KR102575941B1 - Golf Club Face Plates Having Inner Cell Grids and Associated Methods - Google Patents

Abstract

Embodiments of a golf club face plate having an inner cell grid are presented herein. Other examples and related methods are also disclosed herein.

Description

Golf Club Face Plates Having Inner Cell Grids and Associated Methods

CROSS REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/537,278 and is a continuation of U.S. Provisional Patent Application No. 13/352,086, filed Jan. 17, 2012, U.S. Provisional Patent Application No. 157,345, U.S. Provisional Patent Application No. 62/293,914, filed on February 11, 2016, and U.S. Provisional Patent Application No. 62/165,683, filed on May 22, 2015, the contents of which are all incorporated herein by reference. fully covered by the specification.

technical field

The present disclosure relates generally to sports equipment, and more specifically to golf club face plates having an inner cell grid and related methods.

Advances in golf club head technology have been characterized in part by a desire to improve playability characteristics while managing considerations of weight and mass location. However, the ability to change or redistribute mass at or around locations of high stress and/or limited thickness in a golf club head must be balanced with respect to considerations of structural elasticity. Given this, further advances in weight redistribution will evolve the playability characteristics of the golf club head.

The present disclosure will be better understood from an understanding of the following detailed description of exemplary embodiments taken in conjunction with the accompanying drawings. in the drawing,
1 is a front perspective view of a golf club head including a face plate coupled to a club head body;
FIG. 2 is a cross-sectional view of the face plate of FIG. 1 taken along line II-II.
FIG. 3 is a perspective view of a portion of several different layers comprising the face plate of FIG. 1 , showing a condition before being merged together; FIG.
4 is a front view of a middle section layer of the face plate of FIG. 1 including a grid pattern and alignment elements;
FIG. 5 illustrates an infinite element analysis graphic showing a non-uniform stress distribution concentrated in defects in and around void portions of an exposed cell grid in an embodiment of a faceplate without an inner skin layer.
6 is a perspective view of a portion of the cell grid of the face plate of FIG. 1;
7 is a front view of a portion of the cell grid of the face plate.
8 is a side view of a portion of the cell grid of the face plate.
9 is a side view of a portion of the cell grid of the face plate.
10 is a flow diagram of a method of providing a face plate for a golf club head.
11 illustrates a portion of a cell grid of a face plate.
12 illustrates a portion of a cell grid of a face plate.
13 illustrates a portion of a cell grid of a face plate.
14 illustrates a portion of a cell grid of a face plate.
15 illustrates a portion of a cell grid of a face plate.
16 illustrates a portion of a cell grid of a face plate.
17 is a cross-sectional view of a faceplate with a grid of cells having cells that vary in height from one another.
18 is a front “x-ray” perspective view of a face plate having variable cell dimensions in a cell grid;
19 is a front view of a face plate subdivided into several different cell grid regions with one or more cell grids formed therein.
20 is a front view of a face plate subdivided into several different cell grid regions with one or more cell grids formed therein.
21 is a front view of a face plate subdivided into several different cell grid regions with one or more cell grids formed therein.
22 is a front view of a face plate subdivided into several different cell grid regions with one or more cell grids formed therein.
23 is a flow chart of a method for manufacturing a face plate for a golf club head.
24 is a front perspective view of a golf club head including a face plate coupled to a club head body.
25 is a front view of a face plate of a golf club head with a cell grid according to one embodiment.
26 is a front view of a face plate of a golf club head with a cell grid according to another embodiment.
27 is a side view of a portion of the cell grid of the face plate.
28A is a front cross-sectional view of a portion of a face plate with a cell grid, according to one embodiment.
28B is a front cross-sectional view of a portion of a face plate with a cell grid, according to one embodiment.
28C is a front cross-sectional view of a portion of a face plate with a cell grid, according to one embodiment.

For purposes of simplicity and clarity of illustration, the drawings illustrate general manners of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements in the drawings may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. Like reference numbers in different drawings indicate like elements.

In the detailed description and claims, expressions such as "first", "second", "third", "fourth", etc., if used, are used to distinguish between similar elements, but not necessarily in a specific sequential or chronological order. is not used to describe It is to be understood that the expressions so used are interchangeable under appropriate circumstances, such that the embodiments described herein may, for example, operate in orders other than those illustrated or described herein. Moreover, expressions such as “comprise” and “comprise” and any variations thereof do not necessarily mean that a process, method, system, article, or apparatus comprising a list of elements is limited to those elements; It is intended to encompass a non-exclusive inclusion, as may include other elements not expressly listed or inherent to a method, system, article, or apparatus.

In the detailed description and claims, expressions such as "left", "right", "front", "rear", "top", "bottom", "above", "below", if used, are used for descriptive purposes, It is not necessarily used to describe a permanent relative position. It should be understood that the expressions so used are interchangeable under appropriate circumstances, such that the embodiments of devices, methods of manufacture and/or articles of manufacture described herein may, for example, operate in orientations other than those illustrated or described herein. something to do.

In one embodiment, a method of providing a face plate for a golf club head includes providing an inner skin of the face plate, providing an outer skin of the face plate, providing a middle section of the face plate, the steps of providing the face plate; It may include forming a boundary between the inner skin and the outer skin with an intermediate section. Providing a mid-section includes providing a plurality of mid-section layers including a first mid-section layer and a second mid-section layer, forming a first grid pattern through the first mid-section layer, and the second mid-section layer. It may include forming a second grating pattern through the section layer. The step of providing the inner skin, the outer skin, and the middle section may include providing each of the middle section, the inner skin, or the outer skin as separate separating members. forming a mid-section boundary comprising the first and second mid-section layers such that there is a single integral member of material that is substantially seamless between the inner skin and the mid-section and between the mid-section and the outer skin; diffusion bonding the inner skin, the middle section and the outer skin together. After diffusion bonding, the middle section central region of the middle section may include a cell lattice, the cell lattice may include a plurality of walls forming a plurality of cells in a hexagonal pattern, and the plurality of cells of the cell lattice. a wall and said plurality of cells may be formed at least in part by said first and second lattice patterns, said cell lattice being completely bounded between said inner skin and said outer skin of said face plate; A mid-section outer circumferential region of the mid-section may form a boundary of the mid-section center region, and the cell lattice may not exist. Forming the first grid pattern through the first mid-section layer may include forming first cutouts through the first mid-section layer, the first cutout portions of the cell grid. It is configured to form a first volume of a first cell. The forming of the first grid pattern through the second mid-section layer may include forming a second cutout through the second mid-section layer, wherein the second cutout may include forming the first cell through the second mid-section layer. It is configured to form a second volume portion of. Bordering the mid-section includes aligning the second mid-section layer over the first mid-section layer such that the first and second cutouts are centered about a first cell axis of the first cell. can do.

In one embodiment, a method of providing a face plate for a golf club head includes providing an inner skin of the face plate, providing an outer skin of the face plate, providing a middle section of the face plate, and the steps of providing the face plate. The mid section is positioned between the inner skin and the outer skin such that the inner mid section end of the mid section is joined to the inner skin of the face plate and the outer mid section end of the mid section is joined to the outer skin of the face plate. It may include the step of coupling to. The step of providing the middle section may include providing a cell grid in the middle section, the cell grid including a plurality of walls forming a plurality of cells.

In one embodiment, a face plate for a golf club head may include an inner skin, an outer skin and a mid section. The middle section has an inner mid section end coupled to the inner skin, an outer mid section end coupled to the outer skin, and a plurality of walls defining a plurality of cells between the inner mid section end and the outer mid section end. It may contain a single cell grid.

Other examples and embodiments are further disclosed herein. Such examples and embodiments may be presented in the drawings, claims and/or parts of this description.

Referring to the drawings, FIG. 1 is a front perspective view of a golf club head 10 including a face plate 100 coupled to a club head body 109 . FIG. 2 is a cross-sectional view of the face plate 100 taken along line II-II of FIG. 1 . As can be seen in FIG. 2, the face plate 100 includes an inner skin 210, an outer skin 120 and an intermediate section 230 between the inner skin 210 and the outer skin 120; The intermediate section 230 includes a cell grid 240 with walls 241 forming cells 242 . In this example, the cell grid 240 is formed from the inner mid section end 245 (where the cell grid 240 is joined to the inner skin 210) to the outer mid section end 246 (where the cell grid 240 is the inner skin 210). where it is coupled to the skin 210). The cell grid 240 is therefore completely enclosed by the outer circumferential middle section region 232 between the inner skin 120 and the outer skin 210 within the face plate 100 of the example. Inner mid-section end 245 and outer mid-section end 246 are shown along the dotted line in FIG. 2 , but in this embodiment the interface between mid-section 230 and inner skin 210 or outer skin 120 may be seamless or visually and/or structurally imperceptible.

Different portions of the face plate 100 may have different thicknesses. In this example, the outer skin 120 is about 0.03 inch (about 0.08 mm) thick, the middle section 230 is about 0.07 inch (about 1.78 mm) thick, and the inner skin is about 0.07 inch thick toward the center. 0.05 inch (about 0.13 mm) and varies about 0.03 inch (about 0.08 mm) circumferentially. The thickness of the inner skin 210 is greater than the thickness of the outer skin 120 in this example and the inner skin 210 faces away from the impact surface of the face plate 100 so that the impact stress is better distributed across the face plate. do. In some examples, the thicknesses of inner skin 210 and outer skin 120 may be substantially similar to each other and/or may not vary.

In the above example, face plate 100 is illustrated as having inner skin 210, outer skin 120, and middle section 230 merged together to form a single integral member of material. In some examples, inner skin 210, outer skin 120 and/or mid-section 230 may be joined together without the use of adhesives or fasteners, such as through a high pressure and/or high heat process. In the same or another example, this process may include a diffusion bonding process. The ability to bond intermediate section 230 between inner skin 210 and outer skin 120 to form a single integral member of material is such as reducing the weight of faceplate 100 through cell grid 240. It can offer many advantages. In some examples, encapsulating the cell grid 240 within the faceplate 100 may allow for a weight savings of about 8% to about 25%. This result does not compromise the strength or durability of the face plate 100, such as fabrication of the face plate 100 with the cell grid 240 exposed and/or without either the inner skin 210 or the outer skin 120. This can be achieved without introducing detrimental susceptibility to bending, elasticity and/or bending resulting from a non-uniform stress distribution in the case of stress. By way of example and skipping forward in the figure, FIG. 5 shows an unfavorably concentrated area, as indicated by the central region of the thick dotted line, in or around void portions of the cell grid that are exposed in an embodiment in which only one skin is bonded to the cell grid. A cross-sectional view of an infinite element analysis graphic showing a non-uniform stress distribution is illustrated.

Turning to FIG. 3 , a perspective view of portions of several different layers 300 including the face plate 100 prior to being merged together, including the mid section layer 330 , is illustrated. In this example, mid section 230 includes mid section layers 330 that are merged together to become face plate 100 of a single integral piece of material. In the same or another example, the plurality of mid-section layers 330 may be merged together through the high-pressure and high-temperature treatment described above. As can be seen in FIG. 3 , inner skin 210 and outer skin 120 may be merged together to form a single integral member material faceplate 100, e.g., outer skin layer 320 and inner skin layer 320. It may be formed from a plurality of layers, such as skin layer 310 . In this embodiment, the inner skin 210 includes more inner skin layers 310 than the outer skin layers 320 of the outer skin 120, but the relationship is reversed or both skins are equal in number. There may be other embodiments that include layers. However, other embodiments may exist in which one or more of inner skin 210, outer skin 120 and/or mid-section 230 may originally include one layer rather than multiple layers bonded together.

3 shows portions of layer 300 as a sheet of metallic material, illustrating mid-section layers 330 configured such that typical cutouts when merged together form cell grid 240 . 4 illustrates a front view of mid-section layer 331 of mid-section 230 that includes grid pattern 341 and alignment elements 351 - 354 . Grid pattern 341 includes a plurality of cutouts, such as cutouts 342 forming layer portions of walls 241 and cell portions of the volume of cells 242 of cell grid 240 . In the same example, cell grid 240 can be fabricated, such as by machining and/or chemically etching cutouts of different grid patterns in mid-section layer 330 prior to merging the various layers 300 (FIG. 3) together. It can be formed by one or more processes. In examples involving machining one or more of the cell grid 240 or elements thereof, such machining may be performed by one or more techniques, such as through computer numerical control (CNC) machining, water jet cutting, and/or electrical discharge machining. can be performed through

Although the cutouts of the grid pattern 341 in the above example are all similar to each other, the cutouts may have different shapes and different dimensions, such as, for example, different radii, different circumferential lengths, different areas and/or different volumes. Other examples may exist. The same or other examples include a pattern in which the density of the number of cells 242 decreases towards the target hitting area 150 of the face plate 100 and/or the size or dimension of the cells 242 is the target hitting the face plate 100. Other patterns may be included, such as a pattern that decreases towards area 150.

Referring to FIG. 4 , alignment elements 251 - 354 of mid section layer 331 are representative of corresponding alignment elements of other layers of layer 300 ( FIG. 3 ). Alignment elements 351 - 354 are configured such that individual alignment elements 351 - 354 of different layers of layer 300 align with each other only in a single orientation when layer 300 is stacked as illustrated in FIG. 3 . Thus, when the alignment elements 351 - 354 are aligned with each other throughout layer 300, the different lattice patterns of the mid-section layer 330, such as lattice pattern 341, once the layers 300 are merged together. The walls 241 will be aligned to form the cell grid 240 (FIGS. 2-3). In the above example, by aligning the alignment elements 351-354 across the layers 300, the cutouts of the different layers 300 will also align with respect to each other. For example, as can be seen in FIG. 3 , when alignment elements 351 - 354 are aligned across layers 300 , cutouts 342 , 343 may form other ones of mid-section layers 330 . Although located in layers, both are center aligned to the cell axis 350. Once the layers 300 are merged together, the different cutouts of the mid section layer 330 centered about the cell axis 350 form a single cell of the cells 242 of the cell grid 240 . However, other examples may exist where the cutouts of different layers of mid-section layers 330 may be offset from each other rather than centered about the cell axis.

In this example, each of the layers 300 of the face plate 100 include the same type of material. By way of example, middle section 230, inner skin 210 and outer skin 120 and individual middle section layers 330, inner skin layer 310 and outer skin layer 320 may be made of a metallic material such as a metallic alloy. include In this example, an individual layer of layers 300, such as layer 331, may have a thickness of about 0.01 inch or about 0.25 mm. In the same or another embodiment, one or more of these layers 300 may have a thickness ranging from about 0.25 mm to about 2.54 mm.

In this embodiment, the metal material for the layers 300 of the face plate 100 may include a titanium alloy containing at least about 8% aluminum (volume %). In the same or another example, the metal alloy may contain 8% Al, 1% V and 0.2% Si, with the remainder alloy composition comprising titanium and possibly a titanium alloy such as Ti-9S with some trace elements. In some embodiments, Ti-9S is 6.5% to 8.5% Al, 1% to 2% V, up to 0.08% C, up to 0.2% Si, up to 0.3% Fe, up to 0.2% O, up to 0.05%. of N, a trace amount of Mo, and a trace amount of Sn, and the balance of the alloy composition is titanium. In the same or another example, the metal alloy may include a titanium 8-1-1 alloy having about 8% aluminum, 1% vanadium, and 1% chromium. Other materials may be used depending on their strength while considering brittleness/elasticity as a beta crystal structure. For example, a titanium 6-4 alloy with about 6% aluminum and 4% vanadium may be used in some embodiments, but may be 5% to 12% less elastic than titanium 8-1-1, thus reducing golf impact stress. Additional reinforcement or thickness may be required for the face plate 100 to withstand adequately. In contrast, other materials, such as commercially pure titanium, may not be suitable to adequately withstand the stresses that the face plate 100 is subjected to.

For example, through the high-temperature and high-pressure treatment described above, there may be instances where the metal alloy of the layers 300 may have an alpha-type crystal structure before being merged together and a beta-type crystal structure after being merged together. As an example, the alpha-type crystal structure can have a hexagonal crystal phase and/or the beta-type crystal structure can have a body-centered cubic crystal phase. Once the merging process is complete to form faceplate 100 of a single integral member material, the transformation to the beta crystal structure can cause the crystal structures of adjacent ones of layers 300 to be matched together at the molecular level. .

As can be seen in FIGS. 3-4 , the sheets of metal material comprising layers 300 are larger than the example face plate 100 . In the same or another example, the face plate 100 forms the face plate edge 101 of the face plate 100, such as the cut circumference shown in dotted lines in FIG. 4 once the layers 3000 are merged into a single integral member material. It may be separated from the rest of the sheets of metal material through water-jetting or other cutting along the cut perimeter.

In this example, the face plate 100 includes a cell grid 240 in the central region of the mid section 230 as can be seen from the exemplary mid section layer 331 shown in FIG. 4 . The middle section 230 includes a perimeter middle section region 232 bounded by the cell grid 240 and devoid of cells 242 . Thus, the cell grid 240 is separated from the face plate edge 101 by a circumferential middle section region 232 . In some examples, separating the cell grid 240 from the face plate edge 101 is such that when the face plate 100 is coupled to the front end of the golf club head 10, the cell grid 240 is attached to the club head body ( 109) or away from the weld area. In the same or another example, the spacing of this cell grid 240 from its interface with the face plate edge 101 and the club head body 109 will ensure that the face plate 100 and club head body 109 are well welded or bonded. It may be advantageous to make it possible. However, other examples may exist where cell grid 240 may extend within intermediate section 230 to or adjacent to face plate 100 .

The cell grid 240 has a hexagonal isogrid pattern with 6 sub-cells per hexagon in the above example, as shown in FIG. 4, thereby providing the strength-weight performance and versatility of the reinforced honeycomb structure. do. In this embodiment, each of the six sub-cells has the same triangular shape. In the same or another example, the depth of the walls of a cell or sub-cell (between inner skin 210 and outer skin 120) may be about 0.07 inches (about 1.78 mm), and the length of the walls of a cell or sub-cell may be may be about 0.06 inches (about 1.53 mm), and/or the thickness of the walls of a cell or sub-cell may be about 0.01 inches (about .025 mm). In the same or another example, the depth of the walls of a cell or sub-cell can be from about 1.27 mm to about 3.05 mm, the length of the walls of a cell or sub-cell can be from about 1 mm to about 3.05 mm, and/or Alternatively, the thickness of the walls of the sub-cell may be from about 0.20 mm to about 0.76 mm. However, other examples of cell grids may have other shapes and/or dimensions.

With continued reference to the drawings, FIG. 6 is a perspective view of a portion of the cell grid 240 of the faceplate 100 with the inner skin 210, outer skin 120 and outer circumferential mid-section region 232 removed for clarity. foreshadow Cell grid 240 includes a plurality of cell junctions, such as cell junction 443 where two or more walls 241 are bonded together. In this example, the cell junction provides an arcuate transition between the walls of the cell. For example, walls 6412 and 6413 meet at cell junction 443, where the interface between them is arcuate rather than pointed or sharp. In the example above, this arcuate interface has a radius of about 0.05 inches (about 0.13 mm), but there may be other examples where the arcuate interface can have a radius of about 0.025 mm to about 0.40 mm. Such arcuate features can be useful, for example, to avoid sharp edges that can concentrate stresses that can cause material fatigue and/or cracking within the cell lattice.

Also in the example above, one or more cell junctions may include individual junction channels, such as junction channel 4431, extending into cell junction 443 from inner mid section end 245 to outer mid section end 246. . Bonding channel 4431 has a maximum dimension or diameter of about 0.015 inches (about 0.38 mm) in the above example, but examples are provided where similar bond channels may have a diameter and/or maximum dimension of about 0.2 mm to about 0.66 mm. can exist

Additionally, the cell grid 240 also includes one or more cross passages, such as cross passages 644 between at least two adjacent ones of the cells 242 in the example above. Transversal passageway 644 has a maximum dimension or diameter of about 0.05 inches (about 1.27 mm) in the above example, but there are examples where similar cross passages may have a diameter and/or maximum dimension of about 0.5 mm to about 1.27 mm. can exist

The addition of features such as bonding channels 4431 and cross passages 644 may allow for additional weight reduction without compromising the strength or integrity of faceplate 100 . Additionally, the shape and/or form of junction channel 4431 and/or passage 644 can be changed to be the same shape and/or form as cell 242 or a different shape and/or form. Additionally, junction channels and passages other than junction channels 4431 and/or passages 644 may have other shapes and/or configurations.

7 illustrates a portion of a cell grid 740 . In some examples, cell grid 740 can be similar to cell grid 240 ( FIGS. 1-4 , 6 ), as described above with respect to faceplate 100 in FIGS. 1-3 , with an inner skin. 210 and skins such as outer skin 120. Cell grid 740 includes walls 741 and cells 742 similar to walls 241 and 242 (FIGS. 1-4, 6), respectively, but walls 741 have varying wall dimensions. . As an example, the wall thickness dimension of wall 7411 varies along its length, with the wall thickness thinning towards the center of its length and becoming thicker towards the ends of its length. In the example above, this change in wall thickness dimension also affects the dimensions of cell 742, where the walls of the isogrid triangular cells have thick legs and are bound to cells bordering cell junctions, such as cell junctions 743. The hexagonal shape formed by is arcuate and/or circular. In another example, the wall thickness dimension may be otherwise varied, such as by becoming thicker towards the center of the length and thinner towards the ends of the length.

8 illustrates a portion of a cell grid 840 . Cell grid 840 may be similar to cell grid 240 ( FIGS. 1-4 , FIG. 6 ) and/or cell grid 740 ( FIG. 7 ). Cell lattice 840 is skin 810, which may be similar to inner skin 210 and/or outer skin 120, respectively, as described above with respect to faceplate 100 (FIGS. 1-4, 6). 820) is located between. Cell lattice 840 has walls 841 and cells 841 that can be similar to walls 241 and cells 242 ( FIGS. 1-4 , FIG. 6 ) and/or walls 741 and cells 742 ( FIG. 7 ). cell 842. Wall 841 has variable wall dimensions in this embodiment. As an example, the wall thickness dimension of wall 8411 varies along its height, with the wall thickness thinning towards the center of its height and becoming thicker towards the ends of its height. In the example above, this change in wall thickness dimension also affects the dimensions of cell 842 so that cell 842 can have a larger volume and arcuate dimensions. In another example, the wall thickness dimension may be otherwise varied, such as by becoming thicker toward the center of the height and thinner toward the height end.

Skipping forward in the drawing, FIG. 27 illustrates a portion or cross-section of a cell grid 1840 with varying wall dimensions. In some embodiments, cell grid 1840 may be similar to cell grid 240 (FIG. 1-4, FIG. 6), cell grid 740 (FIG. 7), and/or cell grid 840 (FIG. 8). can Cell lattice 1840 is skin 1810, which may be similar to inner skin 210 and/or outer skin 120, respectively, as described above with respect to faceplate 100 (FIGS. 1-4, 6). 1820) is located between. The cell grid 1840 may include walls 241 and cells 242 (FIGS. 1-4 and 6), walls 741 and cells 742 (FIG. 7), and/or walls 841 and cells 842. It includes walls 1841 and voids or cells 1842, each of which may be similar to (FIG. 8).

Referring to FIG. 27 , in the illustrated embodiment, the cell wall 1841 has a wall thickness 1851 that varies similarly to the wall 841 . In some embodiments, the wall thickness 1851 is thicker near the inner skin 1810 and outer skin 1820 than near the central region of the grating. For example, in the illustrated embodiment, the wall thickness dimension of wall 1841 varies along its height, being thinner towards the center of its height and thicker towards the ends of its height. Also, in the illustrated embodiment, the cell wall thickness 1851 varies to form an hourglass shape. The change in wall thickness 1851 also affects the dimensions of cell 1842 so that cell 1842 can have a larger volume and arcuate dimensions. In other embodiments, the wall thickness 1851 may vary otherwise, such as by becoming thicker toward the center of the height and thinner toward the height end. Also, in other embodiments, the cell walls 1841 may have other shapes, such as circular, elliptical, square, rectangular, triangular, or any other polygon or shape having at least one curved surface.

In many embodiments, the smallest or smallest wall thickness 1851 may range from about 0.005 inches to about 0.2 inches. In some embodiments, the smallest or minimum wall thickness 1851 may be less than or equal to about 0.20 inches, less than or equal to about 0.15 inches, less than or equal to about 0.10 inches, less than or equal to about 0.05 inches, or less than or equal to about 0.02 inches. For example, in the illustrated embodiment, the smallest or minimum wall thickness 1851 is about 0.020 inches. In other embodiments, the smallest or minimum wall thickness 1851 may be about 0.025 inches, about 0.05 inches, about 0.10 inches, about 0.15 inches, or about 0.2 inches.

With further reference to FIG. 27 , cell 1842 has a cell width 1852 . Cell width 1852 varies with distance from inner skin 1810 and/or outer skin 1820 . In the illustrated embodiment, cell width 1852 is larger near the center of cell 1851 and decreases near inner skin 1810 and outer skin 1820 . In other embodiments, the cell width 1852 can vary to any capacity. For example, in another embodiment, cell width 1852 may be greatest near inner skin 1810 and outer skin 1820 and decrease near the center of cell 1851 .

In some embodiments, the largest or maximum tongue width 1852 may range from about 0.005 inches to about 0.2 inches. In some embodiments, the largest or largest tongue width 1852 may be about 0.20 inches or less, about 0.15 inches or less, about 0.10 inches or less, about 0.05 inches or less, or about 0.025 inches or less. For example, in the illustrated embodiment, the largest or maximum tongue width 1852 is about 0.045 inches. In other embodiments, the largest or largest tongue width 1852 may be about 0.025 inches, about 0.05 inches, about 0.10 inches, about 0.15 inches, or about 0.2 inches.

In the illustrated embodiment, the cells 1842 are coupled to each other or contiguous throughout the cell grid 1840 . In another embodiment, cells 1842 may be separate.

Referring further to FIG. 27 , in this embodiment, the cell walls 1841 are substantially hourglass shaped. Also, in this embodiment, the cell walls 1841 overlap, contact, or overlap adjacent cell walls 1841 at one first point near the inner skin 1810 and at one second point near the outer skin 1820. cross The cell wall 1841 includes a cell wall axis 1844 extending centrally within the cell wall 1841 between the inner skin 1810 and the outer skin 1820 . Cell walls 1841 are spaced apart from adjacent cell walls 1841 by a center-to-center distance 1854, measured as the distance between adjacent cell wall axes 1844.

In some embodiments, the center-to-center distance 1854 between adjacent axes 1844 may range from about 0.005 inches to about 0.2 inches. In some embodiments, the center-to-center distance 1854 between adjacent axes 1844 may be about 0.20 inches or less, about 0.15 inches or less, about 0.10 inches or less, about 0.05 inches or less, or about 0.025 inches or less. For example, in the illustrated embodiment, the center-to-center distance 1854 between adjacent axes 1844 is about 0.050 inches. In other embodiments, the center-to-center distance 1854 between adjacent axes 1844 may be about 0.025 inches, about 0.05 inches, about 0.10 inches, about 0.15 inches, or about 0.2 inches.

With further reference to FIG. 27 , cell walls 1841 extend at an angle 1850 from cell wall axis 1844 . In some embodiments, the cell walls 1841 extend at an angle of about 45 degrees or less from the cell wall axis 1844. In these or other embodiments, the faceplate 100 having the cell grid 1840 may be printed as described in method 50000 below without using support structures within the cells 1842. In other embodiments, the cell walls 1841 can extend any angle greater than 0 degrees and less than 180 degrees from the cell wall axis 1844.

Referring to FIGS. 25 and 26 , in the illustrated embodiment, a portion of the face plate 100 is formed to have a cell grid 1840 . In these or other embodiments, a portion of the face plate 100 formed to have the cell grid 1840 may subsequently be joined to the remaining portion of the face plate 100 as described in method 50000 below. . In another embodiment, the entire faceplate 100 may be formed as a single component having a cell grid comprising at least a portion of the faceplate 100 . For example, in another embodiment, the entire faceplate 100 may include the cell grid 1840 and may be formed as a single component. As a further example, in another embodiment, a portion (eg, center) of face plate 100 may include cell grid 1840, and face plate 100 may be formed as a single component.

In the illustrated embodiment, the portion of the face plate 100 having the cell grid 1840 is substantially circular. In other embodiments, the portion of the face plate 100 having the cell grid 1840 may have any other shape. For example, in another embodiment, a portion of the faceplate 100 having the cell grid 1840 may have an elliptical shape, as described in more detail in method 50000 below. As a further example, in another embodiment, the portion of the faceplate 100 having the cell grid 1840 may have a square shape, a triangle shape, any other polygonal shape, or any shape having at least one curved surface.

28A, 28B, and 28C illustrate front cross-sectional views of a portion of a faceplate 100 having a cell grid 1840 in accordance with various embodiments. In the embodiment illustrated in FIG. 28A , the cell wall axis 1844 is located radially from the center of the face plate 100 . In other embodiments, the cell wall shaft 1844 may have other configurations. For example, the cell wall axis 1844 can be configured in a diamond-shaped pattern as illustrated in FIG. 28B, a hexagonal pattern as illustrated in FIG. 28C, or any other configuration. Also, in the embodiment illustrated in FIGS. 28A-28C, the cell wall axes 1844 are equally spaced. In other embodiments, the cell wall axes 1844 may have other spacing.

In some embodiments, the cell grid 1842 of the face plate 100 reduces the weight of the face plate. In some embodiments, the cell grid 1842 of the face plate 100 reduces the weight of the face plate without sacrificing durability. In some embodiments, the cell grid 1842 of the face plate 100 reduces the weight of the face plate and increases the thickness of the face plate to maintain the durability of the face plate. For example, in some embodiments, the cell grid 1842 can reduce the weight of the face plate by about 3 grams. In many embodiments, the reduced weight of the faceplate 100 due to the cell grid 1842 allows any additional weight to be placed elsewhere on the club head to achieve a desired head center of gravity or reduce the club head moment of inertia. to improve the performance characteristics of the club head. For example, any increased weight placed on the circumference of the club head increases the club head moment of inertia to improve the club head's forgiveness. In many embodiments, weight transferred from the face plate to the circumference of the club head may increase inertia greater than weight transferred from other portions of the club head (eg, the crown). Additionally, in some embodiments, the cell lattice 1842 of the faceplate 100 increases the flexibility of the faceplate, thereby increasing the bending of the faceplate upon impact with the golf ball, thereby increasing the energy transferred to the golf ball. , which increases batted ball speed and travel distance.

Turning back to the drawing, FIG. 11 illustrates a portion of a cell grid 1140 with varying wall dimensions. In some examples, cell grid 1140 may be similar to cell grid 240 (FIG. 1-4, FIG. 6), cell grid 740 (FIG. 7), and/or cell grid 840 (FIG. 8). can Cell grid 1140 may be skin 1110, which may be similar to inner skin 210 and/or outer skin 120, respectively, as described above with respect to faceplate 100 (FIGS. 1-4, 6). 1120) is located between. The cell grid 1140 may include walls 241 and cells 242 ( FIGS. 1 to 4 and 6 ), walls 741 and cells 742 ( FIG. 7 ), and/or walls 841 and cells 842 . It includes walls 1141 and cells 1142, each of which may be similar to (FIG. 8). Wall 1141 has varying wall dimensions in this embodiment so that the thickness between skin 1110 and skin 1120 is tapered. As an example, wall 11411 becomes thicker toward skin 1120 and decreases to a thinner thickness toward skin 1110 . In the same or another example, skin 1120 is configured with the outer surface of the face plate such that the thicker portion of wall 1141 faces toward the impact surface of the face plate. However, other embodiments may exist in which the thin portion of wall 1141 may face toward the impact surface of the face plate.

Turning back to the drawing, FIG. 9 illustrates a portion of cell grid 940 . In some examples, cell grid 940 includes cell grid 240 ( FIGS. 1-4 , FIG. 6 ), cell grid 740 ( FIG. 7 ), cell grid 840 ( FIG. 8 ), and/or cell grid ( 1140) (FIG. 11). The cell grid 940 may include an inner skin 210 and/or an outer skin ( 120) is located between skins 910 and 920. Cell grid 940 includes cells 242 (FIG. 1-4, FIG. 6), cells 742 (FIG. 7), cells 842 ) (FIG. 8) and/or cell 942, which may be similar to cell 1142 (FIG. 11). Cells 942 are offset from each other in the example above. For example, cell 9421 is offset from cell 9422 offset from cell 9423. Further, in the above example, mid section layers 931-933 form mid section 930 that includes cell grid 940. Middle Section layers 931 - 933 may be similar in relation to middle section layer 330 of face plate 100 (FIG. 3) and may be merged together as described above. Mid section layers 931 - 933 may each include multiple layers before being merged to form mid section 930 . In the example above, cell 9422 is at least partially capped or formed by the solid portion of mid section layers 931, 932, and 933, and cell 9421 is at least partially formed by solid portion of mid section layer 931, 932. It is capped or formed by portion and skin 920 .

However, other examples may exist that may include cell grids with other types of geometries, dimensions, or combinations thereof. Skipping forward to eg FIG. 12 , a cell grid 1240 is provided with walls 1241 forming hexagonal cells 1242 . 13 shows a cell grid 1340 with walls 1341 forming diamond or square cells 1342 . 14 shows a cell grid 1440 with walls 1441 forming round or circular cells 1442 . Other shapes, such as pentagonal cells, octagonal cells, triangular cells, and/or combinations thereof among other examples of the same or other cell grids may also be implemented. For example, FIG. 15 shows a cell grid 1540 with walls 1541 forming circular cells 1542 in which triangular cells 1543 are disposed.

There may also be examples in which individual cells of the cell grid may have sub-cells therein. For example, cells 242 ( FIGS. 1-4 , 6 ) may be considered to form a sub-cell of a large hexagonal cell of cell grid 240 in some examples. As another example, FIG. 16 shows a cell grid 1640 with walls 1641 forming cells 1642, where cell subset 1650 of cells 1642 is cell subset 1650 sub-cells 1652 formed by sub-walls 1651 within the individual cells of . A cell subset, such as cell subset 1650, may be placed in a specific location for reinforcement corresponding to the stress expected at that location. In some examples, these cell subsets may be located in or by a target striking area of a faceplate, such as target striking area 150 of faceplate 100 (FIG. 1). Other combinations of cells, sub-cells, shape and/or dimensions for a cell grid may be formed by combining different cells, sub-cells, shapes and/or dimensions as disclosed herein or similar.

Cell lattice 1240 (FIG. 12), cell lattice 1340 (FIG. 13), cell lattice 1440 (FIG. 14), cell lattice 1540 (FIG. 15), cell lattice 1640 (FIG. 16) Although they may be different in many respects, they are different from the cell grid 240 (FIGS. 1 to 4, 6), the cell grid 740 (FIG. 7), the cell grid 840 (FIG. 8), and/or the cell grid ( 1140 (FIG. 11).

In some examples, the heights of the cells of the cell grid may vary from cell to cell. As an example, FIG. 17 provides a cross-sectional view of a faceplate 17100 with a cell grid 17240 similar to cell grid 240 ( FIGS. 1-4 and 6 ). However, cell grid 17240 includes cells that vary in height from one another. In this example, the height of cell 17242 is greater than the height of cell 17246, and the height of cell 17246 is greater than the height of cell 17248. The cells of the cell grid 17240 are positioned such that the height decreases towards the center of the target hit area 17150 where, for example, higher stress can be expected in the example above. Additionally, in the very center of the target striking area 17150, there are no cells of the cell grid 17240 for additional reinforcement in the above example. However, other examples exist including cell grids with cells that vary in height in different patterns.

18 provides a front “x-ray” perspective view of a face plate 18100 of a golf club head. The face plate 18100 includes a cell grid 18240 of varying cell dimensions. In the above example, the cell grid 18240 includes grid-like cells 18242 whose size decreases towards the center of the target hitting area 18150. In the same or another example, the walls between the cells 18242 of the cell grid 18240 may increase in thickness towards the center of the target striking area 18150. In another example, the size of the cells 18242 and/or the thickness of the walls therebetween may increase or decrease in size towards other regions of the face plate 18100, such as, for example, the crown region, the bottom region, the posterior region, and/or the anterior region. can

In the same or another example, the size of cell 18242 may increase or decrease as a function of distance from the center of target striking area 18150. However, in another example, the size and/or density of the cells 18242 may increase or decrease, eg, by increasing or decreasing from the top edge of the face plate to the bottom edge and/or, eg, by increasing or decreasing from the rear end to the front end of the face plate. It can vary relative to other features of the face plate. In some embodiments, cells 18242 may decrease in size or dimensions from about 1% to about 10% per cell as their distance to the center of target striking area 18150 decreases. In the same or another embodiment, the distance between cells 18242 may increase from about 1% to about 10% per cell as the distance to the center of target striking area 18150 shortens. In addition, there may be examples in which the size or density of the cells 18242 relative to the center of the target hitting area 18150 may change nonlinearly and/or in a step function manner.

Although cells 18242 of cell grid 18240 are illustrated as circular cells in FIG. 18 , cells 18242 may exhibit other shapes, sizes or dimensions that may be applied to implement the variable cell size described above. For example, the cells of the cell grid 18240 may still vary in size or density across at least a portion of the faceplate 18100 while in some implementations, e.g., triangles, hexagons, diamonds, octagons, pentagons, isogrids and/or or some combination thereof.

19 shows a front view of a face plate 19100 of a golf club head subdivided into different cell grid regions 19500 having one or more cell grids therein. In the above example, the cell grid region 19500 includes a central grid region 19510 and a peripheral grid region 19520, and the central grid region 19510 is bounded by the peripheral grid region 19520 around its outer periphery. It is located in the central region of the face plate 19100. The center grid region 19510 may be more rigid than the more elastic peripheral grid region 19520 in the example above, and the elasticity of the cell grid region 19500 may be determined by the appropriate cell pattern, properties, and/or Or it can be precisely adjusted by implementing dimensions. In some examples, making the center grid region 19510 harder than the peripheral grid region 19520 may allow more forgiveness for golf shots that do not hit the target striking region of the face plate. In the same or another example, the characteristic time (CT) of the golf club may also be adjusted or adjusted by adjusting the flexibility or resiliency of other portions of the face plate, such as the cell grid region 19500. However, the center grid region 19510 need not be harder than the peripheral grid region 19520 and/or the center grid region 19510 and the peripheral grid region 19520 may have substantially similar stiffness or modulus of elasticity. Other examples may exist.

In some examples, center grid region 19510 may be similar to or correspond to target striking region 150 of faceplate 100 (FIG. 1) or other target striking regions of other faceplates disclosed herein. In the example above, the cell grid regions 19500 may include or be similar to one or more of the cell grids disclosed herein, but may differ from each other with respect to at least one feature. As an example, center grid region 19510 may include a cell grid similar to isogrid cell grid 240 ( FIGS. 1-4 , 6 ), while peripheral grid region 19520 may include hexagonal cell grid 1240 (FIG. 12) may include a similar cell grid. As another example, the center grid region 19510 can include a cell grid similar to the circular cell grid 1440 (FIG. 14), while the peripheral grid region 19520 is a multi-shaped cell grid 1540 (FIG. 15). ) and a similar cell grid. As another example, some cells of the cell grid region 19500 may include sub-cells and/or sub-walls. For example, the cells of the central grid region 19510 may include sub-cells and sub-walls similar to the cell subset 1650 (FIG. 16), while the cells of the peripheral grid region 19520 are sub-cells or sub-walls. It is not necessary to include walls. In the same or another example, the cell grid region 19500 may include cells of different heights. For example, center grid region 19510 may include cells of reduced height, e.g., cells of target striking region 17150 of FIG. 17, while peripheral grid region 19520 may be may include cells with a height higher than that of In the same or another example, the central grid region 19510 may be partially or entirely cell-free while being surrounded by the cells of the peripheral grid region 19520.

20 shows a front view of a face plate 20100 of a golf club head subdivided into different cell grid regions 20500 having one or more cell grids therein. In the above example, the cell grid region 20500 includes a center grid region 20510 and a peripheral grid region 20520, and the peripheral grid region 20520 includes a back grid region 20521 and a front grid region 20522. do. A center grid region 20510 is located in a central region of the face plate 20100 bounded at least in part by a peripheral grid region 20520 . Cell grid region 20500 may include or be similar to one or more of the cell grids described herein above, but with respect to, for example, stiffness, elasticity, and/or at least one characteristic of the type of cell grid constructed. may differ from each other. As an example, center grid region 20510 extends toward the top and bottom ends of face plate 20100, and may otherwise be similar to center grid region 19510 (FIG. 19), but peripheral grid region 20520 may be It may be similar to grid area 19520 (FIG. 19). In the above example, the cell grids of the peripheral grid area 20520 may be similar to each other, but there may be other examples in which these cell grids may be different from each other.

In the above example, the center grid region 20510 may be harder than the back grid region 20521 and the front grid region 20522, but the hardness of the back grid region 20521 and the front grid region 20522 are similar to each other. can do. However, examples in which the hardness of the rear grating region 20521 is greater than the hardness of the front grating region 20522 or vice versa may exist. The ability to provide such different stiffness options for different areas of the faceplate 20100 may include, for example, the rotation of the club head about the golf shaft axis during the swing, the offset of the bias of the average impact position, and/or Alternatively, it may allow for optimization of batted ball velocity based on differences in club head velocity across the face plate derived from fine tuning of the shape or position of the target striking area of the club head. Additionally, in the example above, the cell grid regions 20500 are separated from each other by one or more border channels 20600. Border channel 20600 does not have a cell grid therein, but there may be instances where border channel 20600 can include a cell grid similar to one or more of the cell grids described herein. However, in another example, face plate 20100 may not have boundary channels 20600 such that cell grid regions 20500 may contact or merge with each other.

21 shows a front view of a face plate 21100 of a golf club head subdivided into different cell grid regions 21500 having one or more cell grids therein. In the above example, the cell grid region 21500 includes a center grid region 21510 and a peripheral grid region 21520, and the peripheral grid region 21520 includes a rear grid region 21521, a front grid region 21522, and an upper grid region. A grid area 21523 and a bottom grid area 21524 are included. Center grid region 21510 is located in a central region of face plate 21100 bounded at least in part by peripheral grid region 21520 . Cell grid region 21500 may include or be similar to one or more of the cell grids described herein, but with respect to, for example, stiffness, elasticity, and/or at least one characteristic of the type of cell grid constructed. may differ from each other. As an example, center grid region 20510 can be similar to center grid region 19510 (FIG. 19) and/or center grid region 20510 (FIG. 20). Peripheral grid region 21520 may be similar to perimeter grid region 19520 (FIG. 19) and/or perimeter grid region 20520 (FIG. 20). In the above example, the cell lattices composed of the peripheral lattice regions 21520 are different from each other. For example, the cell grids of the upper grid area 21523 and the bottom grid area 21524 are different from those of the rear grid area 21521 and the front grid area 21522. In the same or another example, the cell grid of top grid region 21523 can be similar to the cell grid of bottom grid region 21524, while the cell grid of front grid region 21522 is the cell grid of back grid region 21521. It can be like a grid. However, in another example, cell grids of the upper grid region 21523, the bottom grid region 21524, the front grid region 21522, and the rear grid region 21521 may all be similar to each other.

In the above example, the central grid region 21510 may be more rigid than the peripheral grid region 21520. Hardness of the peripheral grid regions 21520 may be similar to or different from each other according to embodiments. For example, the hardness of the upper grid region 21523 and the bottom grid region 21524 may be harder than that of the rear grid region 21521 and the front grid region 21522 or vice versa. Also, there may be examples in which each of the peripheral grating regions 21520 may have a different hardness. The ability to provide different hardness options as above for different regions of face plate 21100 may allow for additional alternative benefits relative to similar benefits to those described above with respect to face plate 20100. . In this example, cell grid regions 21500 are separated from each other by one or more border channels 21600, which may be similar to border channels 20600 (FIG. 20).

22 shows a front view of a face plate 22100 of a golf club head subdivided into different cell grid regions 22500 having one or more cell grids therein. In the above example, the cell grid region 22500 includes a center grid region 22510 and a peripheral grid region 22520, and the peripheral grid region 22520 includes an upper-rear grid region 22521 and an upper-front grid region ( 22522), a bottom-front grid area 22523, and a bottom-rear grid area 22524. Center grid region 22510 is located in a central region of face plate 22100 bounded at least in part by peripheral grid region 22520 . Cell grid region 22500 may include or be similar to one or more of the cell grids described herein, but with respect to, for example, stiffness, elasticity, and/or at least one characteristic of the type of cell grid constructed. may differ from each other. In some examples, center grid region 22510 can be similar to center grid region 21510 ( FIG. 21 ), while peripheral grid region 22520 can be similar to peripheral grid region 21520, but with a faceplate ( 22100) is moved relative to the position across. In one example, the stiffness and/or cell lattice of top-rear grid region 22521 and top-front grid region 22522 is the same as the stiffness of bottom-back grid region 22524 and bottom-front grid region 22523. /or may be different from the cell grid. As another example, the stiffness and/or cell lattice of top-front grid region 22522 and bottom-front grid region 22523 is the same as the stiffness of top-back grid region 22521 and bottom-front grid region 22524. /or may be different from the cell grid. In addition, there may be embodiments in which the hardness and/or the cell lattice of each of the peripheral lattice regions 22520 are different from each other. The ability to provide different hardness options as described above for different regions of face plate 22100 adds additional pertaining to benefits similar to those described above with respect to face plate 20100 and/or face plate 21100. Alternative benefits may be allowed. In this example, cell grid regions 22500 are separated from each other by one or more border channels 22600, which may be similar to border channels 20600 (FIG. 20).

Turning back to the drawings, FIG. 10 illustrates a flow diagram of a method 10000 of providing a face plate for a golf club head. In some embodiments, the face plate includes one or more cell grids such as those described above with respect to face plate 100 (FIGS. 1-4, 6) and FIGS. 7-9, 11, and/or 12-11. It can be similar to one face plate.

Block 10100 of method 10000 includes providing an inner skin of a face plate. Block 10200 of method 10000 includes providing an outer skin of the face plate. In some examples, the inner skin of block 10100 can be similar to inner skin 210, while the outer skin of block 10200 can be similar to outer skin (FIGS. 2-3). In the same or another example, block 10100 may include providing first and second inner skin layers of an inner skin, wherein the first and second inner skin layers are inner skin layers 310 (FIG. 3). ) can be similar to In the same or another example, block 10200 may include providing first and second outer skin layers of outer skin, wherein the first and second outer skin layers are outer skin layer 320 (FIG. 3). ) can be similar to

Block 10300 of method 10000 includes providing a middle section of a face plate. In some examples, the middle section can be similar to middle section 230 ( FIGS. 1-4 , FIG. 6 ) and/or middle section 930 ( FIG. 9 ). In the same or another example, the 10300 block may include a 10310 sub-block providing first and second middle section layers of the middle section of the 10300 block. There may be examples where the first and second middle section layers can be similar to mid section layer 330 (FIG. 3). In the example above, the inner skin of the 10100 block, the outer skin of the 10200 block and the middle section of the 10300 block are provided as separate individual parts, but there may be other embodiments where two of these may be provided already joined together. .

In some examples, a 10300 block may include 10320 sub-blocks forming a cell grid with a plurality of walls forming a plurality of cells in the middle section. In some examples, cell grids may include cell grids 240, 740 (FIG. 7), 840 (FIG. 8), 940 (FIG. 9), 1140 (FIG. 9), 1140 (FIGS. 11), 1240 (FIG. 12), 1340 (FIG. 13), 1440 (FIG. 14), 1540 (FIG. 15), 1640 (FIG. 16), 17240 (FIG. 17), and/or 18240 (FIG. 18)) As described above, one or more of the cell grids composed of cell grid regions of faceplates 19100 (FIG. 19), 20100 (FIG. 20), 21100 (FIG. 21), and/or 22100 (FIG. 22), and/or herein Other cell lattice variations similar to those described may be similar.

The 10320 sub-block includes a 10321 sub-block forming a first grid pattern of the cell grid through the first middle section layer and/or a 10322 sub-block forming a second grid pattern of the cell grid through the second intermediate section layer. can do. In some examples, the first grid pattern of the 10321 sub-block may be similar to the cell grid pattern 341 through the middle section layer 331 (FIGS. 3-4). In the same or another example, the second lattice pattern of the 10322 sub-block may be similar to another lattice pattern of another mid section layer, such as lattice pattern 242 of mid section layer 332 (FIG. 3). Additionally, the first and second lattice patterns of the 10321-10322 sub-blocks may correspond to the lattice patterns for the cell lattice of FIGS. 7 to 9 or 11 to 22 and/or other cell lattice variations similar to those described herein. .

The 10321 sub-block may include forming a first cutout through the first middle section layer, wherein the first cutout is configured to form a first volume of a first cell of a cell grid. Similarly, the 10322 sub-block may include forming a second cutout through the second middle section layer, wherein the second cutout is configured to form a second volume of a first cell of the cell grid. . As an example, the first cutout can be similar to the cutout 342 through the middle section layer 331 (FIG. 3), and the second cutout can be similar to the cutout through the middle section layer 332 (FIG. 3). Since it may be similar to the out portion 343, when the middle section layer 330 is joined together, e.g., via a 10411 sub-block (described below), the volume formed by the cutouts 342 and 343 is joined so that It forms at least a part of the volume of the cells of the cell grid 240 . Examples may exist that may include forming the second cutout such that the 10322 sub-block has a different dimension than the first cutout, eg, a different radius, a different circumferential length, a different area, or a different volume. Thus, the first and second cutouts need not be identical to each other, adding flexibility to further form desired features for the volume and/or shape of the cells of the cell grid.

In some examples, forming the cell grid at block 10320 may include forming a second mid section layer over the first mid section layer such that the first and second cutouts are centered on the first cell axis of the cells of the cell grid 240. A sorting step may be included. As an example, as described above with reference to FIGS. 3-4. The mid section layer 300 includes individual alignment elements 351 - 354 and can be aligned with each other by aligning the individual alignment elements 351 - 354 throughout the stack of mid section layers 300 . Thus, the cutout 342 of the layer 331 and the cutout 343 of the layer 332 are eventually aligned with each other by being centered on the cell axis 350, where the cell axis 350 is the stacked The cells of the cell grid 240 are formed in the middle section 230 by being traversed through cutouts in the layer 330 . In some examples, the alignment elements can include features such as holes and/or recesses that can be matched to one another for alignment by corresponding shape and/or location. 3-4, alignment elements 351-354 are offset from each other to allow adjacent ones of layers 300 to align in a single direction.

Also, there may be instances where it is not necessary for all cutouts of the stacked layers of the middle section to be aligned with each other centered on the cell axis. In some embodiments, the cutouts and/or cells of the cell grid may be offset from each other. For example, forming a first grid pattern in block 10321 may include forming a first cutout through the first middle section layer to form a first volume of a first cell, and in block 10322 Forming the second lattice pattern may include forming a second cutout through the second middle section layer to form a second volume of the second cell of the cell lattice. In the same or another example, the second cell may be at least partially capped or formed by the solid portion of the first middle section layer and/or the outer skin, and/or the first cell may be formed by the solid portion of the second middle section layer. and/or may be at least partially capped or formed by an inner skin. For example, as illustrated in FIG. 9 , mid-section layers 931 - 933 have cells 9421 at least partially capped or formed by solid portions 9321 of layer 932 and cells 9422 Cells 9421 , 9422 , 9423 may be aligned and stacked so that they are offset from each other such that they are at least partially capped or formed by solid portion 9311 of layer 931 . While middle section 930 is illustrated as layers 931 - 933 for brevity in FIG. 9 , layers 931 - 933 may each represent a plurality of mid section layers stacked together in the same or different embodiments.

Block 10400 of method 10000 includes joining the middle section of block 10300 between the inner skin of block 10100 and the outer skin of block 10200. In some examples, the middle section may include an inner mid section end coupled to the inner skin of the 10100 block and an outer mid section end coupled to the outer skin of the 10200 block such that the mid section is “sandwiched” therebetween. In the same or another example, the 10400 block may include 10410 sub-blocks that merge together the inner skin, middle section, and outer skin into a single integral member material without the use of adhesives or fasteners. For example, the inner skin, mid-section and outer skin may be merged together through a high temperature and high pressure process as described above with reference to FIGS. 2-3, such as a diffusion bonding process. There may be embodiments in which the 10410 sub-block may be implemented such that a single integral member material is seamless between the inner skin and the middle section and between the middle section and the outer skin. In the same or another example, the 10410 sub-block may include a 10411 sub-block that merges the first middle section layer and the second middle section layer together into a single unit of material. As an example, the 10411 sub-block may include merging the middle section layer 330 (FIG. 3) together as described above. In the same or another example, merging together inner skin layers 310 (FIG. 3) and/or merging outer skin layers 320 (FIG. 3) together so that the 10410 sub-block becomes a single piece material face plate. may further include.

The merging of the inner skin, the middle section and the outer skin and/or between their respective layers into a seamless single piece can occur when such merging takes place at the molecular level. For example, the inner skin, mid-section, and outer skin may all be provided to include the same metal material, which when exposed to high temperature and high pressure processing, such as, for example, a diffusion bonding process, may bind different parts of the face plate to molecules. It can be selected as suitable for merging into levels. In some examples, the metal material may include a metal alloy as described above, and the molecular level incorporation may utilize the crystal structure of the metal material to achieve an integral bond to form a faceplate of single piece material. . As an example, the inner skin can be provided with a first crystal structure of alpha structure at block 10100, the outer skin can be provided with a second crystal structure of alpha structure at block 10200, and the middle section is In block 10300, it may be provided to have a mid-section crystal structure of an alpha-type structure. Then, at block 10400, the first crystal structure of the inner skin, the second crystal structure of the outer skin, and the mid section crystal structure of the mid section are determined such that the mid section crystal structure matches the first crystal structure and the mid section crystal structure matches the second crystal structure. It can transform into a beta-type structure to match the structure. In some examples, the alpha structure can include a hexagonal crystalline phase and the beta structure can include a body centered cubic crystalline phase.

Block 10500 of method 10000 may be optional and includes coupling a face plate to a front end of a golf club head. In some instances, the golf club head may be similar to golf club head 10 as illustrated in FIG. 1 . The face plate may be engaged by engaging a face plate edge such as face plate edge 101 (FIGS. 1-2) to an opening in the front of the golf club head. In some examples, this bonding may be accomplished through a welding process and/or a brazing process.

In some examples, the cell lattice of the middle section formed in the 10320 sub-block is located in the center middle section area of the middle section, but the cell lattice and/or its cells are located in the middle section area around the middle section bordering the center middle section area. may be positioned such that they do not exist. By way of example, the peripheral mid-section region may be similar to the peripheral mid-section region 232 of the mid-section 230 bordering the central region of the mid-section 230 comprising the cell grid 240 (FIGS. 1-4). can In some embodiments, the peripheral mid-section region 230 may separate the cell grid 240 in the central mid-section region away from the face plate edge 101 by at least about 0.1 inch (2.54 mm).

In the same or another example, coupling the face plate at the 10500 block may include placing the front end of the golf club head to the inner skin perimeter area of the 10100 block, such as the inner skin perimeter area 212 (FIG. 2), to the outer skin perimeter area. bonding to the outer skin peripheral region of the 10200 block's outer skin, such as peripheral region 222 (FIG. 2), or to both. For example, the inner skin perimeter region and/or the outer skin perimeter region may be aligned with the aforementioned peripheral mid section region such that, for example, it does not contact the cell grid of the mid section center region. However, other examples may exist where the cell grid may extend throughout the middle section area of the face plate such that the area around the inner and outer skin is in contact with the cell grid.

A cell lattice formed in block 10320 may have one or more of various characteristics. For example, the plurality of cells of the cell lattice may be formed in a hexagonal pattern with respect to the cell lattice 240, as shown, for example, in FIGS. 4 and 6-7. In the same or another example, the cell grid may be formed in an isogrid pattern as also seen with respect to cell grids 240 and 740 . A cell grid may include a plurality of cell junctions where two or more of the plurality of walls are bonded together in the same or other examples. For example, the cell junction can be similar to cell junction 443 (FIGS. 4, 6) and/or cell junction 743 (FIG. 7). One or more of the cell junctions extend from the inner mid-section end of the mid-section, such as junction channel 4431 extending from the inner mid-section end to the outer mid-section end through cell junction 443 as illustrated in FIG. 6 . It may include a junction channel extending to the end of the outer mid-section.

Continuing with the examples of one or more features for the cell grid of block 10320, there may be embodiments where forming the cell grid may include forming one or more walls of the cell grid to have varying dimensions. By way of example, the cell lattice may include, for example, one of walls 741 ( FIG. 7 ) of varying length thickness dimensions, and/or one of walls 841 and/or 1141 ( FIGS. 8 and 11 ) of varying depth thickness dimensions and Same, can include walls. In the same or another example, forming the cell grid may include forming a plurality of cells in a decreasing density pattern and/or decreasing size pattern. For example, in a decreasing size pattern, the plurality of cells may decrease in size or dimension towards the target striking area of the face plate as illustrated and described with reference to, for example, FIGS. 17-18 . In a decreasing density pattern, the plurality of cells may decrease in density towards the target striking area of the face plate.

In the same or another example, a cell lattice may include one or more traversing passages between adjacent cells of the cell lattice. As an example, a cell grid may include traverse passages as illustrated in FIG. 6 , where traverse passages 644 traverse through walls 6411 between adjacent ones of cells 242 . In the same or another example, the formation of the cross-passage can be done, for example, by layered formation of the intermediate section 230 (FIGS. 1-4, 6), wherein the cross-passage feature, such as the cross-passage 644, is 10400 It may be formed in 10300 blocks per middle section layer 330 prior to performing the block.

Examples in which one face plate may include a plurality of cell lattice regions as described above with reference to FIGS. 19 to 22 may also exist. In some examples, cell grid regions of a plurality of cell grid regions may be similar to each other. In another example, two or more regions of the cell grid regions of the plurality of cell grid regions may differ from each other with respect to at least one characteristic, such as, for example, stiffness, elasticity, and/or type of cell grid configured.

In some examples, one or more of the several blocks of method 10000 can be combined into a single block or performed concurrently, and/or the order of these blocks can be changed. For example, the inner skin of block 10100 may be provided concurrently with the middle section of block 10300, and/or the outer skin of block 10200 may be provided concurrently with the middle section of block 10300. As another example, the order of subblocks 10321 and 10322 may be changed.

In the same or other examples, some of the various blocks of method 10000 may be subdivided into several sub-blocks. For example, a 10500 block may include a sub-block that fastens the face plate to the front end of the golf club head, and another sub-block that grinds the face plate and/or joint bonded to the front end of the golf club head. There may also be examples where method 10000 may include additional blocks or other blocks. Additionally, there may be examples where method 10000 may include only some of the steps described above. For example, the 10500 block may be optional in some examples. Other variations may be implemented to the method 10000 without departing from the scope of the present disclosure.

23 illustrates a flow diagram of a method 50000 of manufacturing a face plate for a golf club head. In some embodiments, the face plate is face plate 100 ( FIGS. 1-4 , 6 ) and/or described above with reference to, eg, FIGS. 7-9 , 11 , 12-22 and/or 24-27 . It may be similar to a face plate comprising one or more cell grids, such as one.

Block 50100 of method 50000 is a face plate for a golf club head having an inner skin 210, an outer skin 120, a mid section 230 and a cell grid having a plurality of holes 160 (FIG. 24) or and printing a portion of the face plate. The plurality of apertures 160 are each from a cell in the middle section of the cell grid through the inner skin, from a cell in the middle section of the cell grid through the outer skin, or from a cell in the middle section of the cell grid through the outer skin of the face plate. may be extended.

Referring to FIG. 24 , a plurality of holes may be positioned on the cell grid to allow removal of excess powdered material of the 50100 block. In some examples, at least one of the plurality of apertures 160 is located near the center or cell grid region of the face plate, and additional apertures 160 are located towards or near the periphery or cell grid region of the face plate. For example, in the embodiment illustrated in FIG. 25 , plurality of apertures 160 include a aperture located near the center of the face plate and additional apertures located around the periphery of the cell grid. In another embodiment, plurality of apertures 160 may include two or more apertures located near the center of the face plate and additional apertures located around the periphery of the face plate or cell grid area. Also, in another embodiment, as illustrated in FIG. 26 , plurality of apertures 160 are located around the periphery of the cell grid forming peripheral channels 168 with one or more apertures located near the center of the face plate. Additional holes may be included. Referring to FIG. 26 , in the illustrated embodiment, the peripheral channel has a width ranging from about 0.03 inches to about 0.05 inches. For example, the peripheral channel may have a width of about 0.03 inches, about 0.035 inches, about 0.04 inches, about 0.045 inches, or about 0.05 inches. In some embodiments, peripheral channels may be located through the inner skin of the cell grid. In other embodiments, the peripheral channels may be located through the outer skin of the cell grid.

In some examples, plurality of apertures 160 may be located on or through the face plate having the inner skin. In some examples, plurality of apertures 160 may be located on or through the face plate with the outer skin. In some examples, some of the plurality of holes 160 may be positioned on or through the face plate having the inner skin, and the remaining holes 160 are positioned on or through the face plate having the outer skin. It can be.

In some embodiments, the diameter of the plurality of apertures 160 may range from about 0.005 inches to about 0.2 inches. In some embodiments, the diameter of plurality of holes 160 may range from about 0.025 inches to about 0.075 inches, from about 0.02 inches to about 0.10 inches, or from about 0.01 inches to about 0.15 inches. For example, in the illustrated embodiment, the diameter of the plurality of apertures 160 is about 0.05 inches. Also, in the illustrated embodiment, the plurality of holes 160 each have the same diameter. In other embodiments, the plurality of holes may each have a different diameter.

In some embodiments, plurality of apertures 160 are each spaced apart from the other apertures by a distance of at least twice the diameter of the plurality of apertures. In other embodiments, each of the plurality of apertures may be spaced apart from the other apertures by a distance greater than three, four, five, or six times the diameter of the plurality of apertures.

In some examples, the faceplate of the 50100 block may be printed layer by layer using direct metal laser sintering. In another example, the faceplate may be printed using other processes such as, for example, selective laser sintering, 3D printing, stereolithography, layered object fabrication, molten deposition modeling, or electron beam melting. In some embodiments, faceplates having cell grids (eg, 1840) cannot be formed using methods other than printing. For example, in many embodiments, cells 1842 of cell grid 1840 have dimensions that are too small to cast. As a further example, in many embodiments, the contiguous cells 1842 of the cell grid 1840 avoid the use of a merger of the inner skin, middle section, and outer skin layer, since this process maintains the continuity of the middle section layer. because it needs

In some examples, the face plate may be printed using a powdered material. In some examples, the powdered material may be a powdered metal material. In some examples, the powdered metal material of the 50100 block may be a titanium alloy comprising at least about 8% aluminum by volume. In the same or another example, the metal alloy may include a titanium 8-1-1 alloy having about 8% aluminum, 1% vanadium, and 1% chromium. In the same or another example, the powdered metal material of the 50100 block contains 8% Al, 1% V and 0.2% Si, the balance of which alloy composition is a titanium alloy such as titanium and possibly some trace elements, Ti-9S. can In some embodiments, Ti-9S is 6.5% to 8.5% Al, 1% to 2% V, up to 0.08% C, up to 0.2% Si, up to 0.3% Fe, up to 0.2% O, up to 0.05%. of N, a trace amount of Mo, and a trace amount of Sn, and the balance of the alloy composition is titanium. Other materials may be used depending on their strength while considering brittleness/elasticity as a beta crystal structure. For example, a titanium 6-4 alloy with about 6% aluminum and 4% vanadium may be used in some embodiments, but may be 5% to 12% less elastic than titanium 8-1-1, thus reducing golf impact stress. Additional reinforcement or thickness may be required for the face plate 100 to withstand adequately.

Block 50200 of method 50000 includes removing excess powdered metal material from the faceplate printed in block 50100. In some examples, removing excess powdered material may be accomplished using compressed air directed toward the plurality of apertures 160 as described below.

Block 50200 of method 50000 may include a sub-block 50210 of applying compressed air to remove excess powdered material from plurality of apertures 160 . Compressed air may be directed toward the plurality of apertures 160 located at the periphery of the face plate to form voids in the excess powdered material around the periphery of the face plate. In some examples, the compressed air may have a pressure range of about 30 to 60 PSI (pounds per cubic inch).

Block 50200 of method 50000 may further include block 50220 applying force, pressure or vibration to the face plate to loosen excess powdered material in the cell grid. In some examples, force or pressure may be applied to the face plate using a rubber mallet. In another example, force or pressure may be applied to the face plate using any other method capable of loosening excess powdered material within the cell lattice. In some examples, vibration in the form of ultrasonic vibrations may be applied to the face plate. In another example, any kind of vibration that can loosen excess powdered material in the cell lattice can be applied to the face plate. In some examples, vibration may be applied to the face plate using a tumbler or shaker. In another example, any method capable of applying vibration to the face plate to loosen excess powdered material may be applied.

Block 50200 of method 50000 may further include a sub-block 50230 for applying compressed air to at least one hole 160 near the center of the face plate. Compressed air directed toward the at least one hole 160 near the center of the face plate pushes excess loose powdered material from the cell lattice to the periphery side of the face plate. In some examples, the compressed air may range in pressure from about 30 to 60 PSI.

Block 50200 of method 50000 includes applying compressed air to the periphery of the face plate in the 50230 sub-block to remove excess bloody powdered material that has moved from the center of the face plate within the cell grid to the periphery of the face plate 50230. It may further include sub-blocks. In some examples, the steps of sub-blocks 50220 and 50230 may be repeated as needed to remove any remaining excess powdered material from the cell grid of the face plate.

In method 50000, the plurality of holes 160 in the face plate serve as an exhaust system that removes excess powdered material from the cell lattice of the face plate. For simplified removal compared to faceplates that do not have at least one hole 160 located near the center of the face plate, the at least one hole 160 near the center of the face plate is placed near the center of the face plate in the cell grid. It helps to move excess powdered material from the cell grid to the peripheral side of the face plate.

Block 50300 of method 50000 may include filling the plurality of holes 160 with a material similar or identical to that of the face plate. In some examples, plurality of holes 160 may be filled by welding. In another example, the plurality of holes 160 may be filled using another method whereby the face plate may have coplanar inner and outer surfaces by filling the plurality of holes 160 .

Block 50400 of method 50000 may be optional and includes coupling a face plate or portion thereof to a front end of a golf club head. In some examples, the golf club head may be similar to golf club head 10 as illustrated in FIG. 1 . In some instances (e.g., where the entire face plate with the cell grid is formed as a single component), the face plate may have a face plate edge such as face plate edge 101 (FIGS. 1-2) in front of the golf club head. It can be coupled by coupling to the hole of In some examples, this bonding may be accomplished through a welding process and/or a brazing process. In an example where a portion of the face plate having a cell grid is formed, a portion of the face plate may be joined to the remainder of the face plate and/or the front of the golf club head through a welding and/or brazing process.

In the same or other examples, some of the blocks of method 50000 may be subdivided into several sub-blocks. Also, there may be examples where the method 50000 may include additional blocks or other blocks. For example, a step including chemical dissolution may be performed after the step of block 50200 to remove any additional excess powdered material in the cell grid. In some embodiments, chemical dissolution may be performed using an elevated temperature (e.g., about 37° C.) acidic liquid or any other material capable of removing additional excess powdered material within the cell grid. , acid is an acid having a pH less than about 4.0, such as acetic acid, benzoic acid, carbonic acid, citric acid, hydrochloric acid, nitric acid, sulfuric acid, or any other acid having a pH less than about 4.0. In some embodiments, chemical dissolution may be performed using isopropyl alcohol or any other liquid capable of removing excess powdered material within the cell grid.

As a further example, method 50000 can further include an additional step comprising bending the face plate to include a bulge. In some examples, bending of the face plate may be performed after forming the face plate with the cell grid but before joining the face plate to the front end of the club head. In another embodiment, the face plate may be formed with bulges so that secondary bending is not required. In these or other embodiments, the geometry of the cell grid is such that the cell walls are at an angle of less than about 45 degrees from a vertical axis positioned perpendicular to a plane formed by the layer of printed material when the faceplate or portion thereof is formed by printing. It can be adjusted so that it can be extended.

In the same or other examples, method 50000 may include only some of the steps described above. For example, the 50400 block may be optional in some examples. Also, there may be examples where the steps of method 50000 may be performed in a different order. For example, in some examples, block 50400 may be performed before block 50300. Other variations may be implemented to method 50000 without departing from the scope of the present disclosure.

Although the golf club face plate having an inner cell grid and related methods disclosed herein have been described with reference to specific embodiments, various changes may be made without departing from the spirit or scope of the present disclosure. For example, golf club head 10 is illustrated in FIG. 1 as a driver club head, but the disclosure herein is intended for use with other types of club heads, such as fairway woods, hybrids, and even non-cavity club heads such as putters and irons. It can also be applied to golf club heads. Additional examples of such variations are provided in the foregoing description. Other permutations of other embodiments having one or more of the various features of the various figures are also contemplated. Accordingly, the specification, claims and drawings of this application are intended to illustrate the scope of the disclosure and not to limit it. It is intended that the scope of this application be limited only to the extent necessary by the appended claims.

The golf club face plate having an inner cell grid and related methods disclosed herein may be implemented in a variety of embodiments, and the foregoing description of some of these embodiments does not necessarily represent an exhaustive description of all possible embodiments. Rather, the detailed description of the drawings and the drawings themselves disclose at least one preferred embodiment, and may disclose alternative embodiments.

Item 1: A golf club head comprising: a face plate, the face plate comprising: an inner skin; outer skin; and a cell lattice having a plurality of walls, the plurality of walls comprising: a plurality of axes centrally extending through a wall between the inner skin and the outer skin; a wall thickness that varies relative to position from the inner skin and the outer skin; and a plurality of cells formed by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin and having a cell width that varies relative to the position from the inner skin and the outer skin. a plurality of cells, the wall extending at an angle of less than about 45 degrees from the axis, the wall adjoining at a first point near the inner skin and at a second point near the outer skin A golf club head that intersects with.

Item 2: The golf club head of item 1, wherein said wall thickness is greater near said inner skin and said outer skin than near a central region of said cell grid.

Item 3: The golf club head of item 3, wherein the minimum wall thickness is in the range of 0.005 inch to 0.2 inch.

Item 4: The golf club head of item 1, wherein the maximum cell width ranges from 0.005 inches to 0.2 inches.

Item 5: The golf club head of item 1, wherein the wall thickness varies to form a plurality of hourglass shapes.

Item 6: The golf club head of item 1, wherein the center-to-center distance between adjacent said axes ranges from 0.005 inches to 0.2 inches.

Item 7: The golf club head of item 1, wherein the axis is positioned radially from the center of the face plate.

Item 8: As Cell Grid: Inner Skin; outer skin; a plurality of walls having a plurality of axes extending centrally through the wall between the inner skin and the outer skin, the walls extending at an angle of less than about 45 degrees from the axes, the walls comprising the inner skin and the outer skin; a plurality of walls, the plurality of walls having wall thicknesses that vary relative to position from the outer skin; a plurality of cells formed by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin; and a plurality of holes for removing excess material in the cell lattice, having a first hole positioned at least near the center of the cell lattice and the remaining holes positioned around the periphery of the cell lattice. Cell grid containing a.

Clause 9: The cell grid of clause 8, wherein the wall thickness is greater near the inner skin and the outer skin than near the central region of the cell grid.

Item 10: The cell grid of item 8, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches.

Item 11: The cell grid of item 8, wherein the maximum width of the cell ranges from 0.005 inches to 0.2 inches.

Item 12: The cell grid of item 8, wherein the wall thickness varies to form a plurality of hourglass shapes.

Item 13: The cell grid of item 8, wherein the center-to-center distance between adjacent said axes ranges from 0.005 inches to 0.2 inches.

Item 14: The cell grid of item 8, wherein the axis is positioned radially from a center of the cell grid.

Item 15: The cell grid of item 8, wherein the plurality of apertures are positioned through the inner skin of the cell grid or through the outer skin of the cell grid.

Item 16: The cell grid of item 8, wherein the diameter of the holes ranges from about 0.005 inches to about 0.2 inches.

Clause 17: The cell grid of clause 8, wherein each of the plurality of apertures is spaced from the other apertures by a distance greater than twice the diameter of the aperture.

Item 18: A method of manufacturing a face plate for a golf club head:

printing at least a portion of the face plate to have a cell grid, the cell grid comprising: an inner skin; outer skin; a plurality of walls having a plurality of axes extending centrally through the wall between the inner skin and the outer skin, the walls extending at an angle of less than about 45 degrees from the axes, the walls comprising the inner skin and the outer skin; a plurality of walls, the plurality of walls having wall thicknesses that vary relative to position from the outer skin; a plurality of cells formed by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin; and a plurality of holes for removing excess material in the cell lattice, positioned through the inner skin or the outer skin, at least around the periphery of the cell lattice and a first hole positioned near the center of the cell lattice. a step comprising a plurality of apertures having the remaining apertures located; removing excess powdered material from the cell grid; and filling the plurality of holes.

Item 19: The method of item 18, wherein removing the excess powdered material comprises applying compressed air to the plurality of holes positioned proximate the periphery of the cell grid, applying force or pressure to the face plate. and applying compressed air to the plurality of holes positioned proximate the center of the cell grid.

Clause 20: The golf club of clause 18, wherein the hole diameter is in the range of about 0.005 inch to 0.2 inch, and each of the plurality of holes is spaced from the other hole by a distance at least twice the diameter of the hole. A method for manufacturing the face plate of the head.

Substitution of one or more claimed elements constitutes a reconstruction, not a modification. Additionally, benefits, other advantages, and solutions to problems have been described with respect to specific embodiments. However, the benefit, advantage, solution to the problem, as well as any element or elements that may make possible any benefit, advantage, or solution that is conceived or becomes more evident, is such that such benefit, advantage, solution, or element is within the scope of a claim. It should not be construed as an important, necessary, or necessary feature or element of any or all of the claims, unless expressly stated in

As the rules for golf may change from time to time (e.g., new rules may be adopted by golf standards bodies and/or governing bodies such as the United States Golf Association (USGA), Royaland Ancient Golf Club of St. Andrews (R&A), etc.) Rules may be removed or modified), golf equipment associated with the devices, methods and articles of manufacture described herein may or may not conform to the Rules of Golf at any given time. Accordingly, golf equipment associated with the devices, methods, and articles of manufacture described herein may be advertised, offered for sale, and/or sold as compliant or non-compliant golf equipment. The articles of manufacture, methods, and apparatus described herein are not limited thereto.

Although the foregoing examples may have been described with respect to driver type golf clubs, the articles of manufacture, methods and apparatus described herein may be used for fairway wood type golf clubs, hybrid type golf clubs, iron type golf clubs, wedge type golf clubs, or It may also be applied to other types of golf clubs, such as putter type golf clubs. Alternatively, the articles of manufacture, methods, and apparatus described herein may be applied to other types of sports equipment, such as hockey sticks, tennis racquets, fishing rods, ski poles, and the like.

Moreover, the embodiments and limitations disclosed herein are provided so that those embodiments and/or limitations are: (1) not expressly claimed in the claims, and (2) subject to the doctrine of equivalents as express elements of the claims and and/or limited equivalents or potential equivalents, they are not dedicated to the public according to the theory of public consecration.

Claims (20)

As a golf club head:
face plate
Including, the face plate is:
inner skin;
outer skin; and
Cell grid with multiple walls
and wherein the plurality of walls:
a plurality of shafts centrally extending through a wall between the inner skin and the outer skin;
a wall thickness that varies relative to position from the inner skin and the outer skin; and
a plurality of cells formed by the plurality of walls, the plurality of cells positioned between the inner skin and the outer skin and having a cell width that varies relative to the position from the inner skin and the outer skin; cell of
wherein the wall extends at an angle of less than 45 degrees from the axis, the wall intersects an adjacent wall at a first point near the inner skin and at a second point near the outer skin. in golf club head. 2. The golf club head of claim 1 wherein said wall thickness is greater near said inner skin and said outer skin than near a central region of said cell grid. 2. A golf club head according to claim 1, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches. 2. A golf club head according to claim 1, wherein the maximum cell width ranges from 0.005 inches to 0.2 inches. 2. The golf club head of claim 1, wherein the wall thickness varies to form a plurality of hourglass shapes. 2. The golf club head of claim 1, wherein the center-to-center distance between adjacent axes is in the range of 0.005 inches to 0.2 inches. 2. The golf club head of claim 1 wherein the axis is positioned radially from the center of the face plate. As a grid of cells:
inner skin;
outer skin;
A plurality of walls having a plurality of axes extending centrally through the wall between the inner skin and the outer skin, the walls extending at an angle of less than 45 degrees from the axes, the walls comprising the inner skin and the outer skin. a plurality of walls, the plurality of walls having wall thicknesses that vary relative to position from the skin;
a plurality of cells formed by said plurality of walls, said plurality of cells positioned between said inner skin and said outer skin; and
A plurality of holes for removing excess material in the cell lattice, having a first hole positioned at least near the center of the cell lattice and the remaining holes positioned around the periphery of the cell lattice.
Cell lattice comprising a. 9. The cell grid of claim 8, wherein the wall thickness is greater near the inner skin and the outer skin than near the central region of the cell grid. 9. The cell grid of claim 8, wherein the minimum wall thickness ranges from 0.005 inches to 0.2 inches. The cell grid according to claim 8, wherein the maximum width of the cell is in the range of 0.005 inch to 0.2 inch. 9. The cell grid of claim 8, wherein the wall thickness varies to form a plurality of hourglass shapes. 9. The cell grid of claim 8, wherein a center-to-center distance between adjacent said axes ranges from 0.005 inches to 0.2 inches. 9. The cell grid of claim 8, wherein the axis is positioned radially from the center of the cell grid. 9. The cell grid of claim 8, wherein the plurality of apertures are positioned through the inner skin of the cell grid or through the outer skin of the cell grid. 9. The cell grid of claim 8, wherein the diameter of the apertures ranges from 0.005 inches to 0.2 inches. 9. The cell grid of claim 8, wherein each of the plurality of holes is spaced apart from the other holes by a distance equal to or greater than twice the diameter of the hole. A method of manufacturing a face plate for a golf club head comprising:
Printing layer by layer at least a portion of the face plate to have a cell grid, the cell grid comprising:
inner skin;
outer skin;
A plurality of walls having a plurality of axes extending centrally through the wall between the inner skin and the outer skin, the walls extending at an angle of less than 45 degrees from the axes, the walls comprising the inner skin and the outer skin. a plurality of walls, the plurality of walls having wall thicknesses that vary relative to position from the skin;
a plurality of cells formed by said plurality of walls, said plurality of cells positioned between said inner skin and said outer skin; and
A plurality of holes for removing excess material in the cell lattice, located through the inner skin or the outer skin, around the periphery of the cell lattice and a first hole positioned at least near the center of the cell lattice. A plurality of holes, with the remaining holes being positioned
Including, step;
removing excess powdered material from the cell grid; and
Filling the plurality of holes
A method for manufacturing a face plate of a golf club head comprising a. 19. The method of claim 18, wherein removing the excess powdered material comprises:
applying compressed air to the plurality of holes positioned near the periphery of the cell grid;
applying force or pressure to the face plate; and
applying compressed air to the plurality of holes positioned near the center of the cell grid;
A method of manufacturing a face plate of a golf club head comprising a. 19. The manufacture of a face plate for a golf club head according to claim 18, wherein the diameter of the holes ranges from 0.005 inches to 0.2 inches, and each of the plurality of holes is spaced from the other holes by a distance of at least twice the diameter of the hole. method.

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