Golf club head

• US 7,134,971 B2
• Filed: 02/10/2004
• Issued: 11/14/2006
• 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.
• Primary Examiner(s): Kim, Eugene
• Assistant Examiner(s): HUNTER, ALVIN A
• Application Number:
  US10/774,696
• Publication Number:
  US 20040180730A1
• Time in Patent Office: 1,008 Days
• Field of Search: 473324-350
• US Class Current: 473/340
• 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, and substantially all of the first surface being formed from the first material;

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;

at least one depression that is defined by the primary element and extends toward the second surface front the cavity; and

an insert element formed of a second material and positioned within the cavity, the insert element including at least one protrusion extending into the depression, and the second material being different than the first material, the second material having a lesser density 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 extends through one of a lower surface and an upper surface of the primary element to expose the insert element.

4. The golf club recited in claim 3, wherein the at least one depression is formed in the one of the lower surface and the upper surface.

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

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

7. 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, and the cavity forming an opening in a lower surface of the primary element and extending only partially between the lower surface and an upper surface of the primary element, the cavity having a substantially constant thickness, the cavity extending in a direction between a heel side end a toe side of the head, and the cavity having at least one depression formed in the lower surface and extending toward the rear surface; and

an insert element formed of a polymer material with a lesser density than the metal material, the insert element being positioned within the cavity, and a portion of the insert element being located within the at least one depression.

8. The golf club recited in claim 7, wherein at least a portion of the cavity extends in a direction that is substantially parallel to the face.

9. The golf club recited in claim 7, wherein the metal material is steel.

10. The golf club recited in claim 7, wherein dimensions of the inset element are substantially similar to dimensions of the cavity.

11. 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 by casting the primary element with a mold, 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 by positioning a protrusion in the mold that forms the cavity, 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 the cavity including at least one depression extending toward the rear surface; and

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

12. The method recited in claim 11, wherein the step of forming includes milling the primary element.

13. The method recited in claim 11, wherein the step of positioning includes molding an insert element by introducing the second material in a molten state into the cavity.