club head base member separating the first opening and the second opening is provided in the aft portion of the golf club head base member.

3. A method according to claim 1, wherein the golf club head base member includes a face portion and a frame member, wherein the portion of the golf club head base member separating the first opening and the second opening is provided in the frame member, and wherein the engaging includes covering both an interior and an exterior of the frame member with the polymer material at the portion of the frame member separating the first opening and the second opening.

4. A method according to claim 1, wherein the engaging includes rotational molding.

5. A method according to claim 1, wherein the first opening and the second opening are located at a crown area of the golf club head base member.

6. A method according to claim 1, wherein the golf club head base member includes a face member and a return portion extending rearward from the face member, and wherein the engaging includes forming an entire exterior of the golf club head rearward of the return portion from the polymer material.

7. A method according to claim 1, wherein the engaging includes forming at least a portion of the golf club body member as a shell of the polymer material engaged with the portion of the golf club head base member separating the first opening and the second opening.

8. A method according to claim 1, further comprising:

after the engaging, applying a layer of a metal material over at least some of the polymer material forming the portion of the golf club body member.

9. A method of forming a golf club head, comprising:

placing a golf club head base member in a mold, wherein the golf club head base member includes a hollowed out interior and a frame portion defining plural open cells;

introducing a polymer material for forming a portion of a golf club body member to at least a portion of the mold; and

engaging the polymer material with the golf club head base member in the mold including molding the polymer material, filling the plural open cells with the polymer material, and embedding at least some of the frame portion of the golf club head base member within the polymer material.

10. A method according to claim 9, wherein the engaging includes rotational molding.

11. A method according to claim 9, wherein at least some of the plural open cells are located at a crown area of the golf club head base member.

12. A method according to claim 9, wherein the golf club head base member includes a face member and a return portion extending rearward from the face member, and wherein the engaging includes forming an entire exterior of the golf club head rearward of the return portion from the polymer material.

13. A method according to claim 9, wherein the engaging includes forming at least a portion of the golf club body member as a shell of the polymer material engaged with the frame portion.

14. A method according to claim 9, further comprising:

after the engaging, applying a layer of a metal material over at least some of the polymer material forming the portion of the golf club body member.

15. A method of forming a golf club head, comprising:

placing a golf club head base member in a mold, wherein the golf club head base member includes a frame defining plural open cells;

introducing a polymer material for forming a portion of a golf club body member to at least a portion of the mold; and

engaging the polymer material with the golf club head base member in the mold, wherein the engaging includes molding the polymer material and locating the polymer material so as to close the plural open cells and so as to cover an exterior of at least a portion of the frame, wherein said portion of the frame underlies the polymer material.

16. A method according to claim 15, wherein the engaging includes rotational molding.

17. A method according to claim 15, wherein at least some of the plural open cells are located at a crown area of the golf club head base member.

18. A method according to claim 15, wherein the golf club head base member includes a face member and a return portion extending rearward from the face member, and wherein the engaging includes forming an entire exterior of the golf club head rearward of the return portion from the polymer material.

19. A method according to claim 15, wherein the engaging includes forming at least a portion of the golf club body member as a shell of the polymer material engaged with the frame.

20. A method according to claim 15, wherein the engaging includes embedding said portion of the frame within the polymer material.

21. A method according to claim 15, further comprising:

after the engaging, applying a layer of a metal material over at least some of the polymer material forming the portion of the golf club body member.