Golf club head with integrally cast sole plate and fabrication method for same
First Claim
1. A method for fabricating a metal wood golf club head, comprising a sequence of the following steps:
- providing a sole plate member constructed of a first material having a relatively high specific weight density, said sole plate member having an exterior surface and an interior surface;
providing an interior mold core;
disposing said mold core in a predetermined position relative to said interior surface of said plate member;
disposing an external mold about said mold core so that said external mold, said mold core and said interior surface of said sole plate member define a cavity having an external periphery in the shape of a portion of said golf club head;
disposing a second material in a fluid state into said cavity, wherein said second material flows into contact with at least a portion of said sole plate interior surface, said second material having a lower specific weight density than said first material and permitting said second material to harden into a solid state, wherein said sole plate member becomes cast into place relative to said second material as a result of said hardening of said second material; and
removing said external mold from said hardened second material and said sole plate member,whereby said second material forms a club head shell body member, and a unitary club head structure comprising said sole plate and said shell is formed without requiring welding, screws, or force-fitting to secure said sole plate in place.
1 Assignment
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Accused Products
Abstract
A metal wood golf club head with a hollow body shell of a first lightweight material and a sole plate of a second material having a higher specific weight density than the first material. The sole plate is attached to the shell without welding, fasteners or force-fitting. The center of gravity of the head is lowered, and other weight distributions can be achieved by alternate sole plate configurations, such as heel, toe or rear weighting. The head is fabricated by a process which includes the steps of providing the sole plate of the second material, disposing a core adjacent the interior surface of the sole plate, disposing an exterior mold about the core so that the exterior mold, the core and sole plate collectively define a mold cavity in the form of the body shell, filling the cavity with the second material in a fluid state, and permitting the second material to solidify. Upon solidification, the second material locks onto the sole plate, fixing the sole plate in position. The core may comprise a hollow metal structure, or cast sand or ceramic particles in an adhesive binder. The sand or ceramic core is later removed by heating the club head until the binder loses its effectiveness, and pouring the core particles out the hosel opening.
38 Citations
17 Claims
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1. A method for fabricating a metal wood golf club head, comprising a sequence of the following steps:
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providing a sole plate member constructed of a first material having a relatively high specific weight density, said sole plate member having an exterior surface and an interior surface; providing an interior mold core; disposing said mold core in a predetermined position relative to said interior surface of said plate member; disposing an external mold about said mold core so that said external mold, said mold core and said interior surface of said sole plate member define a cavity having an external periphery in the shape of a portion of said golf club head; disposing a second material in a fluid state into said cavity, wherein said second material flows into contact with at least a portion of said sole plate interior surface, said second material having a lower specific weight density than said first material and permitting said second material to harden into a solid state, wherein said sole plate member becomes cast into place relative to said second material as a result of said hardening of said second material; and removing said external mold from said hardened second material and said sole plate member, whereby said second material forms a club head shell body member, and a unitary club head structure comprising said sole plate and said shell is formed without requiring welding, screws, or force-fitting to secure said sole plate in place. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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Specification