Abstract:
A manufacturing method for a golf club head. The method includes the steps of: casting a cast body provided with a recession thereon; cutting the cast body to form with at least one cut opening in the recession on the golf club head; adhering a carbon-fiber plate to the recession to seal the cut opening; defining a buffer groove between the carbon-fiber plate and the cast body; and filling with an elastic material into the buffer groove; processing the cast body to an end product.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention is related to a golf club head and a manufacturing method therefor. More particularly, the present invention is related to a cast body of the golf club head provided with a recession and a cut opening formed therein that increases more precision of the golf club head and the manufacturing method therefor.  
           [0003]    2. Description of the Related Art  
           [0004]    A conventional golf club head, as shown in FIGS. 15 and 16, mainly includes a main body  10  and a striking plate  11  attached thereto. Generally, the main body  10  is consisted of a crown plate, a sole plate and a side plate. One of these plates of the main body  10  is selectively formed with a cast opening  120  and an inner flange  121  thereof in place. A prepared carbon-fiber plate  20  is regarded as a cover plate made of light material, and used to seal the cast opening  120  of the main body  10 . Consequently, the main body  10  is accomplished to sharp its striking sound, to lower its center of gravity and its total weight by adjusting the assembled position, the dimensions and the weight of the carbon-fiber plate  20 . Also, the main body  10  is accomplished to speed up the manufacturing process.  
           [0005]    When the carbon-fiber plate  20  is fittingly adhered to the cast opening  120  of the main body  10 , a plastic deformation may result in damage to a connection portion between the carbon-fiber plate  20  and the main body  10 . To overcome the plastic deformation, the cast opening  120  is slightly greater than the carbon-fiber plate  20  to define a buffer groove (a) in which to fill with an elastic material (not shown) so the carbon-fiber plate  20  and the cast opening  120  are allowed deformable in the groove.  
           [0006]    In casting process, however, the main body  10  of the golf club head is directly formed with the cast opening  120  and it is easily deformed during drawing and cooling of a pattern. In particular, the cast opening  120  is easily deformed due to without forming any mechanical support therein. In the follow-up assembling operation, the cast opening  120  is mismatched with the carbon-fiber plate  20  if the deformation of the cast opening  120  is greater than a predetermined tolerance. Meanwhile, when the carbon-fiber plate  20  is bonded to the deformed periphery of the cast opening  120 , a buffer groove between the carbon-fiber plate  20  and the cast opening  120  has an irregular width that results in a decrease of product quality.  
           [0007]    The present invention intends to provide a golf club head and a manufacturing method therefor, which is consisted of a cast body and a recession in which formed with a cut opening. By the use of the cut opening, the cast body of the golf club head can avoid deformation during drawing a pattern, thereby increasing precision of the dimensions, strength of the entire structure and quality of the products.  
         SUMMARY OF THE INVENTION  
         [0008]    The primary objective of this invention is to provide a golf club head and a manufacturing method therefor, which is consisted of a cast body and a recession in which formed with a cut opening. Thereby, the cut opening of the golf club head can avoid structural deformation during drawing a pattern so that dimensional precision and product quality of the golf club head is increased.  
           [0009]    The secondary objective of this invention is to provide the golf club head and the manufacturing method therefor, which includes a cut opening and a support rib formed therein for supporting the entire structure. Thereby, the golf club head is able to increase strength of the entire structure.  
           [0010]    Another objective of this invention is to provide the golf club head and the manufacturing method therefor, which is formed with a buffer groove between a cover plate and a recession to be filled with an elastic material. Thereby, the elastic material is able to attenuate a striking force to avoid cracking in the recession of the golf club head so that strength and useful life of the golf club head is increased.  
           [0011]    Another objective of this invention is to provide the golf club head and the manufacturing method therefor, which formed with a buffer groove to be filled with a colored elastic material. Thereby, the colored elastic material enhances the appearance of the golf club head and increases the added value of product.  
           [0012]    Another objective of this invention is to provide the golf club head and the manufacturing method therefor, which is provided with a recession adapted to contain various cover plates. Thereby, the various cover plates contained in the recession of the golf club head may increase design choice in manufacture.  
           [0013]    The manufacturing method for the golf club head in accordance with the present invention comprises steps of: casting a cast body provided with a recession thereon; cutting the cast body to form with at least one cut opening in the recession on the golf club head; adhering a carbon-fiber plate to the recession to seal the cut opening; defining a buffer groove between the carbon-fiber plate and the cast body, and filling with an elastic material into the buffer groove; processing the cast body to accomplish an end product.  
           [0014]    Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description and the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    The present invention will now be described in detail with reference to the accompanying drawings herein:  
         [0016]    [0016]FIG. 1 is a block diagram of a golf club head and a manufacturing method therefor in accordance with the present invention;  
         [0017]    [0017]FIG. 2 is a top view of the golf club head in accordance with a first embodiment of the present invention;  
         [0018]    [0018]FIG. 3 is a cross-sectional view of a laser beam processing on a cast body of the golf club head in accordance with the first embodiment of the present invention;  
         [0019]    [0019]FIG. 4 is a top view of forming a cut opening on the golf club head in accordance with the first embodiment of the present invention after a cutting process;  
         [0020]    [0020]FIG. 5 is a cross-sectional view of a crown plate contained in recession of the golf club head for forming a groove between the cover plate and the cast body in accordance with the first embodiment of the present invention;  
         [0021]    [0021]FIG. 6 is an enlarged view, in FIG. 5, of filling an elastic material into the groove formed between the cover plate and the cast body in accordance with the first embodiment of the present invention;  
         [0022]    [0022]FIG. 7 is a top view of forming a pair of cut openings and a support rib thereof on a cast body of the golf club head in accordance with a second embodiment of the present invention;  
         [0023]    [0023]FIG. 8 is a cross-sectional view of a crown plate contained in a recession of the golf club head for forming a groove between the cover plate and the cast body in accordance with the second embodiment of the present invention;  
         [0024]    [0024]FIG. 9 is a top view of a cast of a golf club head formed with a pair of cast openings and a support rib thereof in accordance with a third embodiment of the present invention;  
         [0025]    [0025]FIG. 10 a cross-sectional view of a crown plate contained in a recession of the golf club head for forming a groove between the cover plate and the cast body in accordance with the third embodiment of the present invention;  
         [0026]    [0026]FIG. 11 another cross-sectional view, taken along the support rib, of the groove formed between the cover plate and the cast body in accordance with the third embodiment of the present invention;  
         [0027]    [0027]FIG. 12 a top view of forming a pair of cut openings on a cast body of the golf club head in accordance with the fourth embodiment of the present invention after a cutting process;  
         [0028]    [0028]FIG. 13 a top view of a pair of side cover plates contained in a pair of recessions of the golf club head in accordance with the fourth embodiment of the present invention;  
         [0029]    [0029]FIG. 14 a cross-sectional view of one of the side cover plates contained in the recession of the golf club head in accordance with the fourth embodiment of the present invention;  
         [0030]    [0030]FIG. 15 is an exploded perspective view of a conventional golf club head in accordance with the prior art; and  
         [0031]    [0031]FIG. 16 is a cross-sectional view of the conventional golf club head in accordance with the prior art. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]    Referring initially to FIGS. 1 through 14, reference numerals of the first through fourth embodiments of the present invention have applied the identical numerals of the conventional golf club head, as shown in FIGS. 15 and 16. The construction of the golf club head in accordance with the embodiments of the present invention have similar configuration and same function as that of the conventional golf club head and the detailed descriptions may be omitted.  
         [0033]    Referring to FIGS. 1 and 2, a manufacturing method for a golf club head in accordance with the first embodiment of the present invention comprises a first step that casts a cast body  10  and a recession  12  formed thereon. Preferably, the cast body  10  is cast as a single member and made of material selecting from steel, titanium alloy, soft steel which are specific hardness material of metal or alloy. A front surface of the cast body  10  is connected to a striking plate  11  by welding manner, integrating manner or embedding manner. The amount of the recession  12  is selected and formed on one of plates including a crown plate, a sole plate and a side plate. Preferably, the recession  12  is provided with a stepped edge  121  which is adapted to accommodate a predetermined cover plate  20 , such as a carbon-fiber plate, in the following process. Meanwhile, the stepped edge  121  is integrally connected to a temporary support  122 , such as a cast crown support. The cast crown support is formed as a bottom part of the recession  12 . In drawing operation, the recession  12  supported by the temporary support  122  can avoid deformation.  
         [0034]    Referring to FIGS. 1 through 4, the manufacturing method for the golf club head in accordance with the first embodiment of the present invention comprises a second step that cuts at least one cut opening  120  to remove the temporary support  122  from the recession  12 . In drawing operation, the recession  12  is temporarily supported by the temporary support  122 . When the metal cast body  10  of the golf club head is cooled and hardened, this allows the removal of the temporary support  122  (as well as an unwanted portion) by cutting it to form the cut opening  120  in the recession  12 . In cutting operation, a laser beam cutting machine  30 , a plasma arc cutting machine and a water-jet cutting machine are available. Extending an annular edge within the recession  12  is the cut opening  120  which is corresponding to the stepped portion  121 . In following operation, the stepped portion  121  of the recession  12  is adapted to accommodate a predetermined size of the cover plate  20 .  
         [0035]    Referring to FIGS. 1 and 5, the manufacturing method for the golf club head in accordance with the first embodiment of the present invention comprises a third step that inserting the prepared cover plate  20  into the recession  12 . Preferably, the prepared cover plate  20  is made of carbon fiber. In order to speed up the assembling process, the prepared cover plate  20  is prefabricated. In preparing operation, a plurality of carbon-fiber fabric sheets, preferably 4 through 10 layers, are interlaced in grains in a preferred included angle of 0 degrees, 45 degrees, 90 degrees, and 315 degrees, and piled up each other. In hardening heat-treatment, a heater (not shown) heats the carbon-fiber fabric sheets at 130 degrees Centigrade 20 minutes. After the carbon-fiber fabric sheets are hardened, the carbon-fiber cover plate  20  is formed with predetermined dimensions.  
         [0036]    Furthermore, the present invention can be chosen to employ a bladder (not shown) contained in the cast body  10  to support the carbon-fiber fabric sheets in the recession  12 . First, the carbon-fiber fabric sheets and the cast body  10  are fixed in a molding assembly (not shown). Second, the bladder contained in the cast body  10  is inflated so that the bladder is closely in contact with the carbon-fiber fabric sheets. Third, the carbon-fiber fabric sheets are heated and hardened to have the cover plate  20  with an appropriated configuration corresponding to that of the recession  12  of the cast body  10 .  
         [0037]    As shown in FIG. 5, according to design choice, the amount and dimensions of the recessions  12  and the cover plates  20  are changeable, and thus the center of gravity and its weight of the cast body  10  are adjustable. The major part of the cast body  10  is made of metal so that an inherent feature of sharpening the striking sound is still remained. Preferably, the material of the cover plate  20  can be selected from a group consisted of light metal (specific gravity less than 4.0 for example) and nonmetal (high polymer plastic or high strength glass fiber for example).  
         [0038]    Referring to FIGS. 1, 5 and  6 , the manufacturing method for the golf club head in accordance with the first embodiment of the present invention comprises a fourth step that forms a buffer groove (a) between an outer periphery of the cover plate  20  and an inner periphery of the recession  12 . The buffer groove (a) is filled with an elastic material (c). To accomplish this task, there are two manufacturing methods for the buffer groove (a). First, the outer periphery of the cover plate  20  is slightly less than the inner periphery of the recession  12  so that the buffer groove (a) is directly formed therebetween. Second, the outer periphery of the cover plate  20  is nearly equal to the inner periphery of the recession  12  and a CNC process is adapted to mill on at least one side or either side of the peripheries. The buffer groove (a) is provided with an adequate space for the deformation of the cover plate and the recession  12 , thereby wrinkles can be avoided in the assembling operation and product quality is raised. Preferably, changing the trace and configuration of the buffer groove can enhance appearance of the golf club head.  
         [0039]    The elastic material (c) has various color and is selected from a group consisted of thermoplastic, rubber and high polymer (PU filler). When the elastic material (c) is hardened in the buffer groove (a), it is functioned to absorb vibration without affecting the buffer function of the buffer groove (a). Thereby, a coating or an adhesive (b) formed on the cast body  10  and the crown plate  20  can be avoided cracking that may increase appearance and added value. Furthermore, in addition to changing the configuration of the recession  12  and the cover plate  20 , changing the color of the elastic material (c) may increase its appearance and added value.  
         [0040]    Referring to FIGS. 1, 5 and  6 , the manufacturing method for the golf club head in accordance with the first embodiment of the present invention comprises a fifth step that finishes the cast body  10  to accomplish an end product. A precision finishing process is adapted to polish an outer surface of the golf club head to remove the remaining resin or carbon fiber after the cover plate  20  is mounted in the recession  12 . Subsequent to removal of the remaining resin or carbon fiber, a coating and painting process is treated on the golf club head.  
         [0041]    Referring to FIGS. 1, 7 and  8 , the manufacturing method for the golf club head in accordance with the second embodiment of the present invention comprises a second step that cuts a plurality of cut openings  120  by a laser beam cutting machine, a plasma arc cutting machine and a water-jet cutting machine. In comparison with the first embodiment, at least one support rib  123  is remained in the recession  12  of the cast body  10  to form a permanent support and has two ends integrally connected to the stepped portion  121 .  
         [0042]    When the cover plate  20  is assembled in the recession  12 , the support rib  123  is adapted to reinforce the entire structure of the golf club head without adding any specific weight.  
         [0043]    Referring to FIGS. 1, 9 through  11 , the manufacturing method for the golf club head in accordance with the third embodiment of the present invention comprises a first step that casts a cast body  10  and a recession  12 . In comparison with the first and second embodiments, the cast body  10  is cast to form with a pair of cast opening  12  and at least one support rib  123 . Similarly, the support rib  123  is used to connected with a stepped edge  121  and to support it in drawing operation that may avoid deformation. As shown in FIGS. 9 and 10, when the support rib  123  is regarded as a temporary support member as well as a removable portion, it is cut to remove prior to the cover plate  20  mounted in the recession  11 . As shown in FIGS. 9 and 11, when the support rib  123  is regarded as a permanent support member, the support rib  123  is adapted to combine with the cover plate  20  by adhesive and to reinforce the entire structure of the golf club head.  
         [0044]    Referring to FIGS. 12 through 14, the golf club head in accordance with the fourth embodiment of the present invention comprises a cast body  10 , a pair of recessions  12  and a pair of side cover plates  20 . In comparison with the first through third embodiments, each of the side cover plates  20  of the fourth embodiment is extended from a crown portion to a side portion. In design choice, changing the dimensions of the side cover plate  20  accomplishes an adjustment in its total weight and its center of gravity. Also, changing the configuration of the side cover plate  20  accomplishes enhancement of its appearance and an increase in its added value.  
         [0045]    Referring again to FIGS. 15 and 16, the cast opening  120  of the conventional main body  10  cannot be contained in deformation. Referring again to FIGS. 4, 7,  9  and  12 , by contrast, the golf club head of the present invention has the recession  12  of the cast body  10  that accomplishes reinforcement in the entire structure, an enhancement in the appearance and an increase in the added value.  
         [0046]    Although the invention has been described in detail with reference to its presently preferred embodiment, it will be understood by one of ordinary skill in the art that various modifications can be made without departing from the spirit and the scope of the invention, as set forth in the appended claims.