Patent Publication Number: US-2021170243-A1

Title: Wave sole for a golf club head

Description:
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM 
     This application is a continuation of and claims priority to U.S. patent application Ser. No. 16/598,797, filed 10 Oct. 2019, entitled “WAVE SOLE FOR A GOLF CLUB HEAD,” which is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 15/214,135, filed 19 Jul. 2016, entitled “WAVE SOLE FOR A GOLF CLUB HEAD,” which is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 14/311,913, filed 23 Jun. 2014, entitled “WAVE SOLE FOR A GOLF CLUB HEAD,” which claims the benefit, under 35 U.S.C. § 119(e), of U.S. Provisional Patent Application No. 61/944,119, filed 25 Feb. 2014, entitled “WAVE SOLE FOR A GOLF CLUB HEAD.” The entire contents and substance of each of these applications is incorporated herein by reference in its entirety as if fully set forth below. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     The invention relates generally to golf club heads and, more particularly, to a wood-type golf club head with a wave sole feature. 
     2. Description of Related Art 
     Current driver and fairway wood golf club heads are typically formed of steel or titanium alloys. Oversize driver heads exceeding 300 cc in volume, for example, are usually formed of a lightweight titanium alloy such as Ti 6A1-4V. Unless modified, however, oversize heads can have a relatively high center of gravity (COG), which can adversely affect launch angle, spin, and flight trajectory of a golf ball. Also, unmodified oversized heads tend to have a center of gravity that is located too far away from the face, which can also adversely affect launch angle, spin, and flight trajectory. Thus, many club heads have slots or weight pads, for example, cast into the head to lower the club&#39;s center of gravity, and move it closer to the front of the club (i.e., near the ball-striking face). 
     Several golf clubs currently on the market include sole features located proximate the face that are intended to improve golf ball launch conditions as well as lower the club&#39;s center of gravity. These sole features are often slots or grooves having parallel side walls, as shown in  FIGS. 1 and 2 . In this example, the body of club head  10  may include a ball striking face  12 , a sole  14 , and a slot  16 . The slot  16  has sidewalls  18  having a height  19 , and an upper wall  20  having a width  21 . Because it adds flexibility to the face  12 , the slot  16  can also improve the coefficient of restitution (COR), which can result in improved ball launch properties. 
     Attempts to improve performance using this design have included adding weight directly to the sole  14  of the club, or indirectly by increasing the slot height  19 , the slot width  21 , and/or increasing the thickness of the upper wall  20 . Increases in the slot height  19 , however, generally result in raising the club&#39;s COG. This also increases the difficulty of removing the club head from the mold during the manufacturing process. Increasing the width  21 , on the other hand, can increase the likelihood of unwanted turf interaction with the club (e.g., snagging) during play. Increases in the thickness of the upper wall  20  or the sole  14  can cause manufacturing defects such as casting pin holes and/or uneven wall surfaces. Thus, this design may improve COR, it does so at the expense of control over the COG location and adds difficulty and expense to the manufacturing process. 
     These slot structures are typically selected for ease of manufacture, but they do not provide optimized ball launch conditions. Furthermore, as discussed above, the design of these slot structures is limited because attempting to cast a thicker wall or deeper slots, for example, can cause casting defects and other manufacturing issues. As a result of these limitations, traditional slot designs are limited in the extent to which they can improve the COR and move the COG. 
     More recently, efforts have been undertaken to improve the mass distribution of a golf club head. U.S. Pat. No. 9,770,633 discloses the inclusion of a deflector that is recessed into the sole. The deflector includes a front wall and a rear wall, as well as a toe end wall and a heel end wall, and within the recessed portion of the deflector is a wave surface. This design, however, has shortcomings. For example, this design can also provide uneven wall surfaces, such as in other prior art systems. As another example, sidewalls, which are generally orthogonal to the ball-striking face, can decrease the flexibility and/or compressibility of the golf club head, which can limit energy return from the club head to the ball. The sidewalls can further introduce stress concentrations (e.g., as the intersection of the front wall and sidewalls). Moreover, such designs can limit manufacturability, as the walled-off recess of the deflector can increase the difficulty of disassembling molds during manufacturing, which can slow cycle times. 
     What is needed, therefore, is a golf club construction that provides improved golf ball launch conditions without creating production difficulties such as casting holes, wavy surfaces, and unstable wall thicknesses. Also, there is a need for a golf club construction that offers greater control over the COG and COR. In addition, the club should be easily castable using conventional casting techniques. Further, the club should have a construction that allows for the reduction of stress concentrations during the ball striking event. Embodiments of the present invention address these needs and more. 
     BRIEF SUMMARY 
     Embodiments of the present invention relate to a wood-type golf club, and particularly to a golf club according to the present disclosure comprising a head having a ball-striking face, a crown, and a sole. The sole can include a slot for adding additional weight to the head of the golf club. A slot according to the present disclosure can include a wave feature having one or more wave shapes formed in the slot region of the sole. 
     In some embodiments, the golf club head can comprise a body defining an interior cavity and including a ball-striking face and a sole. In some embodiments, a wave slot can be located on the sole and can comprise a first sidewall, a second sidewall, and at least one wave. The wave slot may have a substantially consistent wall thickness. The first sidewall can extend substantially in a first generally upward direction and can be located proximate the ball-striking face, and the second sidewall can extend substantially in the first generally upward direction and can be located proximate the rear of the sole. In some embodiments, the first and second sidewalls can be disposed at an acute angle to one another. In some embodiments, the waves can be positioned between the first and second sidewalls, and can comprise a valley portion that does not protrude below the sole. 
     In some embodiments, the wave slot can comprise two waves of decreasing height from the ball-striking face of the club head towards the rear of the club head. The height of the first sidewall may be greater than the height of the second (rear) sidewall. In some embodiments, the club head may comprise three or more waves. In the event that there are additional waves, the club head may be formed such that the taller waves are positioned closer to the ball-striking face such that the waves have a descending height as they move toward the rear of the club head (away from the ball striking face). 
     Some embodiments of the present disclosure can comprise a damper attached to the wave slot portion of the golf club head such that it does not protruding below the sole. The damper can comprise, for example and not limitation, tungsten, plastic, aluminum, or steel. In some embodiments, the damper can be attached by, for example soldering, welding, gluing, clipping, or riveting. 
     The foregoing and other objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a prior art golf club having a first sole groove configuration. 
         FIG. 2  is a bottom, perspective view of the prior art golf club of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of a wood-type golf club head, in accordance with some embodiments of the present invention. 
         FIG. 4  is a perspective bottom view of the wood-type golf club head of  FIG. 3 , in accordance with some embodiments of the present invention. 
         FIG. 5  is a perspective bottom-heel-end view of the wood-type golf club head of  FIG. 3 , in accordance with some embodiments of the present invention. 
         FIG. 6  is a perspective bottom-toe-end view of the wood-type golf club head of  FIG. 3 , in accordance with some embodiments of the present invention. 
         FIG. 7  is a perspective bottom-heel-end view of a wood-type golf club head with a wave design, in accordance with some embodiments of the present invention. 
         FIG. 8  is a perspective bottom-toe-end view of a wood-type golf club head with a wave design, in accordance with some embodiments of the present invention. 
         FIG. 9  is a side view from the toe end of a wood-type golf club head with a wave design, in accordance with some embodiments of the present invention. 
         FIGS. 10A-10D  are cross-sectional views of wood-type golf club heads with various wave designs, in accordance with some embodiments of the present invention. 
         FIG. 11  is a perspective bottom view of a wood-type golf club head including a damper, in accordance with some embodiments of the present invention. 
     
    
    
     The detailed description explains exemplary embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. 
     DETAILED DESCRIPTION 
     Embodiments of the present invention relate generally to golf clubs, and more particularly to golf clubs having waves in a weight slot on a sole thereof. In some embodiments, the golf club can have weight added to a bottom front region by using a weight slot. The weight slot can include, for example, wave shapes in order to increase the weight of the slot without adding to the thickness of the slot wall. In some embodiments, the weight slot may include two or more wave shapes. 
     Embodiments of the present invention can comprise a wave slot with a continuous wall that alternatively extends upward and downward in a wave, or zig-zag, shape. The wave can begin at the high point of a front slot sidewall, and end at the high point of a rear slot sidewall. The wave shape can enable a slot wall thickness to be consistent to accommodate existing manufacturing techniques. This wave shape can also increase the mass of the sole of the club adjacent the ball-striking face in order to move the COG location towards the ball-striking face. 
     To simplify and clarify explanation, the invention is described herein as a wood-type golf club. One skilled in the art will recognize, however, that the invention is not so limited. The materials described hereinafter as making up the various elements of the present invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, materials that are developed after the time of the development of the invention. 
     As described above, a general problem with conventional golf clubs is that the use of a weight slot is limited by the ability to increase the thickness of the wall or the depth of the slot. This can be due to conventional manufacturing techniques, which restrict the wall thickness that can be used without manufacturing defects or limit the depth of the weight slot due to casting limitations. This limits the extent to which the COG can be moved forwards, without adding additional pieces or materials. 
       FIGS. 3-6  illustrate an embodiment of a club head  110  according to some embodiments of the present disclosure.  FIGS. 7-9  show an additional embodiment of a club head  110  according to some embodiments of the present disclosure. In any such embodiment, the head  110  can include a ball-striking face  112 , a sole  114 , and a wave slot  116 . In some embodiments, the wave slot  116  can comprise a front sidewall  118 , a rear sidewall  119 , and one or more waves  120 . The wave slot  116  can be located on the sole  114  proximate the ball-striking face  112 . The location and shape of the wave slot  116  can impact the COG and COR of the club head  110 , among other things. 
     By locating the wave slot  116  closer to the ball-striking face  112 , for example, the COG can be moved both forward (i.e., towards the ball-striking face  112 ) and downward (i.e., towards the sole  114 ). The location of the COG can play a role in the spin producing characteristics of club head  110  (e.g., in reducing or increasing the spin imparted to the ball). As a result, the ability to move the COG forward and downward can provide a club with improved spin characteristics. 
     Use of a wave slot feature  116 , as compared to the more rectangular groove used in the prior art, can enable more weight to be added to the sole  114  of the club head  110  with a given wall thickness. Since the wall thickness may be practically limited by the manufacturing process, a wave slot  116  arrangement enables a greater range of club head weights and COG locations (e.g., lower and farther forward) than the prior art. In some embodiments, the number of waves  120  can be varied to control the weight of the wave slot  116 , and by extension the weight and COG of the club head  110 . 
     The use of wave slot  116  can also improve COR characteristics. As compared to a conventional club head, for example, the club head  110  can have an improved COR over a larger surface of the ball-striking face  112 . The wave slot  116  can provide an area of reduced stiffness on the club face  112  and increase the trampoline effect as the wave slot  116  “accordions” on impact. In this manner, greater power can be imparted to the ball over a larger area of the face, improved hitting consistency. The result of improving the COR over a large area of the ball-striking face  112  is a larger “sweet spot,” which can result in improved club performance and require less user skill and precision to (re)produce the desired ball flight. 
     The change in COR can be controlled, for example, by modifying the number and dimensions of the wave slot  116  such as, for example and not limitation, the height of the wave  120  nearest ball striking face. Each wave  120  can have a valley  121 , or low point, and a peak  122 . In some embodiments, the height of the first wave (i.e., from the valley  121  to the peak  122 ) can be, for example, at or above 2.0 mm to provide a desired COR improvement and a larger sweet spot. The height of each sidewall  118 ,  119  can also be selected to create the desired COR improvement and COG location. 
     As shown in  FIGS. 4-9 , the wave slot  116  can be open-ended. That is, the wave slot  116  can include a front sidewall  118 , a rear sidewall  119 , and one or more waves  120 , without also including an end wall (e.g., a wall at the toe side end of the wave slot  116 , a wall at the heel end side of the wave slot). 
       FIGS. 10A-10D  illustrate alternative wave shapes for a club head. Each unique shape can have different COG and COR properties as well as a different overall weight. Patterns such as those illustrated may be selected to provide a club with the properties desired for a particular user or application.  FIGS. 10A-10D  are provided simply to illustrate examples of how the dimensions and wave sizes could be modified and are not intended to limit embodiments of the present disclosure. 
     Some embodiments according to the present disclosure can comprise a club head  210 , a ball-striking face  212 , a sole  214 , and a wave slot  216 . The wave slot  216  can include a front sidewall  218 , a rear sidewall  219 , a first wave  222 , and a second wave  223 . Each wave  222 ,  223  can have a valley portion  221  at the low point of each wave and a peak  229  at the high point of each wave. The sidewalls  218 ,  219  and the waves  222 ,  223  of the wave slot  216  can each have a height  225 ,  226 ,  227 ,  228  associated with them. In some embodiments, for example, the height  225  of the front sidewall  218  can be greater than the height  226  of the first wave  222 , which in turn can be greater than the height  227  of the second wave  223 , which in turn can be greater than the height  228  of the rear sidewall  219 . This decreasing amplitude wave arrangement can result in a reduction of the stress concentrations when compared to arrangements with increasing or mixed height waves. Areas of high stress concentration in the club head can have a negative impact on club durability, and sustained club performance. As such, it is beneficial to have a wave arrangement that appropriately locates the COG, imparts the desired COR, and also limits the peak stress concentrations during ball striking. 
     In  FIG. 10B , the club head  310  is depicted with a ball-striking face  312 , a sole  314 , and a wave slot  316 . In this configuration, the height of the first wave  322  can be greater than the height of wave  222  of  FIG. 10A . Like the wave slot  216  in  FIG. 10A , the wave slot  316  can have a front sidewall  318  that has a height greater than the height of the first wave  322 , which in turn can be greater than the height of the second wave  323 , which in turn can be greater than the height of the rear sidewall  319 . Since wave slot  316  has a greater amplitude, there is more wave material for a given wall thickness and slot width. Because of this, wave slot  316  may weigh more than wave slot  212 , and having additional weight in the slot can move the COG both lower to the ground, and closer to ball striking face  312 . 
     In  FIG. 10C , the club head  410  is depicted with a ball-striking face  412 , a sole  414 , and a wave slot  416 . In this configuration, the height of the first wave  422  can be less than the height of wave  222  of  FIG. 10A . However, like the wave slot  216  in  FIG. 10A , the wave slot  416  can have a front sidewall  418  that has a height greater than the height of the first wave  422 , which in turn can be greater than the height of the second wave  423 , which in turn can be greater than the height of the rear sidewall  419 . Since wave slot  416  has an amplitude less than that of wave slot  216 , there is less wave material for a given wall thickness and slot width, and as a result, wave slot  416  may weigh less than wave slot  412 , and having less weight in the slot can move the COG both further from the ground, and further from ball striking face  412  as compared to club heads  210  and  310 . By altering the heights of the sidewalls, the weight of the wave slot can be located closer to, or further from the ball-striking face of the club head. 
     In  FIG. 10D , the club head  510  is depicted with a wave slot  516 . Vertices  530 ,  532 ,  534 , and  536  are shown having been formed with rounded surfaces. This type of construction can provide the benefits of making the casting process more consistent, as small, tight corners can be difficult to cast. Furthermore, rounding the vertices may also help to further reduce the areas of stress concentration. 
     Embodiments of the present disclosure can include wave slot designs having one, two, three, or more waves. Additionally, embodiments according to the present disclosure can include wave slot designs having sidewall heights and wave heights that vary according to the desired weight, COR value, and COG location for the particular application. 
     Generally, embodiments of the present disclosure having taller front sidewalls and front waves can have a COG location that is closer to the ball striking face, and higher from the sole than a club designed with a shorter front sidewall. When the club has a COG nearer the ball-striking face, it can tend to impart less spin to the ball than would a club having a COG further away from the ball-striking face. Furthermore, the height of the club&#39;s COG can change the location and size of the “sweet spot,” which is the location on the ball-striking face that has the highest COR. These features can be tailored for a golfer who desires, for example, more or less spin. 
     In some embodiments, a shorter wave height can be between approximately 1.0 and 2.0 mm. A taller wave height can be between approximately 2.0 and 4.0 mm. Shorter wave heights for the wave closest to the ball-striking face, for example, may not substantially increase the COR of the lower portion of the ball-striking face, while a taller wave can potentially have such an effect. 
     The technology and designs presented herein provide many advantages over prior art golf club head designs. These advantages include, but are not limited to, increased performance, durability, and manufacturability. As an example relating to increased performance, conventional clubs including a slot on the sole have end walls at the toe and heel ends of the slot. Often, the toe end wall and heel side end wall meet the front wall (i.e., nearest the ball-striking face) and rear wall (i.e., farthest from the ball-striking face) of the slot. Regardless, the toe end wall and heel end wall tend to impede the slot&#39;s ability to flex at impact. In contrast, open-ended waves, such as those shown in  FIGS. 4-10 , can be more readily flexed and/or compressed by the stresses induced upon impact of the golf club head with a ball. This increased flexibility and/or compressibility can allow an increased energy return (e.g., as compared to a similar club with a conventional slot having toe and heel end walls) as the ball leaves the face. Stated otherwise, providing an open-ended wave on the sole of a golf club head can increase the can increase the COR of the golf club head. 
     Further, the various wave structures disclosed herein can increase the durability and useful life of golf club heads. For example, the wave structure can distribute stresses incurred at impact over a larger area of the golf club head. In particular, the decreasing amplitude of the waves (i.e., decreasing in amplitude as the wave patterns moves away from the ball-striking face) and/or the increased flexibility afforded by the open-ended nature of the waves can function to distribute stresses about a larger portion of the golf club head (e.g., as compared to prior art slot designs). This can minimize the likelihood of stress concentration at any given point of the golf club head, which can in turn minimize the likelihood of the golf club head fracturing. 
     Further still, the technology and designs described herein can increase the manufacturability of the golf club heads. Modern cast club heads are typically made by investment casting, which utilizes a multi-piece slide core wax injection mold. That is, wax is injection molded into an initial mold, and the multi-piece wax piece is coated in a refractory material. The wax is subsequently removed and molten metal is poured into the mold of the refractory material. As one of ordinary skill in the art will appreciate, increased complexity in the geometry of the mold designs—such as undercut surfaces, overhanging surfaces, or steep vertical surfaces—can increase the likelihood of the mold process failing (e.g., an insufficient amount of material filling the voids of the initial mold and/or the mold of refractory material). Moreover, conventional slot or channel designs present difficulties for manufacturing because such designs include steep vertical surfaces (e.g., toe end wall, heel end wall, front wall, and rear wall) and an overhanging surface (e.g., the “top” of the slot that extends between the front wall and rear wall). The technology and designs presented herein can overcome these manufacturability shortcomings at least because the wave slot design minimizes the steepness of the slot walls, which can simplify the molding process, and because the open-endedness of the wave slot, which can enable easier disassembly of the mold, which can in turn provide faster cycle times. 
     In some embodiments, as shown in  FIG. 11 , the club head  1110  can be equipped with a damper  24  to, for example and not limitation, control the hitting sound of the club and minimize undesirable turf interaction (e.g., snagging and digging). Unmodified, depending on the design and materials, the club head  1110  may produce an undesirable sound when striking the ball. The club head  1110  may also interact with the turf on which a golf ball rests. Undesirable turf interaction such as snagging, catching, gouging, or the like may result in a misaligned swing, mis-hits, and even injury. To this end, the damper  24  may be employed to reduce the magnitude of these potentially undesirable effects. The damper  24  can be attached to the wave slot, and be sized so as to not protrude below the sole of club head  1110 . 
     In some embodiments, the damper  24  can comprise a particularly dense and heavy material, such as tungsten, to further lower the COG of the club. In other embodiments, the damper  24  can comprise, for example and not limitation, plastic, aluminum, or steel. The damper  24  can be, for example and not limitation, soldered, welded, glued, clipped, or riveted to the sole  114 . 
     While several embodiments according to the present disclosure have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements that fall within the scope of the following claims.