Golf club head

• US 20040180730A1
• Filed: 02/10/2004
• Published: 09/16/2004
• Est. Priority Date: 02/10/2004
• Status: Active Grant

• Current Assignee: Karsten Manufacturing Corporation
• Original Assignee: Nike, Inc.
• Inventors: Tavares, Gary G., Franklin, David N., Stites, John T., Madore, Carl L.
• Granted Patent: US 7,134,971 B2
• Time in Patent Office: Days
• US Class Current: 473/334
• CPC Class Codes: A63B 2209/00 Characteristics of used materials
• 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 53/0433 with special sole configurations
• CPC Class Codes: A63B 53/06 adjustable
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like

Abstract

A golf club head is disclosed that includes a primary element and an insert element formed of different materials. The insert element is located within a cavity formed by the primary element. The cavity is defined by a portion of the primary element that is of unitary construction, and the cavity is positioned between a face and a rear surface of the head. At least a portion of the cavity extends in a direction that is substantially parallel to the first surface. Another aspect of the invention involves a method of manufacturing the golf club head that includes forming the primary element. The cavity is then defined within a portion of the primary element that is of unitary construction, and the insert element is positioned within the cavity.

Claims

1. A golf club having a shaft and a head secured to the shaft, the head comprising:

a primary element at least partially formed of a first material, the primary element defining a first surface and an opposite second surface, the first surface providing an area for engaging a golf ball;

a cavity defined by a portion of the primary element that is of unitary construction, the cavity being positioned between the first surface and the second surface, at least a portion of the cavity extending in a direction that is substantially parallel to the first surface; and

an insert element formed of a second material and positioned within the cavity, the second material being different than the first material.

2. The golf club recited in claim 1, wherein the cavity and the insert element exhibit a substantially constant thickness in a direction extending between the first surface and the second surface.

3. The golf club recited in claim 1, wherein the cavity and the insert element exhibit a varying thickness.

4. The golf club recited in claim 3, wherein the thickness decreasingly-tapers in end portions of the cavity and the insert element.

5. The golf club recited in claim 1, wherein the cavity extends through one of a lower surface and an upper surface of the primary element to expose the insert element.

6. The golf club recited in claim 5, wherein at least one depression extends toward the second surface from the cavity, the at least one depression being formed in the one of the lower surface and the upper surface.

7. The golf club recited in claim 6, wherein the insert element includes at least one tab that is received by the at least one depression.

8. The golf club recited in claim 1, wherein the first material is a metal and the second material is a polymer.

9. The golf club recited in claim 1, wherein the head includes at least one additional element that is secured to the primary element.

10. The golf club recited in claim 1, wherein dimensions of the insert element are substantially similar to dimensions of the cavity.

11. The golf club recited in claim 1, wherein a ring element extends rearward from the primary element.

12. The golf club recited in claim 11, wherein the ring element is formed of a third material, the first material and the second material being different metals.

13. The golf club recited in claim 12, wherein a density of the first material is less than a density of the third material.

14. The golf club recited in claim 11, wherein a protrusion extends from an inner surface of the ring element.

15. A golf club having a shaft and a head secured to the shaft, the head comprising:

a primary element formed of a metal material, the primary element defining a face and an opposite rear surface;

a cavity defined by a portion of the primary element that is of unitary construction, the cavity being positioned between the face and the rear surface, the cavity having a substantially constant thickness, and the cavity extending in a direction between a heel side and a toe side of the head; and

an insert element formed of a polymer material, the insert element being positioned within the cavity.

16. The golf club recited in claim 15, wherein the cavity is positioned between the face and the rear surface, and at least a portion of the cavity extends in a direction that is substantially parallel to the face.

17. The golf club recited in claim 15, wherein the cavity extends through one of a lower surface and an upper surface of the primary element to expose the insert element.

18. The golf club recited in claim 17, wherein at least one depression extends toward the rear surface from the cavity, the at least one depression being formed in the one of the lower surface and the upper surface.

19. The golf club recited in claim 18, wherein the insert element includes at least one tab that is received by the at least one depression.

20. The golf club recited in claim 15, wherein the metal material is steel.

21. The golf club recited in claim 15, wherein the head includes at least one additional element that is secured to the primary element.

22. The golf club recited in claim 15, wherein dimensions of the insert element are substantially similar to dimensions of the cavity.

23. The golf club recited in claim 15, wherein a ring element extends rearward from the primary element.

24. The golf club recited in claim 23, wherein the ring element is formed of a metal material, the metal material of the primary element being different than the metal material of the ring element.

25. The golf club recited in claim 24, wherein the metal material of the primary element is aluminum and the metal material of the ring element is steel.

26. The golf club recited in claim 23, wherein a protrusion extends from an inner surface of the ring element.

27. A method of manufacturing a head for a golf club, the method comprising steps of:

forming a primary element of the head from a first material, the primary element having a face and an opposite rear surface;

defining a cavity within a portion of the primary element that is of unitary construction, the cavity being positioned between the face and the rear surface, at least a portion of the cavity extending substantially parallel to the face; and

positioning an insert element within the cavity, the insert element being formed of a second material that is different from the first material.

28. The method recited in claim 27, wherein the step of forming includes milling the primary element.

29. The method recited in claim 27, wherein the step of forming includes casting the primary element with a mold.

30. The method recited in claim 29, wherein the step of defining includes positioning a protrusion in the mold that forms the cavity.

31. The method recited in claim 27, wherein the step of positioning includes molding an insert element by introducing the second material in a molten state into the cavity.

32. A method of manufacturing a head for a golf club, the method comprising steps of:

forming a primary element of the head from a metal material, the primary element exhibiting a unitary construction with a face and an opposite rear surface;

defining a cavity within the primary element, the cavity being positioned between the face and the rear surface, the cavity having a substantially constant thickness, and the cavity extending in a direction between a heel side and a toe side of the head; and

molding an insert element of the head by introducing a molten polymer material into the cavity.