METHOD FOR FORMING A MULTIPLE MATERIAL GOLF CLUB HEAD (Corporate Docket Number PU2659-WO)

Technical Field

[0001 ] The present invention relates to a method for forming a multiple material golf club head.

Background Art [0002] The prior art discloses several methods for forming a golf club head.

[0003] One method is full casting which involves casting the entire golf club head, usually with a face pull tool. Duquette et ah, U.S. Patent Number 6978976 for a Magnetized Core With Pneumatic Release System For Creating A Wax Mold For A Golf Club Head describes certain aspects of the full casting method. Then a face insert is welded to then golf club head.

[0004] Another method is using a full casting method, using a face pull tool and then cutting a crown opening. A graphite crown is then bonded to cover the opening thereby forming a multiple material golf club head. [0005] Yet another method is forming an entire golf club head from multiple pieces. In this method, several pieces (crown, sole, face and hosel) are welded together to form a precursor golf club head. Then, an opening is cut in the crown creating an opening. A graphite crown is then bonded to cover the opening thereby forming a multiple material golf club head. [0006] Yet another method is a high performance multiple piece golf club head. This forming method involves making a multiple piece golf club head.

The crown material needs to be of high quality expensive titanium so prior to welding the crown component to the sole component, the crown is chemically milled to the limits of drop tower durability. The chemical milling process is necessary to render the crown component to be competitive with graphite strength to weight ratio.

[0007] The current construction includes tacking a face component to sole (called face subassembly). Manually trim and tack crown to face subassembly. Fully weld face, crown, and sole (21 inches of weld). Grind weld and polish head.

[0008] Each of these prior art methods have drawbacks. Both multiple piece graphite crown and full casting require the manufacturer to produce a complete golf club head. The crown opening is then cut and replaced with a graphite crown. This is obviously wasteful because of the need to fabricate an entire golf club head and then removing a portion. The high performance multiple piece golf club head remedies this wastefulness by utilizing an expensive titanium material and which adds more cost to render the crown component weight competitive to graphite crowns.

Summary of the Invention

[0009] The present invention seeks to reduce the waste from current blacktop manufacturing methods while achieving similar or better performance than the high performance multiple piece golf club heads at a price point that is similar to conventional multiple piece golf club heads. [0010] The process includes a face component and a stamped metal sole component preferably welded together without a crown component. The face component and the sole component are preferably welded together with a high tolerance. The face components and sole components are preferably manufactured past "desired points" and trimmed back to match 'net' CAD designs. The face component and the sole component weld line is then polished. This weld line is approximately six inches in length for a 460 cubic centimeter volume driver-type golf club head, hi prior art multiple piece golf club head construction methods the weld line is typically twenty-one inches in length or more for a 460 cubic centimeter volume driver-type golf club head. [0011 ] Thus, the present invention results in a significant reduction in finishing costs. More specifically, the finishing process for weld polishing requires expensive polishing belts. There are approximately five different belts ranging from very coarse to very fine. Each belt can usually polish around four to five golf club heads.

[0012] In the process of the present invention a crown is bonded into the golf club head subassembly.

[0013] The resulting weight of the crown in carbon composite ranges from 15 grams to 35 grams, more preferably from 20 grams to 30 grams and is most preferably 24 grams. The weight of the crown in the high performance multi- piece of the prior art is approximately 31 grams. By using the method of construction of the present invention, a manufacturer is obtains at least an additional seven grams of discretionary weight that can be used in other sections of the golf club head to improve mass properties such as moment of inertias (Izz, Iyy and Izz) through the center of gravity of the golf club head, durability (thicker face regions o other regions open to stress during loading), and lower or positioning of the center of gravity by shifting the mass of the golf club head.

[0014] The process includes welding the face component to the sole component to create a golf club head subassembly. This comprises only six inches of welding as opposed to the prior art twenty-one inches of welding. The golf club head subassembly is ground and polished, specifically the six inches of weld. The crown component is glued to the golf club head subassembly to create an unfinished golf club head. The unfinished golf club head is cleaned and finished.

[0015] This present invention is unique from other composite crown golf club heads or high performance multi-piece construction golf club heads because material is not wasted beyond what is necessary to form the golf club head. In traditional composite crown golf club heads, the whole golf club head is formed (either by casting or welding) and then an opening is cut from this whole golf club head for the composite crown, hi the high performance multi- piece construction golf club heads, the crown component material is very expensive relative to conventional stamped or cast materials, and this high performance multi-piece construction golf club head crown component material needs to be chemically milled to achieve its performance. The cutting and chemical milling wastes material and adds cost to achieve performance. The method of the present invention achieves the same performance without adding additional costs. [0016] The process for forming a driver-type golf club head includes welding the face component to the sole component to create a golf club head subassembly. This comprises only six inches of welding as opposed to the prior art twenty-one inches of welding. The golf club head subassembly is ground and polished, specifically the six inches of weld. The crown component is glued to the golf club head subassembly to create an unfinished golf club head. The unfinished golf club head is cleaned and finished. [0017] The fairway type golf club head comprises a subassembly having a bonding flange extending from a return section of a face component and a crown component having a bonding flange extending downward. The bonding flange of the crown component and the bonding flange of the subassembly do not overlap although both flanges are undercuts and are located to bond with an interior surface of either the crown component or the subassembly. [0018] One aspect of the present invention is a fairway- wood-type golf club head comprising a subassembly and a crown component. The subassembly is preferably composed of a stainless steel material. The subassembly has a mass ranging from 150 grams to 250 grams. The crown component has a mass ranging from 10 grams to 30 grams. The golf club head has a mass ranging from 200 grams to 300 grams. Brief Description of the Drawings

[0019] FIG. 1 is a perspective view of an unfinished golf club head. [0020] FIG. 2 is a side view of an unfinished golf club head. [0021] FIG. 3 is a bottom perspective view of an unfinished golf club head illustrating the weld line to be polished.

[0022] FIG. 4 is an isolated top perspective view of an interior of a subassembly of a golf club head to illustrate the bonding flange of a face component.

[0023] FIG. 5 is an isolated front perspective view of a crown component of a golf club head illustrating the bonding flange of the crown component.

[0024] FIG. 6 is an enlarged isolated view of a crown component of FIG. 5 illustrating the bonding flange and joint for bonding with the subassembly. [0025] FIG. 7 is a cross-sectional view of a bonding joint of a golf club head illustrating a bonding flange of the face component and the crown component. [0026] FIG. 8 is a cross-sectional view of a bonding joint of a golf club head illustrating a bonding flange of a crown component and a sole component. [0027] FIG. 9 is a flow chart of the method of the present invention.

Best Mode(s) For Carrying Out The Invention [0028] The process of the present invention preferably includes the manufacture of a cast face component 10 and a stamped metal sole component 18. The face component 10 and the sole component 18 are assembled together in a welding fixture. The welding fixture locates on the inside of the face component 10 and inside of the sole component 18. The welding fixture also locates on some sections of the outside surfaces of the face component 10 and the sole component 18. The crown component 16 is preferably formed from a carbon composite. Once the face component 10 and sole component 18 are welded into a golf club head subassembly, the golf club head subassembly is polished and prepared for adhesive bonding. The composite crown made by compression mold is bonded to the golf club head subassembly using an adhesive. After the adhesive cures, the unfinished golf club head is cleaned and finished (typically painting).

[0029] As shown in FIGS. 1-8, a golf club head 20 comprises a face component 10 with a striking plate section 12 and a return section 14 having bonding flange 11, a sole component 18 and a crown component 16 with a bonding flange 17 in order to construct the golf club head 20 according to a method of the present invention. [0030] Preferably the face component 10 is cast from titanium 6-4 alloy. The face component 10 comprises a striking plate 12 section and a return section

14. The return section 14 of the face component 10 has a bonding flange 11 extending rearward about 0.200 inch. Preferably the sole component 18 is a stamped titanium alloy. The thickness of the sheet material for the sole component 18 is determined by performance needs and manufacturability. The sole component 18 is trimmed. Preferably the crown component 16 is formed by compression molding a sheet molding compound. A sheet molding compound is a ready to mold fiber-reinforced polyester material primarily used in compression molding. The compound is a fiber glass reinforced thermosetting compound which is made by chopped glass strands between two layers of film, onto which resin paste has already been applied. The pre-preg passes through a compaction system that ensures complete strand impregnation before being wound into rolls. Advantages of using the sheet molding compound include high volume production ability, cost effectiveness, and industry scrap is reduced substantially. The crown component 16 has a bonding flange 17 between itself and the sole 18. Because of this design feature, the compression molded manufacturing technique is a preferred manufacturing technique. Alternative forming techniques include continuous fiber laminate construction and plastic injection molding. [0031] A preferred method of the present invention is illustrated in FIG. 9 and generally designated 100. At block 101, a face component is cast. At block

102, a sole component is stamped from metal, preferably titanium. At block

103, the face component and sole component are assembled, preferably through welding, into a subassembly. At block 104, the weld line of the subassembly is polished. At block 105, a crown component is compression molded from a graphite compound. At block 106, the crown component is adhesively bonded to the subassembly. At block 107, the golf club head is finished.

[0032] In one embodiment, the weld line preferably has a weld line of six inches. The golf club head 20 preferable has a volume of 460 cubic centimeters.

[0033] The bonding flange 17 of the crown component 16 does not overlap the bonding flange 11 of the face component 10. The face component 10 may also comprise a hosel 22, which may either be interior or exterior. Further, the golf club head 20 may have seven grams of additional discretionary mass as compared to high performance golf club head construction. Also, the face component 16 may have a milled variable face thickness pattern. [0034] The present invention is directed at a golf club head that has a high coefficient of restitution thereby enabling for greater distance of a golf ball hit with the golf club head of the present invention. The coefficient of restitution

(also referred to herein as "COR") is determined by the following equation: β ^~ vz→ i U ₁ -U ₂

[0035] wherein Uj is the club head velocity prior to impact; JJ ₂ is the golf ball velocity prior to impact which is zero; vj is the club head velocity just after separation of the golf ball from the face of the club head; V ₂ is the golf ball velocity just after separation of the golf ball from the face of the club head; and e is the coefficient of restitution between the golf ball and the club face.

[0036] The values of e are limited between zero and 1.0 for systems with no energy addition. The coefficient of restitution, e, for a material such as a soft clay or putty would be near zero, while for a perfectly elastic material, where no energy is lost as a result of deformation, the value of e would be 1.0. The present invention provides a club head having a coefficient of restitution ranging from 0.81 to 0.94, as measured under conventional test conditions.

[0037] The mass of the club head of the present invention ranges from 165 grams to 250 grams, preferably ranges from 175 grams to 230 grams, and most preferably from 190 grams to 205 grams. Preferably, the subassembly preferably has a mass ranging from 140 grams to 200 grams, more preferably ranging from 150 grams to 180 grams, yet more preferably from 155 grams to 166 grams, and most preferably 161 grams. The crown component has a mass preferably ranging from 4 grams to 20 grams, more preferably from 5 grams to 15 grams, and most preferably 7 grams.

[0038] The golf club head preferably has a volume that ranges from 290 cubic centimeters to 600 cubic centimeters, and more preferably ranges from 330 cubic centimeters to 510 cubic centimeters, even more preferably 350 cubic centimeters to 495 cubic centimeters, and most preferably 415 cubic centimeters or 460 cubic centimeters.

[0039] The axes of inertia are designated X, Y and Z. The X axis extends from the striking plate insert through the center of gravity, CG, and to the rear of the golf club head. The Y axis extends from the toe end of the golf club head through the center of gravity, CG, and to the heel end 66 of the golf club head. The Z axis extends from the crown section through the center of gravity, CG, and to the sole section.

[0040] As defined in Golf Club Design, Fitting, Alteration & Repair, 4 ^th Edition, by Ralph Maltby, the center of gravity, or center of mass, of the golf club head is a point inside of the club head determined by the vertical intersection of two or more points where the club head balances when suspended. A more thorough explanation of this definition of the center of gravity is provided in Golf Club Design, Fitting, Alteration & Repair. [0041] The center of gravity and the moment of inertia of a golf club head are preferably measured using a test frame (X ^τ , Y ^τ , Z ^τ ), and then transformed to a head frame (X ^H , Y ^H , Z ^H ). The center of gravity of a golf club head maybe obtained using a center of gravity table having two weight scales thereon, as disclosed in U.S. Patent Number 6,607,452, entitled High Moment Of Inertia Composite Golf Club, and hereby incorporated by reference in its entirety. [0042] In general, the moment of inertia, Izz, about the Z axis for the golf club head preferably ranges from 2800g-cm ² to 5000g-cm ² , preferably from 3000g- cm ² to 4500g-cm ² , and most preferably from 3750g-cm ² to 4250g-cm ² . The moment of inertia, Iyy, about the Y axis for the golf club head preferably

0 0 O ranges from 1500g-cm to 4000g-cm , preferably from 2000g-cm to 3500g- cm ² , and most preferably from 2400g-cm ² to 2900g-cm ² . The moment of inertia, Ixx, about the X axis for the golf club head 40 preferably ranges from 1500g-cm ² to 4000g-cm ² , preferably from 2000g-cm ² to 3500g-cm ² , and most preferably from 2500g-cm ² to 3000g-cm ² .

[0043] The width, W, preferably ranges from 4.0 inches to 5.5 inches, and most preferably from 4.75 inches to 5.0 inches. The height, H, preferably ranges from 2.0 inches to 3.0 inches, and most preferably ranges from 2.40 inches to 2.65 inches. The length, L, preferably ranges from 3.5 inches to 4.5 inches, and most preferably from 4.0 inches to 4.25 inches. The golf club head 40 may have an aspect ratio such as disclosed in U.S. Patent Number 6,338,683 for a Striking Plate For A Golf Club Head, assigned to Callaway

Golf Company, and which pertinent parts are hereby incorporated by reference.