US 11,806,587 B2
Method of manufacturing golf club head having stress-reducing features
Evan D. Gibbs, Encinitas, CA (US); Alan Hocknell, Encinitas, CA (US); Austin L. Frederickson, San Diego, CA (US); Christopher A. G. Nunez, Escondido, CA (US); James A. Seluga, Carlsbad, CA (US); Matthew Myers, Carlsbad, CA (US); Matthew Hannen, Carlsbad, CA (US); Bart R. Fliers, Vista, CA (US); and Robert S. Gonczi, Oceanside, CA (US)
Assigned to Topgolf Callaway Brands Corp., Carlsbad, CA (US)
Filed by Callaway Golf Company, Carlsbad, CA (US)
Filed on Sep. 6, 2022, as Appl. No. 17/903,868.
Application 16/411,491 is a division of application No. 15/912,247, filed on Mar. 5, 2018, granted, now 10,335,647, issued on Jul. 2, 2019.
Application 17/903,868 is a continuation of application No. 17/396,971, filed on Aug. 9, 2021, granted, now 11,433,282, issued on Sep. 6, 2022.
Application 17/396,971 is a continuation of application No. 16/742,743, filed on Jan. 14, 2020, granted, now 11,083,937, issued on Aug. 10, 2021.
Application 16/742,743 is a continuation in part of application No. 16/411,491, filed on May 14, 2019, granted, now 10,532,258, issued on Jan. 14, 2020.
Application 15/912,247 is a continuation of application No. 15/808,025, filed on Nov. 9, 2017, granted, now 9,931,550, issued on Apr. 3, 2018.
Application 15/808,025 is a continuation in part of application No. 15/637,902, filed on Jun. 29, 2017, granted, now 9,981,167, issued on May 29, 2018.
Application 15/637,902 is a continuation in part of application No. 15/628,514, filed on Jun. 20, 2017, granted, now 9,908,017, issued on Mar. 6, 2018.
Application 15/628,514 is a continuation of application No. 15/447,638, filed on Mar. 2, 2017, granted, now 9,687,702, issued on Jun. 27, 2017.
Application 15/637,902 is a continuation of application No. 15/446,754, filed on Mar. 1, 2017, granted, now 9,694,257, issued on Jul. 4, 2017.
Application 15/446,754 is a continuation in part of application No. 15/279,188, filed on Sep. 28, 2016, granted, now 9,687,701, issued on Jun. 27, 2017.
Application 15/447,638 is a continuation in part of application No. 15/279,188.
Application 15/279,188 is a continuation of application No. 14/847,227, filed on Sep. 8, 2015, granted, now 9,486,677, issued on Nov. 8, 2016.
Application 14/847,227 is a continuation in part of application No. 14/788,326, filed on Jun. 30, 2015, granted, now 9,597,558, issued on Mar. 21, 2017.
Claims priority of provisional application 62/442,892, filed on Jan. 5, 2017.
Prior Publication US 2023/0277903 A1, Sep. 7, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. B22C 7/02 (2006.01); B22C 9/04 (2006.01); B22C 9/24 (2006.01); A63B 53/04 (2015.01); B21K 17/00 (2006.01); A63B 60/02 (2015.01); A63B 60/52 (2015.01); A63B 60/42 (2015.01)
CPC A63B 53/0466 (2013.01) [A63B 60/02 (2015.10); A63B 60/52 (2015.10); B21K 17/00 (2013.01); B22C 7/02 (2013.01); B22C 9/04 (2013.01); B22C 9/24 (2013.01); A63B 53/045 (2020.08); A63B 53/047 (2013.01); A63B 53/0408 (2020.08); A63B 53/0412 (2020.08); A63B 53/0433 (2020.08); A63B 53/0437 (2020.08); A63B 53/0454 (2020.08); A63B 53/0458 (2020.08); A63B 60/42 (2015.10); A63B 2053/0491 (2013.01); A63B 2209/00 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method comprising the steps of:
preparing a wax of a golf club head body, the wax of the golf club head body comprising a striking face section, a sole section extending from a lower edge of the striking face section, and a return section extending from an upper edge of the striking face section, the striking face section, sole section, and return section defining a hollow body interior, the return section comprising an elongated through-hole, and the sole section comprising an elongated receiving pocket;
preparing a wax of a plate comprising an upper end and a lower end;
inserting the plate into the elongated through-hole and seating the lower end in the elongated receiving pocket;
bonding the plate to the body with an adhesive material to form a combined wax mold; and
casting a golf club head from the combined wax mold,
wherein the through-hole is aligned with the receiving pocket,
wherein the plate is located within 1 inch of a rear surface of the striking face section measured along a vertical plane extending through a face center perpendicular to the striking face section, and wherein the plate comprises at least one cutout.
 
11. A method comprising the steps of:
preparing a wax of a golf club head body, the wax of the golf club head body comprising a striking face section, a sole section extending from a lower edge of the striking face section, and a return section extending from an upper edge of the striking face section, the striking face section, sole section, and return section defining a hollow body interior, the return section comprising an elongated receiving pocket, and the sole section comprising an elongated through-hole;
preparing a wax of a plate comprising an upper end, a lower end, and at least one cutout;
inserting the plate into the elongated through-hole and seating the upper end in the elongated receiving pocket so that the plate is located within 1 inch of a rear surface of the striking face section measured along a vertical plane extending through a face center perpendicular to the striking face section;
bonding the plate to the body with an adhesive material to form a combined wax mold; and
casting a golf club head from the combined wax mold, and
wherein the elongated through-hole is aligned with the receiving pocket.
 
17. A method comprising the steps of:
preparing a wax of a golf club head body, the wax of the golf club head body comprising a striking face section, a sole section extending from a lower edge of the striking face section, and a return section extending from an upper edge of the striking face section, the striking face section, sole section, and return section defining a hollow body interior, the return section comprising an elongated receiving pocket, and the sole section comprising an elongated through-hole;
preparing a wax of a plate comprising at least one cutout, an upper end, and a lower end;
inserting the plate into the elongated through-hole and seating the upper end in the elongated receiving pocket so that the plate is located within 1 inch of a rear surface of the striking face section measured along a vertical plane extending through a face center perpendicular to the striking face section;
bonding the plate to the body with an adhesive material to form a combined wax mold;
applying hot wax to the lower end of the plate to seal the lower end of the plate to the sole section; and
casting a golf club head from the combined wax mold,
wherein the through-hole is aligned with the receiving pocket,
wherein the plate has a length of 1 inch to 2.5 inches,
wherein the plate extends through the hollow body interior approximately parallel with the rear surface, and
wherein the plate comprises a plurality of cutouts.