Abstract:
Deadblow hammers capable of minimizing or eliminating recoils when the hammers impact their targets are discussed which have easy access anti-recoil chambers and which have open sockets for receiving handles that extend the length of the hammerhead body. These hammers incorporate filler materials, which function to negate the effects of the hammer recoils, with improved filling port(s) for filling the filler materials. Golf clubs with anti-recoil chambers and insert elements are also discussed.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This is a divisional application of application Ser. No. 10/246,867, filed on Sep. 17, 2002, the contents of which are expressly incorporated herein by reference. 
     
    
     
         [0002]    Deadblow hammers and golf clubs capable of minimizing or eliminating recoils when the hammers or golf clubs impact their targets are generally discussed herein. These hammers and golf clubs incorporate filler materials that function to reduce or negate the effects of the recoils.  
         BACKGROUND  
         [0003]    It is a well-known principle that every action has is an equal and opposite reaction (Newton&#39;s Third Law). Thus, for a hammer, when the impact surface of the hammerhead impacts a target, the hammer is jolted backwards due to the reaction caused by the hammerhead striking its target. This opposite reaction is commonly referred to as hammer recoil.  
           [0004]    For minimizing or eliminating hammer recoils, which cause vibrations and injuries to the user, numerous hammers were invented. Broadly speaking, these hammers utilize some form of inserts placed in a hollow chamber within the hammerhead, or within a separate hollow body having a hollow chamber attached to the hammerhead. The inserts are configured to move from a rear surface of the hollow chamber to a front surface of the hollow chamber. Accordingly, when the hammer moves in a first direction to impact its target, the inserts are pushed by the rear surface of the hollow chamber to move in the same first direction.  
           [0005]    As the impact surface of the hammerhead impacts a target and starts its recoil in a second direction, the inserts still move in the first direction within the hollow chamber and impact the front surface of the hollow chamber, in the first direction. The inserts impacting against the front surface of the hollow chamber thus cancel the recoil in total or substantially. The amount of cancellation depends, in part, on the weight percentage of the inserts compared to the weight of the hammerhead. Without being restricted to any particular theory, the deadblow impact or feel to the user also depends on the distance the insert travels before it impacts the front surface, which will influence how far the hammer recoils before the insert impacts the front surface to cancel out the effect.  
           [0006]    U.S. Pat. No. 6,234,048 to Carmien discloses a non-recoil hammer, with a hammerhead that has an open socket for receiving a separate hollow canister. The hollow canister connects to a tool handle and contains a relatively high mass moveable filler material in a hollow chamber, such as steel shot pellets. The hollow canister is received within the open socket to form a completed hammer. Due to the two-piece design, the hammer is more complicated and costly to manufacture.  
           [0007]    U.S. Pat. No. 5,916,338 to Bergkvist et al. discloses a hammer having a hammerhead with an impact element and a cavity at least partially filled with particulate material, such as steel shot, so as to dampen the recoil of the hammer. The impact element is forged with the head as a single piece or may be formed as a separate part that is connected to the head by welding. However, since the cavity extends the full length of the hammerhead, the handle cannot attach to the hammerhead by passing through central portion of the hammerhead, but is attached via partial through hole at the central portion of the hammerhead. This makes the handle more susceptible to slippage or separation from the hammerhead. Furthermore, because of the cavity, a conventional handle with a split end for wedging the handle with a wedge is not useable with the disclosed hammerhead.  
           [0008]    U.S. Pat. No. 4,039,012 to Cook discloses a non-rebound hammer having a hammerhead portion with forwardly and rearwardly facing metallic impact surfaces. The head portion contains a hollow cylindrical core for receiving a quantity of pellets, such as small lead shots. The hammerhead also contains a core hole for receiving a handle rod. The handle rod and the hammerhead are then co-molded with an encasement. Due to the co-molded configuration, the entire hammer must be discarded when damage is done to the handle.  
           [0009]    U.S. Pat. No. 2,604,914 to Kahlen discloses a hammerhead having a rebound-preventing means. The hammerhead has a body with a striking head at each end of the body. Each striking head is formed integrally with the body, or alternatively it may be secured to the body as a separate piece. A chamber is formed in the body immediately behind the striking heads. The chamber contains irregularly shaped particles 26, as shown in FIG. 3 of the &#39;914 patent. The particles almost completely fill the chamber, with the total weight of the particles dependent on the recoil quality of the striking head, the size of the hammer, and the weight of the head. Due to the lengthwise chamber, a ferrule is used to connect a handle to the body. This makes the body unnecessarily bulky.  
           [0010]    There is therefore a need for a non-recoil hammer or deadblow hammer that minimizes or negates the effects of hammer recoils and that do so without the shortcomings of prior art deadblow hammers. Additionally, there is also a need for a method of making the desired deadblow hammer.  
         SUMMARY  
         [0011]    The present invention specifically addresses and alleviates the above-mentioned deficiencies associated with the prior art anti-recoil hammers. More particularly, the present invention comprises a deadblow hammer comprising a hammerhead having a body, an anti-recoil chamber for receiving a plurality of insert elements located within a section of the body, and an open socket defined by a handle chamber which passes through the body for receiving a handle. The anti-recoil chamber comprises a first opening that is in communication with the open socket and that provides a first passage into the anti-recoil chamber, the first opening allows the plurality of insert elements to be placed into the anti-recoil chamber by way of the open socket; and wherein insertion of the handle into the handle chamber seals off the first opening and occupies the open socket. Together, these features define a deadblow hammer that is more economical to make and that has an anti-recoil chamber that is easy to access.  
           [0012]    The present invention also involves a deadblow hammer comprising a hammerhead having a body, two anti-recoil chambers, each having a plurality of insert elements situated therein and an impact surface attached adjacent thereto, and an open socket defined by a handle chamber that passes through the body for receiving a handle. This hammer is commonly known in the art as a sledge hammer.  
           [0013]    The two anti-recoil chambers in the sledge hammer each comprising a first opening that is in communication with the open socket and that provides a first passage into the anti-recoil chamber from the open socket; the first opening allows the plurality of insert elements to be placed into the anti-recoil chamber by way of the open socket; and wherein an insertion of the handle into the handle chamber seals off the first opening of each of the anti-recoil chamber and causes the open socket to be occupied.  
           [0014]    The present invention also involves a golf club head comprising a club face, a hosel for attaching the club head to a shaft, and a hollow chamber disposed within the club head; and wherein the hollow chamber includes insert elements for negating and dampening recoils when the golf club head impacts a solid surface. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    These and other features, aspects and advantages of the present invention will be more fully understood when considered with respect to the following detailed description, appended claims and accompanying drawings, wherein:  
         [0016]    [0016]FIG. 1 is a semi-schematic perspective view of an exemplary deadblow hammer provided in accordance with practice of the present invention;  
         [0017]    [0017]FIG. 2 is a semi-schematic cross-sectional side view of the deadblow hammer of FIG. 1;  
         [0018]    [0018]FIG. 3 is a semi-schematic cross-sectional side view of the hammer of FIG. 2 with an alternative anti-recoil chamber;  
         [0019]    [0019]FIG. 4 is a semi-schematic cross-sectional side view of the hammer of FIG. 2 with another alternative anti-recoil chamber;  
         [0020]    [0020]FIG. 5 is a semi-schematic cross-sectional side view of the hammer of FIG. 2 with yet another alternative anti-recoil chamber;  
         [0021]    [0021]FIG. 5 a  is a semi-schematic cross-sectional side view of the hammer of FIG. 2 with side openings;  
         [0022]    [0022]FIG. 6 is a semi-schematic plan view of the hammer of FIG. 1;  
         [0023]    [0023]FIG. 7 is a semi-schematic end view of the hammer of FIG. 2 taken at line A-A;  
         [0024]    [0024]FIG. 8 is a semi-schematic end view of the impact plate provided in accordance with practice of the present invention;  
         [0025]    [0025]FIG. 9 is a semi-schematic cross-sectional view of the impact plate of FIG. 8 taken at line B-B;  
         [0026]    [0026]FIG. 10 is a semi-schematic cross-sectional view of an alternative hammerhead provided in accordance with practice of the present invention;  
         [0027]    [0027]FIG. 11 is a manufacturing flow diagram provided in accordance with practice of the present invention;  
         [0028]    [0028]FIG. 12 is a metal golf club having an anti-recoil chamber provided in accordance with practice of the present invention; and  
         [0029]    [0029]FIG. 13 is a metal wood golf club having an anti-recoil chamber made from a tube provided in accordance with practice of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0030]    The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of the deadblow hammer in accordance with the present invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the features and the steps for constructing and using the deadblow hammer of the present invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention. Also, as denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.  
         [0031]    Referring now to FIG. 1, there is shown a deadblow hammer (“hammer”) provided in accordance with practice of the present invention, which is generally designated  10 . The hammer  10  comprises a hammerhead  12 , which includes a body  14 , an impact section  16 , an impact plate  17  having an impact surface  18  and a claw  20 . The hammer  10  further comprises a handle  22 , which includes an attachment portion  24  for attaching to the open socket  26  of the hammerhead  12  and a handle portion  28  for facilitating gripping of the hammer  10 . The handle  22  is shown with an optional handle grip  30 , which may be made from a rubber material and slidably inserted over the handle portion  28  of the handle  22 .  
         [0032]    The hammerhead  10  is preferably cast from a steel material but alternatively may be forged from a steel block. The handle  22  may be any number of conventional handles, including handles made from wood, plastic, and fiberglass.  
         [0033]    Referring now to FIG. 2, there is shown a semi-schematic cross-sectional view of the hammer  10  of FIG. 1. As shown, the hammerhead  12  comprises a hollow chamber  32 , which is also referred to herein as an anti-recoil chamber. The hollow chamber  32  comprises an enlarged chamber section  34 , a relatively smaller tail chamber section  36 , and a tapered transitional section  38 . The tapered transitional section  38  may include a straight taper, as shown, or a curved taper. The hollow chamber  32  further includes a first opening  40  that is just proximal of the tail chamber section  36 . The first opening  40  opens into the open socket  26  and is in communication with the open socket. However, once the handle  22  is inserted into the open socket  26 , the communication is severed and the attachment portion  24  of the handle occupies the open socket (FIG. 2). Although the open socket  26  is shown with a straight wall, it is understood that a tapered wall may be incorporated without deviating from the scope of the present invention.  
         [0034]    A separate impact plate  17  is shown attached to the body  14  of the hammerhead  12  and covers the hollow chamber&#39;s second opening  42 . The second opening  42  is shown larger than the first opening  40 . However, the arrangement is merely a designer&#39;s choice as the relative dimensions between the first opening  40  and the second opening  42  may be reversed. The impact plate  17  may be attached to the body  14  by conventional welding methods, by threads, or by inertia welding. In inertia welding, the body  14  is held in a lath and spins at relatively high speed. The lath used for inertia welding can be a vertical standing lath or a horizontal lath. The impact plate  17 , which is not spinning, is then pushed against the spinning end surface  44  of the second opening  42 . The friction generated by the contact causes the impact plate  17  and the end surface  44  to partially melt, which results in their fusion. As a by-product of their impact, a protruding section  46  is formed on the impact plate  17 , which protrudes into the hollow chamber  32 . Alternatively, the impact plate  17  can be rotated in the lath and the body  14  held stationary.  
         [0035]    A plurality of insert elements  48  are shown placed in the hollow chamber  32 . The insert elements  48  can be any number of weighted materials such as spherical pellets, small metal scraps, lead shots, or their equivalence. In one embodiment, steel pellets  50  are used for the insert elements  48 . The quantity of steel pellets  50  used is approximately equal to 25% to 70% of the weight of the hammerhead  12  with 30% to 60% being more preferred. In another embodiment, tungsten shots are used for their relatively heavier density than steel. Consequently, less space or volume is required for the same weight percentage when tungsten shots are used.  
         [0036]    The insert elements  48  are added to the hollow chamber  32  by individually depositing the steel pellets  50  in through the first opening  40 , before attaching the handle  22  into the open socket  26  and after attaching the impact plate  17  to the end surface  44 . Alternatively, the steel pellets  50  may be added to the hollow chamber by first magnetizing the pellets or gluing the pellets so that they form a single large mass. The single large mass can then be added to the hollow chamber via the second opening  32 , before attaching the impact plate  17  to the end surface  44 . Subsequently, the impact plate  17  may be attached to the end surface  44  by inertia welding, using a vertical standing lath, or by conventional welding. Due to the size of the single large mass, it will not fall out of or fall through the first opening  40  when the welding is taking place. It is understood that if conventional welding is utilized to attach the impact plate  17  to the end surface  44 , the surfaces to be welded should be chamfered to provide a v-groove for welding.  
         [0037]    Turning now to FIG. 3, there is shown an alternative hammerhead  12   a  provided in accordance with practice of the present invention. The hammerhead includes a single large opening  42  leading into the hollow chamber  32 . The smaller opening has been eliminated from the hammerhead  12  shown in FIG. 2, but the tail chamber section  36  and the tapered transitional section  38  still incorporated. The hammerhead  12   a  may be made by casting or forging the body  14   a  separately from the impact plate  17 . The insert elements  48  may be added to the hollow chamber  32  and the impact plate  17  welded to the end surface  44  of the body  14   a  in the same fashion as discussed above with reference to FIG. 2.  
         [0038]    Turning now to FIG. 4, there is shown another alternative hammerhead  12   b  provided in accordance with practice of the present invention. The hammerhead  12   b  includes a single large opening  42  leading into the hollow chamber  32 . The hollow chamber  32  is preferably cylindrical but may take on other or additional contours, such as a slight taper from the large opening  42  towards the back wall  52  of the hollow chamber. The hammerhead  12   b  may be made by casting or forging the body  14   b  separately from the impact plate  17 . The insert elements  48  may be added to the hollow chamber  32  and the impact plate  17  welded to the end surface  44  of the body  14   b  in the same fashion as discussed above with reference to FIG. 2.  
         [0039]    Turning now to FIG. 5, there is shown yet another alternative hammerhead  12   c  provided in accordance with practice of the present invention. The hammerhead  12   c  includes a single small opening  40  that leads into the hollow chamber  32 , as shown in FIG. 2. However, the impact plate  17  is now integrally formed with the body  14   c . The hammerhead  14   c  is therefore made from casting only, as further discussed below. The insert elements  48  may be added to the hollow chamber  32  by adding the individual pellets in through the small opening  40  before inserting the handle  22  into the open socket  26 , as discussed above with reference to FIG. 2.  
         [0040]    [0040]FIG. 5 a  shows still yet another alternative hammerhead  12   d  provided in accordance with practice of the present invention. Similar to the other embodiments (i.e., FIGS.  1 - 5 ), the present embodiment preferably includes two openings  33 , one on each of the left and right side surface of the hammerhead body  14   d  and each being in communication with the hollow chamber  32 . The impact surface  18  is integrally cast with the body  14   d  and the open socket  26  extends through the body without an opening, like the embodiment of FIG. 5. Thus, the insert elements  48  are added to the hollow chamber  32  via the side openings  33  and then subsequently sealed by plugs or caps. Alternatively, the openings  33  may be located along the upper and lower side surfaces of the hammerhead body  14   d , and may take on 1 or more than 2 openings. The present embodiment, as well as other embodiments disclosed elsewhere herein, allows a conventional handle with a split attachment portion  24  to be used as it permits a wedge or several wedges to be inserted into the split attachment portion from the top of the open socket to wedge-in or lock-in the handle.  
         [0041]    [0041]FIG. 6 is a top view of the hammerhead  12  of FIGS.  1 - 5 . Although shown with the particular impact plate  17 , impact section  16 , open socket, and claw  20 , it is understood that the hammerhead  12  may vary in any of these features, and in addition, in length, width, tapered neck section  54 , stepped collar section  56  (located in between the impact section  16  and the tapered neck section), etc. without deviating from the scope the present invention. For example, the present invention may be practiced by varying the metallurgy, the overall hammerhead weight, and replacing the claw  20  with another impact section, as further discussed below.  
         [0042]    [0042]FIG. 7 is an end view of the hammerhead  12  of FIG. 2 taken at line A-A. As shown, the large opening  42  opens into the hollow chamber  32 , which has a circular chamber surface  58 . The circular chamber surface  58  intersects the transitional section  38 , which connects to the tail chamber section  36 , which terminates into the small opening  40 .  
         [0043]    [0043]FIG. 8 is an end view of the impact plate  17  provided in accordance with practice of the present invention. The impact plate  17  includes an impact surface  18  having an array of bumps or serrations  60 , which may be formed from casting, forging, or machining from bar stocks. However, a smooth surface or a dispersed array of bumps may be used instead of the serrated impact surface  18 .  
         [0044]    [0044]FIG. 9 is a semi-schematic cross-sectional view of the impact plate  17  of FIG. 8 taken at line B-B. As evident by FIG. 9, a neck or stepped surface on the rear surface  62  of the impact plate  17  is not necessary as a protruding section  46  will form as a by-product of the inertia welding (See, e.g., FIG. 2).  
         [0045]    [0045]FIG. 10 shows an alternative hammerhead provided in accordance with practice of the present invention, which is generally designated  64 . The hammerhead  64  is commonly found in a sledge hammer. In particular, the hammerhead  64  comprises a body  66 , a central open socket  68  (which is shown with a tapered surface but may include a straight surface), and two impact sections  70  with integrally molded impact surfaces  72 . The hammerhead  64  further includes two hollow chambers  74 , one in each of the impact section  70 . Each hollow chamber  74  includes a tapered transition section  76  that leads to a tail chamber section  78  and that leads to an opening  80 . As previously discussed with reference to FIGS.  1 - 5 , the insert elements  48  may be added to each of the hollow chamber  74  by way of the small opening  80 , and preferably in equal amount. As before, the total insert elements should range from about 25% to 70% of the weight of the hammerhead  64 , with about 30% to 60% of the total weight being more preferred.  
         [0046]    Although the hammerhead  64  is shown with integrally formed impact surfaces  72 , separate impact plates may be used and thereafter welded to the body  66 , as previously discussed with reference to FIGS.  2 - 4 . If separate impact plates are used, the small openings  80  may be eliminated from the hammerhead  64 , such as that shown in FIGS. 3 and 4.  
         [0047]    [0047]FIG. 11 is a block flow diagram  82  of an exemplary manufacturing method provided in accordance with practice of the present invention. As shown, the method includes creating a metal die for the hammerhead  84 . The metal die for the hammerhead can take on any number of configurations, including a hammerhead with a single opening, an integral impact surface, a sledge hammerhead, a finishing hammerhead, or a framing hammerhead, just to name a few.  
         [0048]    Next, melted wax is pour into the die to create a wax replica of the hammerhead  86 . The wax is then dipped into a slurry bath comprising silica flour and a chemical binder to form an “investment”  88 . After the investment hardens, the wax is removed from the investment by heating the investment and the wax in an oven or a steam chamber  90  to melt the wax. Once the wax is removed, the investment is baked or fired in a heater  92  to cure. Molten metal is then poured into the cured investment  94  to form the cast hammerhead.  
         [0049]    Once the cast hammerhead sufficiently cools, the investment is removed  96  by impacting the hammerhead to break up the investment. The hammerhead is now ready to receive the insert elements  98 . As discussed above with reference to FIGS.  2 - 5 , if the impact plate is separately produced, the impact plate is then attached to the hammerhead via welding. A handle is then attached to the hammerhead  100  to complete the deadblow hammer.  
         [0050]    [0050]FIG. 12 depicts a metal golf club  102  that incorporates a hollow chamber  104  for receiving insert elements  48 . The golf club head  106  is preferably cast so that the hollow chamber  104  may be formed into the sole  105  of the club head during fabrication. The hosel  107  shown can be any prior art hosel, including an offset hosel or a more conventional hosel for attaching to a shaft. The hollow chamber  104  preferably runs the width of the club face  108  (the direction that is perpendicular to the viewing plane) and is sealed by a cap (not shown). The cap can be attached to the club head  106  by welding. In an exemplary embodiment, steel pellets, making up about 10% to 50% of the club head  10 , are used to dampen the vibration and the recoil effects of the club head  106  as the club face  108  miss hits and strikes the ground. Exemplary metal golf clubs are disclosed in U.S. Pat. No. 6,344,000, which is incorporated herein by reference.  
         [0051]    [0051]FIG. 13 depicts a metal wood golf head  110  that incorporates a hollow chamber  112  for receiving insert elements  48 . The hollow chamber is formed by attaching retaining clips  114  to the club face  116  and to the shell  118  and connecting a hollow tube  120  thereinbetween. Although a hosel is not shown, it is understood that any prior art hosel may be incorporated into the golf club head  110  for attaching to a shaft. Similar to the golf club head of FIG. 12, the insert elements  48  preferably make up about 10% to about 50% of the weight of the metal wood  110 . Exemplary metal wood golf clubs are disclosed in U.S. Pat. No. 5,873,791, which is incorporated herein by reference.  
         [0052]    Although the preferred embodiments of the invention have been described with some specificity, the description and drawings set forth herein are not intended to be delimiting, and persons of ordinary skill in the art will understand that various modifications may be made to the embodiments discussed herein without departing from the scope of the invention, and all such changes and modifications are intended to be encompassed within the appended claims. Various changes to the hammerhead and golf club head may be made including changing the contour, the weight, the hollow chamber configuration, and the overall dimensions, etc. Accordingly, many alterations and modifications may be made by those having ordinary skill in the art without deviating from the spirit and scope of the invention.