Golf club heads with grooves and methods of manufacture

Embodiments of golf clubs, golf club heads, and methods of manufacture are described herein. In one embodiment, a golf club head includes a strike face having one or more grooves with edges, where one or more of the edges is unsmooth. Other embodiments are also described herein.

TECHNICAL FIELD

This disclosure relates generally to golf clubs, and relates more particularly to golf club heads with grooves and their methods of manufacturing.

BACKGROUND

Typically, a golf club head can include a club face with a plurality of parallel grooves extending between a toe end and a heel end of the club face. In particular, the plurality of grooves in an iron-type club head can channel out water, sand, grass, and/or other debris that may come between a golf ball and the club face in order to improve the grip between the golf ball and the club face. The grooves can have various cross-sectional shapes such as a square or rectangular shape, a V-shape, or a U shape.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “side,” “under,” “over,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of golf clubs and methods of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein. The term “coupled,” as used herein, is defined as directly or indirectly connected in physically, mechanical, or other manner.

Description of Exemplary Embodiments

In one embodiment of golf club heads and methods of manufacture, a golf club head includes a strike face including one or more grooves with edges, where one or more of the edges is unsmooth and includes at least one machining mark or other protrusion having a maximum height from the edge of about 0.033 millimeters or 0.0013 inches. Other embodiments of golf clubs and methods of manufacture are also disclosed herein.

Turning now to the figures,FIG. 1depicts a front view of golf club100, according to a first embodiment. Golf club100can be an iron-type golf club head, such as a 1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an 8-iron, a 9-iron, a sand wedge, a lob wedge, a pitching wedge, an n-degree wedge (e.g., 44 degrees (°), 48°, 52°, 56°, 60°, etc.), etc.

As the rules to golf may change from time to time (e.g., new regulations may be adopted or old rules may be eliminated or modified by golf standard organizations and/or governing bodies), golf equipment related to the methods, apparatus, and/or articles of manufacture described herein may be conforming or non-conforming to the rules of golf at any particular time. Accordingly, golf equipment related to the methods, apparatus, and/or articles of manufacture described herein may be advertised, offered for sale, and/or sold as conforming or non-conforming golf equipment. The methods, apparatus, and/or articles of manufacture described herein are not limited in this regard.

Golf club100includes golf club head body110and shaft120coupled to golf club head body110. In the illustrated embodiment ofFIG. 1, golf club head body110includes hosel114to which shaft120is coupled. In a different embodiment, golf club head body110has a hole, instead of hosel114, to which shaft120is coupled.

Golf club head body110includes toe portion115and heel portion116, where hosel114is located at heel portion116. Golf club head body110also includes a perimeter121comprising sole117at a bottom portion of golf club head body110and also comprising top rail118at a top portion of golf club head body110. Golf club head body110can also include notch119at heel portion116.

Golf club head body110further includes back face124and front face111opposite back face124. Front face111can also be referred to as a strike face. The strike face can be an integral part of golf club head body110, or the strike face can be a separate piece from, or an insert for, golf club head body110. The strike face includes one or more grooves112, including groove113. Groove113can be referred to as a channel, and grooves112can be referred to as channels. Grooves112can extend across the strike face from toe portion115of golf club head body110to heel portion116of golf club head body110. Grooves112can also be stacked vertically above one another from sole117to top rail118.

In one embodiment, grooves112, including groove113: (1) are straight and parallel with each other; (2) have a symmetrical cross-section and have sidewalls that do not converge toward the groove opening; (3) have a width, spacing, and cross-section that is consistent throughout the impact area of front face111; (4) have a width that does not exceed 0.940 millimeters (mm) or 0.037 inches (in.) using the United States Golf Association's (USGA's) thirty degree method of measurement, and where less than half of the widths of grooves112exceed 0.889 mm or 0.035 in. using the same measurement technique; (5) have a distance between adjacent grooves that is not less than three times the maximum width of the adjacent grooves minus 0.203 mm or 0.008 in. and that is not less than 1.854 mm or 0.073 in., and where less than half of the distances between adjacent ones of grooves112are less than three times the maximum width of the adjacent grooves and are less than 1.905 mm or 0.075 in.; (6) have a depth that does not exceed 0.559 mm or 0.022 in., and where less than half of the depths of grooves112exceed 0.508 mm or 0.020 in.; (7) have a cross-sectional area divided by a groove pitch (i.e., groove width plus spacing between adjacent grooves) that does not exceed 0.0813 mm or 0.0032 in., and where the less than half of the cross-sectional areas divided by the respective groove pitches exceed 0.0762 mm or 0.0030 in.; (8) have a range of widths that do not exceed 0.254 mm or 0.010 in.; and (9) have a range of depths that do not exceed 0.254 mm or 0.010 in. Additional details regarding grooves112are explained in the subsequent figures.

FIG. 2depicts a cross-sectional view of a portion of groove113of golf club head body110(FIG. 1). The cross-sectional view ofFIG. 2is defined by dashed region122inFIG. 1. As depicted inFIG. 2, groove113has edges210and211, sidewalls220and221, and bottom230. Edge210is adjacent to and couples front face111and sidewall220, and edge211is adjacent to and couples front face111and sidewall221. Bottom230is adjacent to and couples sidewalls220and211. Edges210and211can also be referred to as borders. Groove113has depth231, as defined by a substantially perpendicular distance between front face111and bottom230.

Groove113can have a variety of overall cross-sectional shapes including, but not limited to, a U-shape, a V-shape, a rectangular-shape, a square-shape, and the like. In the embodiment illustrated inFIG. 2, groove113is symmetric such that edges210and211are substantially mirror images of each other, sidewalls220and221are substantially mirror images of each other, and the left and right halves of bottom230are substantially mirror images of each other. In a different embodiment, groove113can be asymmetric such that edges210and211are different from each other, sidewalls220and221are different from each other, and/or the left and right halves of bottom230are different from each other.

Turning toFIG. 3, a portion of edge210is depicted. The portion ofFIG. 3is defined by dashed region233inFIG. 2. As depicted inFIG. 3, edge210has an overall convex curve shape. Within that overall shape, however, edge210is unsmooth or uneven because edge210comprises one or more machining marks330, which do not include the overall shape of edge210. Also,FIG. 3illustrates edge210to include five of machining marks330, but edge210can include more or less than five of machining marks330. Furthermore, machining marks330have peaks or peak points that remain below front face111and do not extend out of groove113(FIG. 2), but in a different embodiment, the peaks do not remain below front face111and/or do extend out of groove113(FIG. 2). In one embodiment, the peaks of machining marks330do not create an overall sharpness for edge210, as best seen inFIG. 2. Additional details regarding machining marks330are described below.

Referring briefly back to the embodiment depicted inFIG. 2, the machining marks at edge210do not form a raised lip or a sharp edge for edge210or groove113. Also, edge211is symmetric with edge210such that edge211is also unsmooth in the same manner as edge210. In a different embodiment, edge211is unsmooth in a different manner than edge210(i.e., a different number, shape, or size of machining marks).

In another embodiment, still referring toFIG. 2, edge211is smooth while edge210is unsmooth. In this embodiment, the bottom edges of grooves112(FIG. 1) (i.e., the edges of a groove that are closer to sole117of golf club head body110) can be smooth while the top edges of grooves112(FIG. 1) (i.e., the edges of a groove that are closer to top rail118of golf club head body110) can be unsmooth.

In a further embodiment, edge211is unsmooth while edge210is smooth. In this embodiment, the bottom edges of grooves112(FIG. 1) can be unsmooth while the top edges of grooves112(FIG. 1) can be smooth.

The unsmooth or uneven characteristic of edge210(and/or edge211(FIG. 2)) can be defined by, as one example, two or more inflection points. The unsmooth or uneven characteristic of edge210can produce a sharp corner for edge210, or the unsmooth or uneven characteristic of edge210can produce a non-sharp or even a dull corner for edge210.

The unsmooth or uneven characteristic of edge210and/or edge211can, under certain conditions, increase the grip that front face111(FIG. 1) has on a golf ball when front face111of golf club head body110(FIG. 1) impacts the golf ball. As a result of the increased or improved grip, the golf ball can, under certain conditions, have a higher rate of backspin, which can, under certain conditions, improve the consistency of a golf shot from golf club100(FIG. 1) in a variety of playing conditions.

As also depicted inFIGS. 2 and 3, machining marks330are located at edge210and/or edge211, but are absent from sidewalls220and221. In a different embodiment, machining marks330can also be located at one or both of sidewalls220and221. This different embodiment can be useful if front face111and/or edges210and211are soft or otherwise deformable so that machining marks330at sidewalls220and221can grip the golf ball when front face111impacts the golf ball.

Machining marks330can also be referred to as projections and can include protuberances, extensions, and undulations. As best seen inFIGS. 2 and 3, machining marks330can be substantially parallel to groove113. Accordingly, in an embodiment where each edge of grooves112(FIG. 1) have machining marks330, each of machining marks330can be parallel to each of grooves112.

Machining marks330can be regularly or irregularly shaped. Machining marks330can also be symmetric (vertically, horizontally, or otherwise) such that a first half of a machining mark is substantially a mirror image of a second half of the same machining mark, or machining mark330can be asymmetric such that a first half of a machining mark is different from a second half of the same machining mark. Machining marks330can further be symmetric such that a first one of machining marks330is substantially a mirror image of a second one of machining marks330, or machining marks330can be asymmetric such that a first one of machining marks330is different from a second one of machining marks330.

Machining marks330have peaks and concave sides. The concave sides between adjacent machining marks330define valleys340. Accordingly, machining marks330can have a scallop-like configuration, as depicted inFIG. 3, but other configurations are also contemplated, as shown in the subsequent figures.

The peaks of machining marks330inFIG. 3define curve332. Curve332is represented by a dashed line inFIG. 3, and curve332has a radius331. Similarly, the bottom portions of valleys340define curve342. Curve342is represented by another dashed line inFIG. 3, and curve342has radius341. As depicted inFIG. 3, curves332and342are concentric or parallel with each other; radii331and341originate from the same point335; and radius341is smaller than radius331. In one embodiment, each of radius331and radius341is greater than or equal to approximately 0.254 mm or 0.01 in. In another embodiment, each of radius331and radius341is greater than or equal to approximately 1.016 mm or 0.04 in. Either one or both of radius331and radius341can be referred to as an effective radius of edge210, and in the same or different embodiment, each edge of grooves112(FIG. 1) can have radius331and radius341, or only one edge of each of grooves112(FIG. 1) can have radius331and radius341while the other edge of each of grooves112(FIG. 1) has radius341. In one embodiment, the height of the machining marks, as measured from curve342to curve332, is approximately 0.0127 mm to 0.0508 mm or 0.0005 in to 0.002 in. In this embodiment, the difference between radius331and radius341is within the same range of approximately 0.0127 mm to 0.0508 mm or 0.0005 in. to 0.002 in.

Referring back toFIG. 1, one or more other ones of grooves112can be similar, identical, or symmetric to groove113. In one embodiment, groove113is asymmetric, but each of grooves112is symmetric with groove113. As another example, in another embodiment, groove113is symmetric, and every second one or every third one of grooves112is symmetric with groove113. In this embodiment, the ones of grooves112that are not symmetric to groove113can have a different cross-sectional shape, one smooth edge and one unsmooth edge, one or two edges with a different number of machining marks, a different shape of machining marks, and/or a different height or width of machining marks. Other variations are also contemplated herein.

Turning toFIG. 4, a previously proposed USGA measurement of the sharpness of edge210of groove113ofFIGS. 2 and 3is depicted. In particular,FIG. 4shows two dashed concentric circles442and444having radii441and443, respectively. The smaller circle, circle442, is tangential to front face111and to sidewall220, and sidewall220has an angle453.

In one embodiment, edge210is not sharp where:

radius341≥radius441+radius443-radius441(1-2sin⁡(angle453)⁢1-cos⁡(angle453))⁢⁢and(Eq.⁢1)radius331≥radius441+radius443-radius441(1-2sin⁡(angle453)⁢⁢1-cos⁡(angle453)).(Eq.⁢2)
In the same or a different embodiment, radius441has a length of 0.254 mm or 0.01 in., and radius443has a length of 0.279 mm or 0.011 in. In another embodiment, radius441has a length of 0.508 mm or 0.020 in., and radius443has a length of 0.533 mm or 0.021 in. In the same or other embodiments, radius441has a length that is from 0.254 mm to 0.508 mm or 0.010 in. to 0.020 in., and radius443has a length that is from 0.279 mm to 0.533 mm or 0.011 in. to 0.021 in.

In one embodiment, edge210can be defined by the portion of groove113that is located within circles442and444. In the same or different embodiment, edge210is defined as being located between front face111and sidewall220. In one example of this embodiment, front face111and sidewall220can be flat such that edge210is the non-flat portion located between the flat surfaces of front face111and sidewall220. Other configurations for edge210are also contemplated herein.

Referring back toFIG. 3, machining marks330protrude or extend from edge210. Arrow350shows a direction that a drill bit or micromachining tool can move along edge210to form valleys340and machining marks330after casting, forging, machining, or otherwise forming front face111and/or golf club head body110(FIG. 1). In one embodiment, each of valleys340represents a single cut or pass of a micromachining tool along edge210. In a different embodiment, a single cut or pass of a micromachining tool along edge210can simultaneously form two or more of valleys340.

FIG. 5depicts a first simplified representation of a portion of edge210ofFIG. 3, according to the first embodiment.FIG. 5is a simplified representation because, in part, the overall shape of edge210is not shown to be curved, as depicted inFIG. 3. Also,FIG. 5shows only a portion of edge210.

Each of machining marks330has a width532, which is less than a width of groove113(FIG. 2). Each of machining marks330also have a height531above edge210. Height531is the difference between radius331and341, and therefore, height531is measured radially from edge210. Height531of machining marks330is less than depth231(FIG. 2) of groove113(FIG. 2). In one embodiment, distance531is up to approximately 0.0254 mm or 0.001 in. In the same embodiment, width532is approximately 0.254 mm or 0.01 in. or greater, and the ratio of distance531to width532can be approximately 1:10 or greater. In the same or a different embodiment, distance531is up to approximately ten percent of radius331and/or radius341. In another embodiment, width532can be less than 0.254 mm or 0.01 in., and/or distance531can be greater than 0.0254 mm or 0.001 in.

As also depicted inFIG. 5, portions533of edge210located between two adjacent ones of machining marks330are substantially smooth, substantially uniform, and substantially curved. The curves are depicted to be concave, but in another embodiment, the curve can be convex.

FIG. 6depicts a second simplified representation of a portion of edge210ofFIG. 3, according to a second embodiment.FIG. 6is similar toFIG. 5, except that adjacent ones of machining marks330inFIG. 6are spaced apart from each other by portions633of edge210. As an example, portions633can space apart adjacent ones of machining marks330by a distance of up to approximately 0.3 mm or 0.012 in. In one embodiment, adjacent ones of machining marks330can be separated from each other by the same distance, or by different distances. In contrast, the distance between adjacent ones of machining marks330inFIG. 5is substantially zero. Portions633inFIG. 6can be substantially planar, or can be convexly or concavely curved or can have a different configuration.

FIG. 7depicts a third simplified representation of a portion of edge210ofFIG. 3, according to a third embodiment.FIG. 7is similar toFIG. 5, except thatFIG. 7depicts machining marks730, which have substantially straight sides instead of the concave sides of machining marks330inFIG. 5. Also, inFIG. 7, portions733of edge210are located between adjacent ones of machining marks730and have an overall V-shape.

FIG. 8depicts a fourth simplified representation of a portion of edge210ofFIG. 3, according to a fourth embodiment.FIG. 8is similar toFIG. 7, except that adjacent ones of machining marks730inFIG. 8are spaced apart from each other by portions633of edge210.

FIG. 9depicts a fifth simplified representation of a portion of edge210ofFIG. 3, according to a fifth embodiment.FIG. 9is similar toFIG. 5, except thatFIG. 9depicts machining marks930, which have curved top surfaces or rounded peaks instead of the pointed peaks of machining marks330inFIG. 5. In a different embodiment, adjacent ones of machining marks930can be separated by portions633(FIG. 6) of edge210.

FIG. 10depicts a sixth simplified representation of a portion of edge210ofFIG. 3, according to a sixth embodiment.FIG. 10is similar toFIG. 6, except thatFIG. 10depicts machining marks1030, which are substantially rectangularly shaped and have a substantially planar top surface. In a different embodiment, machining marks1030can have rounded top surfaces, which can be concentric or parallel with curve342.

FIG. 11depicts a seventh simplified representation of a portion of edge210ofFIG. 3, according to a seventh embodiment.FIG. 11is also similar toFIG. 6, except thatFIG. 11depicts machining marks1130, which are substantially trapezoidally shaped and have a substantially planar top surface. In a different embodiment, adjacent ones of machining marks1130can be contiguous with each other, and/or machining marks1130can have rounded top surfaces, which can be concentric or parallel with curve342.

FIG. 12depicts an eighth simplified representation of a portion of edge210ofFIG. 3, according to an eighth embodiment.FIG. 12is similar toFIG. 7, except thatFIG. 12depicts machining marks1230, which have curved top surfaces or rounded peaks. Machining marks1230can be vertical combinations of machining marks730(FIG. 7) and machining marks930(FIG. 9). Other combinations and permutations for the machining marks are also contemplated herein. For example, instead of stacking machining marks930above machining marks730, the machining marks across edge210can alternate between machining marks930and machining marks730. As an example, machining marks1230can be created by using a drill bit, and a shape that is reversed from what is shown inFIG. 12can be created by using an electrical discharge machine.

FIG. 13depicts a second cross-sectional view of a portion of groove113of golf club100ofFIG. 1, according to a ninth embodiment, where the cross-sectional view ofFIG. 13is defined by dashed region122inFIG. 1.FIG. 14depicts a portion of edge210ofFIG. 13, according to the ninth embodiment, where the portion of edge210inFIG. 14is defined by dashed region1344inFIG. 13.

FIGS. 13 and 14are similar toFIGS. 2 and 3, respectively, except thatFIGS. 13 and 14depict machining marks1430and valleys1440to not be substantially parallel to groove113whileFIGS. 2 and 3depict machining marks330and valleys340to be substantially parallel to groove113. Except for their non-parallel orientation, machining marks1430and valleys1440inFIGS. 13 and 14can be similar to machining marks330and valleys340inFIGS. 2 and 3. Also,FIG. 14illustrates edge210to include five of machining marks1430, but edge210can include more or less than five of machining marks1430.

Although machining marks1430are not parallel to groove113, machining marks1430can be perpendicular to the direction of the golf ball when front face111(FIG. 1) of golf club head body110(FIG. 1) is “open” or otherwise “misaligned” during impact of front face111with the golf ball. Machining marks1430can have the different variations described with reference toFIGS. 5-12. In a different embodiment, the machining marks can be slanted in an opposite direction than depicted inFIG. 13such that the machining marks are substantially perpendicular to the direction of the golf ball when front face111(FIG. 1) of the golf club head body110(FIG. 1) is “closed” during impact of front face111with the golf ball. Other variations for the machining marks are also contemplated herein.

FIG. 15depicts a third cross-sectional view of a portion of groove113of golf club100ofFIG. 1, according to a tenth embodiment, where the cross-sectional view ofFIG. 15is defined by dashed region122inFIG. 1.FIG. 16depicts a portion of edge210ofFIG. 15, according to the tenth embodiment, where the portion of edge210inFIG. 16is defined by dashed region1566inFIG. 15.

FIGS. 15 and 16are similar toFIGS. 2 and 3, respectively, except that the peaks of machining marks1630inFIG. 16do not extend out or otherwise enlarge a radius of edge210, as shown inFIGS. 3,5-12, and14. Instead, the bottoms of valleys1640extend into or reduce a radius of edge210. Therefore, machining marks1630and valleys1640inFIG. 16are formed using a different process than used to form machining marks330and valleys340inFIG. 3. In particular, valleys1640inFIG. 16are formed as depressions, and the formation of valleys1640forms machining marks1630. Accordingly, curve1632, which is drawn as a dashed line inFIG. 16, represents the original surface of edge210before forming valleys1640and machining marks1630. Therefore, in this way, curve1632inFIG. 16can be analogous to curve332inFIGS. 3 and 4. AlthoughFIG. 16illustrates edge210to include five of machining marks1630, but edge210can include more or less than five of machining marks1630.

After forming valleys1640and machining marks1630, the peaks of machining marks1630define dashed curve1632. The bottoms of valleys1640define dashed curve1642, and curves1632and1642have radii1631and1641, respectively. Machining marks1630and valleys1640inFIGS. 15 and 16are formed using a different process than the machining marks and valleys described with reference toFIGS. 2,3, and5-14, but edge210inFIGS. 15 and 16can still have the following characteristics:

radius1641≥radius441+radius443-radius441(1-2sin⁡(angle453)⁢1-cos⁡(angle453))⁢⁢and(Eq.⁢3)radius1631≥radius441+radius443-radius441(1-2sin⁡(angle453)⁢1-cos⁡(angle453)).(Eq.⁢4)
In the same or a different embodiment, radius441has a length of 0.254 mm or 0.01 in., and radius443has a length of 0.279 mm or 0.011 in. In another embodiment, radius441has a length of 0.508 mm or 0.020 in., and radius443has a length of 0.533 mm or 0.021 in. In the same or other embodiments, radius441has a length that is from 0.254 mm to 0.508 mm or 0.01 in. to 0.020 in., and radius443has a length that is from 0.279 mm to 0.533 mm or 0.011 in. to 0.021 in.

FIG. 17depicts a simplified representation of a portion of edge210inFIG. 16, according to the tenth embodiment.FIG. 17is a simplified representation because, in part, the overall shape of edge210is not shown to be curved, as depicted inFIG. 16. AlsoFIG. 17shows only a portion of edge210.

As depicted inFIG. 17, machining marks1630have height1731, which also represents the depth of valleys1640from the original surface of edge210. Portions1733located between two adjacent ones of machining marks1630are substantially smooth, substantially uniform, and substantially curved. The curves are depicted to be concave, but in another embodiment, the curve can be convex.

FIG. 18depicts another simplified representation of a portion of edge210inFIG. 16, according to an eleventh embodiment.FIG. 18is similar toFIG. 17, except that adjacent ones of machining marks1630inFIG. 18are spaced apart from each other by portions1833. As an example, portions1833can space apart adjacent ones of machining marks1630by a distance of up to approximately 0.3 mm or 0.012 in. In one embodiment, adjacent ones of machining marks1630can be separated from each other by the same distance, or by different distances. In contrast, the distance between adjacent ones of machining marks1630inFIG. 17is substantially zero. Portions1833inFIG. 18can be substantially planar, or can be convexly or concavely curved or can have a different configuration.

FIG. 19depicts another simplified representation of a portion of edge210ofFIG. 16, according to a twelfth embodiment.FIG. 19is similar toFIG. 17, except thatFIG. 19depicts machining marks1930, which have substantially straight sides instead of the concave sides of machining marks1630inFIG. 17. Also, inFIG. 19, portions1933are located between adjacent ones of machining marks730and have an overall V-shape.

FIG. 20depicts another simplified representation of a portion of edge210ofFIG. 16, according to a thirteenth embodiment.FIG. 20is similar toFIG. 19, except that adjacent ones of machining marks1930inFIG. 20are spaced apart from each other by portions1833.

FIG. 21depicts another simplified representation of a portion of edge210ofFIG. 16, according to a fourteenth embodiment.FIG. 21is similar toFIG. 17, except thatFIG. 21depicts machining marks2130, which have curved top surfaces or rounded peaks instead of the pointed peaks of machining marks1630inFIG. 17. In a different embodiment, adjacent ones of machining marks2130can be separated by portions1833(FIG. 18) of edge210.

FIG. 22depicts another simplified representation of a portion of edge210ofFIG. 16, according to a fifteenth embodiment.FIG. 22is similar toFIG. 18, except thatFIG. 22depicts machining marks2230, which are substantially rectangularly shaped and have a substantially planar top surface. In a different embodiment, machining marks2230can have rounded top surfaces, which can be concentric or parallel with curve1632.

FIG. 23depicts another simplified representation of a portion of edge210ofFIG. 16, according to a sixteenth embodiment.FIG. 23is also similar toFIG. 18, except thatFIG. 23depicts machining marks2330, which are substantially trapezoidally shaped and have a substantially planar top surface. In a different embodiment, adjacent ones of machining marks2330can be contiguous with each other, and/or machining marks2330can have rounded top surfaces, which can be concentric or parallel with curve1632.

FIG. 24depicts another simplified representation of a portion of edge210ofFIG. 16, according to an seventeenth embodiment.FIG. 24is similar toFIG. 19, except thatFIG. 24depicts machining marks2430, which have curved top surfaces or rounded peaks. Machining marks2430inFIG. 24can be similar to machining marks1230inFIG. 12. Other variations to machining marks1630(FIGS. 16 and 17) are also contemplated herein.

FIG. 25depicts method2500of manufacturing a golf club, according to an eighteenth embodiment. Method2500includes forming a strike face comprising one or more grooves having edges, where an edge of at least one of the one or more grooves is unsmooth (a block2510). In one embodiment, block2510could include casting the strike face with the grooves and the unsmooth edge or edges. In a different embodiment, block2510could include casting the strike face with the grooves and, afterwards, machining, micromachining, and/or growing the edges to make them unsmooth. For example, micromachining the edges can include micromachining projections into the edges. In another embodiment, block2510could include casting the strike face without the grooves and, afterwards, machining or micromachining the grooves into the strike face and then machining, micromachining, or growing the edges to make them unsmooth. In a further embodiment, block2510could include casting the strike face without the grooves and, afterwards, machining or micromachining the grooves into the strike face. As an example, machining or micromachining the edges can include electrical discharge machining or laser peening the grooves into the face and, afterwards, not buffing or otherwise finishing the face, not fully buffing or finishing the face, or minimizing the amount of buffing or finishing of the face to maintain at least a portion of the machining marks of the grooves. The machining or micromachining can be controlled to provide the machining marks within the specifications identified above. In an additional embodiment, the casting process identified above can be replaced with a forging process and/or a machining process. In another embodiment, the growing process identified above can include an epitaxial growing process. In a further embodiment, the laser peening process can be used to create the machining marks after machining the grooves into the face. Block2510can be used to form the projections in the edges of the grooves, regardless of whether the projections are similar to the projections of: (a)FIGS. 2,3, and5-12; (b)FIGS. 13-14; or (c)FIGS. 15-24.

Method2500can continue with forming a golf club head body (a block2520). The forming process of block2520could also include casting, forging, and/or micromachining. In some embodiments, blocks2510and2520can be performed in a reverse sequence or simultaneously with each other. In an embodiment where blocks2510and2520are performed separately, method2500includes coupling the strike face to the golf club head body (a block2530). In an embodiment where blocks2510and2520are performed simultaneously, the strike face is integral with the golf club head body, and block2530can be omitted from method2500. In this embodiment, however, the edges of the grooves could still be made unsmooth after or while casting the entire golf club head body.

Method2500continues with coupling a shaft to the golf club head body (a block2540). As explained above, the shaft can be coupled to a hole in the golf club head body or to a hosel of the golf club head body.

Turning to the next figure,FIG. 26depicts edge210of groove113ofFIG. 1, according to a nineteenth embodiment. The view illustrated inFIG. 26is similar to the view illustrated inFIG. 4of a different embodiment of edge210of groove113. InFIG. 26, protrusion2630is located at edge210. Protrusion2630can be similar to machining marks330inFIG. 3and/or any of the other machining marks previously described for edge210. As used herein, the term protrusions includes machining marks. In the embodiment ofFIG. 26, edge210comprises a single one of protrusion2630, but in other embodiments, edge210can comprise more than one of protrusion2630.

In the embodiment where radius441has a length of 0.254 mm or 0.010 in. and where radius443has a length of 0.279 mm or 0.011 in., protrusion2630extends from edge210to beyond circle444having radius443, as illustrated inFIG. 26.FIG. 26also illustrates circle2646having radius2645that is greater than radii441and443. In one embodiment, radius2645can extend up to 0.00762 mm or 0.0003 in. beyond radius443so that radius2645has a maximum length of 0.287 mm or 0.0113 in. In this embodiment, protrusion2630extends beyond circle444to circle2646and, therefore, has a height measured radially from edge210to circle2646. In a different embodiment, protrusion2630can extend beyond circle444, but does not extend all the way to circle2646. In the same or different embodiment, protrusion2630extends beyond circle444by more than 0.00762 mm or 0.0003 in.

FIG. 26also illustrates angle2649defined by: (1) a radius of circle444that is defined by a first region of edge210that intersects circle444; and (2) a radius of circle444that is defined by a second region of edge210that intersects circle444. In one embodiment, angle2649is less than or equal to ten degrees.

In other embodiments, angle2649can be greater than 10 degrees. As an example, angle2649can be greater than 10 degrees on less than fifty percent (50%) of edges210of grooves112(FIG. 1) of front face111(FIG. 1) and can be greater than 10 degrees on less than half of edges211(FIG. 2) of grooves112(FIG. 1) of front face111(FIG. 1).

In one embodiment, a line that is tangent to a part or any part of the portion of edge210where protrusion2630is located does not form a thirty degree angle with front face111. Therefore, as illustrated inFIG. 26, tangent line2651forms an angle2650with front face111, and angle2650is less than thirty degrees. In one example, protrusion2630is at a portion of edge210that is as close to front face111as possible such that angle2650is as small as possible. In this example, protrusion2630can extend above front face111, or protrusion2630can extend up to front face111. In another embodiment, protrusion2630is further away from front face111such that angle2650is greater than thirty degrees. In a different embodiment, protrusion2630is at a portion of edge210such that tangent line2651forms angle2650to be equal to thirty degrees.

Protrusion2630can be a portion of each groove of a golf club head, or can be a portion of only some of the grooves of a golf club head. Also, protrusion2630can be at the same location for each groove in the golf club head, or protrusion2630can be at different locations for different grooves within the same golf club head.

Protrusions2630can also be at the same location for each groove in a particular golf club head, but can be at different locations within the grooves of different golf club heads. For example, the location of protrusion2630at edge210can be based on the loft angle of front face111. In particular, protrusion2630can be located at edge210closer to front face111when front face111has a higher loft angle, and protrusion2630can be located at edge210further away from front face111and closer to sidewall220when front face111has a lower loft angle. In an different embodiment, protrusion2630can be located at edge210closer to front face111when front face111has a lower loft angle and further away from front face111when front face111has a higher loft angle. Additionally, protrusion2630can have different shapes and/or heights based on the loft angle of front face111(e.g., a larger, taller, and/or sharper shape for a larger loft angle in one embodiment, or a larger, taller, and/or sharper shape for a smaller loft angle in a different embodiment). Moreover, the grooves can have a different quantity of protrusions based on the loft angle of front face111(e.g., more protrusions for a larger loft angle in one embodiment, or more protrusions for a smaller loft angle in a different embodiment).

As illustrated in the embodiment ofFIG. 26, sidewall220has a steep slope such that the cross sectional shape of groove113is closer to a U-shape than a V-shape. In a different embodiment, sidewall220has a more gradual slope such that the cross sectional shape of groove113is closer to a V-shape than a U-shape. In either embodiment, sidewall220can be straight and/or curved.

As described above forFIG. 4, the characteristics of edge210can also be present for edge211(FIG. 2) of groove113such that groove113is symmetric. In a different embodiment, only one of edges210and211can have the characteristics described above for edge210inFIG. 26. In a first example of this different embodiment, groove113can be asymmetric, and in a second example of this different embodiment, groove113can still be symmetric to the naked eye because of the small size of protrusion2630. In an embodiment where only one of edges210and211have protrusion2630, the edge that is closer to the top rail of the golf club head can have the protrusion while the edge that is closer to the bottom rail or sole of the golf club head can be without the protrusion. This embodiment can further increase the grip that front face111has on a golf ball when front face111impacts the golf ball. Again, as a result of the increased or improved grip, the golf ball can, under certain conditions, have a higher rate of backspin, which can, under certain conditions, improve the consistency of a golf shot from the golf club in a variety of playing conditions.

FIG. 27depicts edge210of groove113of the golf club ofFIG. 1, according to a twentieth embodiment. In the embodiment ofFIG. 27, protrusion2730is located at edge210. Protrusion2730can be similar to protrusion2630inFIG. 26and, therefore, can also be similar to machining marks330inFIG. 3and/or any of the other machining marks or other protrusions previously described for edge210. InFIG. 27, edge210comprises a single one of protrusion2730, but in other embodiments, edge210can comprise more than one of protrusion2730.

Protrusion2730inFIG. 27is located closer to sidewall220and further away from front face111than protrusion2630inFIG. 26. As explained previously with respect toFIG. 26, the embodiment ofFIG. 27can be used when front face111has a lower loft angle (or vice versa) compared to front face111in the embodiment ofFIG. 26. A line that is tangent to a part of the portion of edge210where protrusion2630is located can form an angle with front face111that is greater than thirty degrees.

FIG. 28depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-first embodiment. In the embodiment ofFIG. 28, edge210comprises more than one protrusion. In particular, edge210comprises protrusions2630,2831, and2832. In a different embodiment, edge210can include less than or more than three protrusions.

Protrusions2831and2832can be similar to protrusion2630, but can have different shapes and/or sizes. As an example, in the embodiment ofFIG. 28, protrusions2831and2832are shorter than, but are proportional to, protrusion2630. Also, protrusion2832is also shorter than protrusion2831, and protrusions2831and2832are located closer to sidewall220than protrusion2630such that the height of each of protrusions2630,2831, and2832sequentially decreases towards sidewall220, as illustrated inFIG. 28In the same or different embodiment, the spacing between protrusions2630,2831, and2832can be consistent or can vary. Additionally, in the same or different embodiment, protrusions2831and2832can be shorter than and non-proportional to protrusion2630. In a different embodiment, each of protrusions2831and2832can be the same height as protrusion2630, or one or more of protrusions2831and2832can be shorter than protrusion2630, but can have heights between circles444and2646.

FIG. 29depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-second embodiment. In the embodiment ofFIG. 29, edge210also comprises more than one protrusion. In particular, edge210comprises protrusions2630and2931. In a different embodiment, edge210can include more than two protrusions.

Protrusion2931can be similar to protrusion2630, but can have a different shape and/or size. As an example, in the embodiment ofFIG. 29, protrusion2931is shorter than, but is proportional to, protrusion2630. Also, protrusion2931is closer to front face111than protrusion2630such that the height of each of protrusions2630and2931sequentially decreases towards front face111, as illustrated inFIG. 29. In a different embodiment, protrusion2931can be shorter than and non-proportional to protrusion2630. In another embodiment, protrusions2931can be the same height as protrusion2630, or protrusion2931can be shorter than protrusion2630, but can have a height between circles444and2646.

FIG. 30depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-third embodiment. The embodiment ofFIG. 30can be similar to a combination of the embodiments ofFIGS. 28 and 29. For example, edge210comprises more than one protrusion, namely, protrusions2630,3031, and3032.

Protrusions3031and3032can be similar to protrusion2630, but can have different shapes and/or sizes. As an example, in the embodiment ofFIG. 30, protrusion3032is shorter than protrusion2630, and protrusion3031is shorter than protrusion3032. In a different embodiment, the relative heights of protrusions3031and3032can be reversed or otherwise changed, and/or edge210can include a different number of protrusions on either side of protrusion2630. In the same or different embodiment, the spacing between protrusions2630,3031, and3032can be consistent or can vary. Furthermore, the concepts related to the additional protrusions described with respect to protrusion2630in the embodiments ofFIGS. 28,29, and30can also be applied to protrusion2730and the embodiment ofFIG. 27.

FIG. 31depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-fourth embodiment. In the embodiment ofFIG. 31, protrusion3130is located at edge210. Protrusion3130can be similar to protrusion2630inFIG. 26, but in the illustrated embodiments, protrusion3130is much smaller than protrusion2630inFIG. 26. In other embodiments, protrusion2630can be more similar in size to protrusion2630(FIG. 26). InFIG. 31, edge210comprises a single one of protrusion3130, but in other embodiments, edge210can comprise more than one of protrusion3130. Also inFIG. 31, at least a portion of protrusion3130is located between circles444and2646, but in other embodiments, protrusion3130can be located only between circles442and444.

Protrusion3130is located at the edge of edge210or at the border or interface between front face111and edge210. To manufacture protrusion3130and/or other protrusions described herein, groove113(including edges210and211(FIG. 2), sidewalls220and221(FIG. 2), and bottom230) can be machined into front face111. The process of machining groove113into front face111can form protrusion3130. As an example, protrusion3130can be formed while using a drill bit to form groove113into front face111. In this example, protrusion3130can be considered a manufacturing artifact or a machining mark. Protrusion3130can also be referred to as a discontinuity between front face111and edge210. To maintain the small size of protrusion3130, a buffing or other finishing process for front face111and/or grooves113that occurs after machining grooves113can be omitted. As a result, this manufacturing process can be faster than other processes using the post-machining buffing process.

Turning to the next figure,FIG. 32depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-sixth embodiment. In the embodiment ofFIG. 32, protrusion3230is located at edge210. Protrusion3230can be similar to protrusion2630inFIG. 26. InFIG. 32, edge210comprises a single one of protrusion3230, but in other embodiments, edge210can comprise more than one of protrusion3230.

Circle442is closer to edge210inFIG. 32than edge210inFIG. 26. Therefore, protrusion3230inFIG. 32can be higher or taller than protrusion2630inFIG. 26, when the protrusions are measured from their respective edges. As an example, protrusion3230can have a maximum height of approximately 0.262 mm or 0.0103 in., as measured radially from edge210.

FIG. 33depicts edge210of groove113of the golf club ofFIG. 1, according to a twenty-seventh embodiment. In the embodiment ofFIG. 33, protrusion3330is located at edge210. Protrusion3330can be similar to protrusion2630inFIG. 26. InFIG. 33, edge comprises a single one of protrusion3330, but in other embodiments, edge210can comprise more than one of protrusion3330.

Circle444is closer to edge210inFIG. 33than edge210inFIG. 26. Therefore, edge210inFIG. 33will be larger or more pronounced than edge210inFIG. 26. in this embodiment, protrusion3330can have a maximum height of 0.0076 mm or 0.0003 in.

The disclosure of embodiments of golf clubs and methods of manufacture is intended to be illustrative of the scope of golf clubs and methods of manufacture and is not intended to be limiting. For example, the details of the grooves described with reference toFIGS. 1-33can be applied to not only irons, but also drivers and other woods, hybrid clubs, putters, and other types of golf clubs. Furthermore, the machining marks or other protrusions at a single edge of a groove can be evenly or unevenly spaced apart from each other, or the density, size, and/or shape of the machining marks or other protrusions can be different at different parts of the same groove. Moreover, the machining marks or other protrusions do not need to extend along the length of the groove. Instead, the machining marks or other protrusions can be more similar to intermittent machining marks or protrusions, or bumps, or punch marks, or other smaller sized machining marks or other protrusions. Additionally or instead, the machining marks or other protrusions can be curved, bent, crooked, etc. As another example, front face111can also be unsmooth and have machining marks or other protrusions. Still further, the unsmooth edges of grooves can be implemented for only certain clubs within a set of golf clubs to adjust or otherwise customize the golf clubs for a particular golfer. For example, in one embodiment, only the groove edges of the sand wedge and the pitching wedge are unsmooth. In another embodiment, if a golfer has problems creating backspin on the golf ball under certain conditions with his lower numbered irons (i.e., a 2-iron, a 3-iron, and a 4-iron), then only the groove edges of those lower number irons can be unsmooth.

Furthermore, the golf clubs and methods of manufacture discussed herein may be implemented in a variety of embodiments, and the foregoing discussion of these embodiments does not necessarily represent a complete description of all possible embodiments. Rather, the detailed description of the drawings, and the drawings themselves, disclose at least one preferred embodiment of golf clubs and methods of manufacture, and may disclose alternative embodiments of golf clubs and methods of manufacture. It is intended that the scope of golf clubs and methods of manufacture shall be defined by the appended claims.