GOLF CLUB FACE PLATES WITH INTERNAL CELL LATTICES AND RELATED METHODS

• US 20160263449A1
• Filed: 05/23/2016
• Published: 09/15/2016
• 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 M.
• Granted Patent: US 9,889,347 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 53/0454 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: 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: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• 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 golf club head comprising:

a face plate having;

an inner skin;

an outer skin;

a cell lattice with a plurality of walls having;

a plurality of axes extending centrally through the walls between the inner skin and the outer skin, wherein the walls extend from the axes at an angle less than or equal to approximately 45 degrees, wherein the walls intersect adjacent walls at a single, first point near the inner skin and at a single, second point near the outer skin;

a wall thickness that varies relative to position from the inner skin and the outer skin; and

a plurality of cells defined by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin and having a cell width that varies relative to position from the inner skin and the outer skin.

2. The golf club head of claim 1, wherein the wall thickness is greater near the inner skin and the outer skin than near a central region of the cell lattice.

3. The golf club head of claim 1, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches.

4. The golf club head of claim 1, wherein the maximum cell width ranges from 0.005 inches to 0.2 inches.

5. The golf club head of claim 1, wherein the thickness of the walls varies defining a plurality of hourglass shapes.

6. The golf club head of claim 1, wherein a center-to-center distance between adjacent axes ranges from 0.005 inches to 0.2 inches.

7. The golf club head of claim 1, wherein the axes are positioned radially from a center of the faceplate.

8. A cell lattice comprising:

an inner skin;

an outer skin;

a plurality of walls having;

a plurality of axes extending centrally through the walls between the inner skin and the outer skin, wherein the walls extend from the axes at an angle less than or equal to approximately 45 degrees; and

a wall thickness that varies relative to position from the inner skin and the outer skin;

a plurality of cells defined by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin; and

a plurality of apertures for removal of excess material in the cell lattice, the plurality of apertures including at least a first aperture positioned near a center of the cell lattice and a the remaining apertures positioned around the perimeter of the cell lattice.

9. The cell lattice of claim 8, wherein the wall thickness is greater near the inner skin and the outer skin than near a central region of the cell lattice.

10. The cell lattice of claim 8, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches.

11. The cell lattice of claim 8, wherein the maximum cell width ranges from 0.005 inches to 0.2 inches.

12. The cell lattice of claim 8, wherein the thickness of the walls varies defining a plurality of hourglass shapes.

13. The cell lattice of claim 8, wherein a center-to-center distance between adjacent axes ranges from 0.005 inches to 0.2 inches.

14. The cell lattice of claim 8, wherein the axes are positioned radially from a center of the cell lattice.

15. The cell lattice of claim 8, wherein the plurality of apertures is positioned through the inner skin of the cell lattice or through the outer skin of the cell lattice.

16. The cell lattice of claim 8, wherein the diameter of the apertures ranges from approximately 0.005 inches to 0.2 inches.

17. The cell lattice of claim 8, wherein each of the plurality of apertures are spaced apart from the remaining apertures by a distance greater than or equal to two times the diameter of the apertures.

18. A method of manufacturing a face plate of a golf club head comprising:

printing layer by layer at least a portion of a face plate having a cell lattice, the cell lattice including;

an inner skin;

an outer skin;

a plurality of walls having;

a plurality of axes extending centrally through the walls between the inner skin and the outer skin, wherein the walls extend from the axes at an angle less than or equal to approximately 45 degrees; and

a wall thickness that varies relative to position from the inner skin and the outer skin;

a plurality of cells defined by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin; and

a plurality of apertures for removal of excess material in the cell lattice, the plurality of apertures positioned through the inner skin or the outer skin, the plurality of apertures including at least a first aperture positioned near a center of the cell lattice and a the remaining apertures positioned around the perimeter of the cell lattice;

removing excess powdered material from the cell lattice; and

filling in the plurality of apertures.

19. The method of manufacturing the face plate of a golf club head of claim 18, wherein removing excess powdered material includes:

applying compressed air to the plurality of apertures positioned near the perimeter of the cell lattice;

applying force or pressure to the face plate; and

applying compressed air to the plurality of apertures positioned near the center of the cell lattice.

20. The method of manufacturing the face plate of a golf club head of claim 18, wherein:

the diameter of the apertures ranges from approximately 0.005 inches to 0.2 inches, and each of the plurality of apertures are spaced apart from the remaining apertures by a distance greater than or equal to two times the diameter of the apertures.