METHOD FOR MANUFACTURING AND GOLF CLUB HEAD

• US 20100178998A1
• Filed: 03/23/2010
• Published: 07/15/2010
• Est. Priority Date: 06/11/2001
• Status: Active Grant

• Current Assignee: Taylor Made Golf Co., Inc.
• Original Assignee: Taylor Made Golf Co., Inc.
• Inventors: Beach, Todd P., Zedelmayer, Erik
• Granted Patent: US 8,579,726 B2
• Time in Patent Office: Days
• US Class Current: 473/345
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 2209/023 Long, oriented fibres, e.g. wound filaments, woven fabrics, mats
• CPC Class Codes: A63B 53/0408 characterised by specific dimensions, e.g. thickness
• CPC Class Codes: A63B 53/0412 Volume
• 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 53/045 Strengthening ribs
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29C 70/86 Incorporated in coherent impregnated reinforcing layers, e.g. by winding
• CPC Class Codes: B29L 2031/5227 Clubs
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material

Abstract

A method for forming a golf club head comprises placing an uncured composite material between a core and a mold that comprises a first piece and a second piece. The second piece is moved towards the first piece such that the uncured composite material is compressed between the core and at least a portion of the mold. The uncured composite material is heated. A first portion of the golf club head is removed from the mold. A second portion of the golf club head is provided. The first portion is attached to the second portion. In certain arrangements, the second portion is formed from a metallic material.

Claims

1. A method for forming a golf club head comprising:

placing an uncured composite material between a core and a mold that comprises a first piece and a second piece;

moving the second piece towards the first piece such that the uncured composite material is compressed between the core and at least a portion of the mold;

heating the uncured composite material;

removing a first portion of the golf club head from the mold;

providing a second portion of the golf club head; and

attaching the first portion to the second portion.

2. The method of claim 1, wherein providing the second portion comprises forming the second portion out of a metallic material.

3. The method of claim 2, wherein forming the second portion further includes casting the second portion out of the metallic material.

4. The method of claim 2, wherein forming the second portion further includes forging the second portion out of the metallic material.

5. The method of claim 2, wherein forming the second portion further includes a combination of casting and forging the second portion out of the metallic material.

6. The method of claim 1, wherein providing the second portion comprises placing a second uncured composite material between a second core and a second mold that comprises a third piece and a fourth piece, moving the fourth piece towards the third piece such that the second uncured composite material is compressed between the second core and at least a portion of the second mold;

and heating the second uncured composite material.

7. The method of claim 1, wherein the first portion comprises a shell of the club head and the second portion comprises a strike/sole plate combination.

8. The method of claim 1, wherein the first portion comprises a shell of the club head and the second portion comprises a strike plate.

9. The method of claim 1, wherein the first portion comprises a shell of the club head and the second portion comprises a sole plate.

10. The method of claim 1, wherein the uncured composite material is a carbon reinforced thermoset resin.

11. The method of claim 1, wherein the uncured composite material is a carbon reinforced plastic resin.

12. The method of claim 1, wherein placing the uncured composite material between the core and the mold includes laying up the uncured composite material around the core and placing the core and uncured composite material in the mold.

13. The method of claim 1, wherein said outer mold further comprises a third piece and the method further comprises attaching the third piece to the first piece.

14. A method for forming a golf club head comprising:

placing an uncured composite material between a core and a mold that comprises a first piece and a second piece;

moving the second piece towards the first piece such that the uncured composite material is compressed between the core and at least a portion of the mold;

heating the uncured composite material;

forming a first mating section on the first portion;

removing a first portion of the golf club head from the mold;

providing a second portion of the golf club head; and

attaching the first portion to the second portion.

15. The method of claim 14, further comprising forming second mating section on the second portion, the second mating section configured to mate with the first mating section.

16. The method of claim 15, wherein attaching the first portion to the second portion further includes applying an adhesive between the first mating section and the second mating section and fitting together the first mating section and the second mating section.

17. The method of claim 14, wherein forming the first mating section includes forming an abutment surface, which is transverse to an outer surface of the first portion of the club head.

18. The method of claim 14, wherein forming the first mating section includes forming an attachment surface, which is generally parallel to an outer surface of the first portion.

19. The method of claim 14, wherein forming the first mating section includes forming a first abutment surface, which is transverse to an outer surface of the first portion of the club head and a first attachment surface, which is generally parallel to an outer surface of the first portion.

20. The method of claim 19, wherein providing the second portion includes forming a second mating section configured to mate with the first mating section, the second mating section including a second abutment surface configured to mate with the first abutment surface and a second attachment surface configured to mate with the first abutment surface.

21. The method of claim 20, wherein attaching the first portion to the second portion includes applying an adhesive between the first attachment surface and the second attachment surface and fitting together the first mating section with the second mating section.

22. The method of claim 14, wherein the uncured composite material is a carbon reinforced thermoset resin.

23. The method of claim 14, wherein the uncured composite material is a carbon reinforced plastic resin.

24. The method of claim 14, wherein heating the uncured composite material comprises heating the uncured composite material to a temperature between approximately 200-500 degrees Fahrenheit.

25. The method of claim 14, wherein heating the uncured composite material comprises heating the composite material to a temperature of approximately 350 degrees Fahrenheit.

26. The method of claim 14, wherein heating the uncured composite material comprises heating the composite material to a temperature of approximately 350 degrees Fahrenheit for approximately 10 minutes.

27. The method of claim 14, wherein placing the uncured composite material between the core and the mold includes laying up the uncured composite material around the core and placing the core and uncured composite material in the mold.

28. The method of claim 14, wherein said outer mold further comprises a third piece and the method further comprises attaching the third piece to the first piece.

29. A golf club head comprising a shell made of a composite material that is attached to a strike plate that is formed of a metallic material, the shell including a first mating section and the strike plate including a second mating section configured to mate with the first mating section.

30. The golf club head of claim 29, wherein the first mating section and the second mating section extend entirely along an interface between the shell and the strike plate.

31. The golf club head of claim 29, wherein the first mating section includes a first abutment surface, which is transverse to an outer surface of the shell and the second mating section includes a second abutment surface, which is substantially parallel to the first abutment surface.

32. The golf club head of claim 29, wherein the first mating section includes a first attachment surface, which is generally parallel to an outer surface of the shell and the second mating section includes a second attachment surface, which is substantially parallel to the first attachment surface.

33. The golf club head of claim 29, wherein the first mating section includes forming a first abutment surface, which is transverse to an outer surface of the shell and a first attachment surface, which is generally parallel to an outer surface of the first portion and the second mating section includes a second abutment surface that is substantially parallel to the first abutment surface and a second attachment surface that is substantially parallel to the first attachment surface.

34. The golf club head of claim 29, wherein adhesive secures the first mating section to the second mating section.

35. A golf club head comprising a shell made of a composite material that is attached to a strike/sole plate combination that includes strike plate and sole plate which are integrally formed and made of a metallic material, the shell including a first mating section and the strike/sole plate combination including a second mating section configured to mate with the first mating section.

36. The golf club head of claim 35, wherein the first mating section and the second mating section extend entirely along an interface between the shell and the strike/sole plate combination.

37. The golf club head of claim 35, wherein the first mating section includes a first abutment surface, which is transverse to an outer surface of the shell and the second mating section includes a second abutment surface, which is substantially parallel to the first abutment surface.

38. The golf club head of claim 35, wherein the first mating section includes a first attachment surface, which is generally parallel to an outer surface of the shell and the second mating section includes a second attachment surface, which is substantially parallel to the first attachment surface.

39. The golf club head of claim 35, wherein the first mating section includes forming a first abutment surface, which is transverse to an outer surface of the shell and a first attachment surface, which is generally parallel to an outer surface of the first portion and the second mating section includes a second abutment surface that is generally parallel to the first abutment surface and a second attachment surface that is generally parallel to the first attachment surface.

40. The golf club head of claim 35, wherein adhesive secures the first mating section to the second mating section.