Note: Descriptions are shown in the official language in which they were submitted.
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GOLF CLUBS PREPARED WITH BASALT FIBER
BACKGROUND
[oil Golf is enjoyed by a wide variety of players - players of different
genders and players
of dramatically different ages and skill levels. Golf is somewhat unique in
the
sporting world in that such diverse collections of players can play together
in golf
events, even in direct competition with one another (e.g., using handicapped
scoring,
different tee boxes, in team formats, etc.), and still enjoy the golf outing
or
competition. These factors, together with increased availability of golf
programming
on television %(e.g., golf tournaments, golf news, golf history, and/or other
golf
programming) and the rise of well known golf superstars, at least in part,
have
increased golf's popularity in recent years both in the United States and
throughout
the world. The number of individuals participating in the game and the number
of
golf courses have increased steadily over recent years.
[02] Golfers at all skill levels seek to improve their performance, lower
their golf scores,
and reach that next performance "level." Manufacturers of all types of golf
equipment have responded to these demands, and recently, the industry has
witnessed
dramatic changes and improvements in golf equipment. For example, a wide range
of
different golf ball models now are available, with some balls designed to
complement
specific swing speeds and/or other player characteristics or preferences,
e.g., with
some balls designed to fly farther and/or stra.ighter, some designed to
provide higher
or flatter trajectories, some designed to provide more spin, control, and/or
feel
(particularly around the greens), etc. A host of swing aids and/or teaching
aids also
are available on the market that promises to help lower one's golf scores.
[031 Being the sole instruments that set golf balls in motion during play,
golf clubs also
have been the subject of much technological research and advancement in recent
years. For example, the market has seen improvements in putter designs, golf
club
head designs, shafts, and grips in recent years. Additionally, other
technological
advancements have been made in an effort to better match the various elements
and/or
characteristics of the golf club and/or characteristics of a golf ball tf) a
particular
user's swing features or characteristics (e.g., club fitting technology, ball
launch angle
measurement technology, ball spin rate characteristics, etc.).
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[04] Conventional golf clubs have three basic parts, a grip, a shaft, and a
head. As shown
by the golf club 100 in Figure 1, a grip 101 is attached to/around the upper
portion of
shaft 102. The shaft 102 connects the grip 101 to the head 103. The shaft 102
is held
by the golfer and the head 103 is the part that actually strikes the ball.
[05] The golfer holds grip 101 of the golf club 100. With the exception of
grips for
putters, the grip 101 generally is round and generally without obvious bumps,
lumps,
or hollows. Cuips can be made of any suitable material, generally polymers,
rubber or
leather, and can contain small holes, grooves, ridges, cord elements, or
fabric
materials designed to make it easier for the golfer to hold onto the club 100
without
making the grip 101 so large that it will violate the Rules of Golf. There are
various
sizes of grips to accommodate different hand sizes and grip styles. The
material and
design of the grip are. generally a matter of personal preference.
[06] The shaft 102 of the golf club 100 connects between the grip 101 and the
head 103
and, like the grip, is basically round in cross section. The shaft 102 may be
a straight
or generally a tapered tubular member roughly, but not limited to, '/a inch in
diameter
(12 mm) near the grip, and generally between 18 and 48 inches (48-122 cm) (and
typically between 35 to 45 inches (89-115 cm) in length.
[071 Most modern golf club shafts typically have been made of steel or fiber-
reinforced
resin composites utilizi.ng fibers such as fiberglass and carbon or graphite
fiber.
Carbon fiber composites are lighter than steel, but they tend to be more
expensive.
.Some shafts utilize two or more types of material, such as a graphite
composite shaft
with a steel tip.
[08] Figure 2 shows a conventional head 103 of a golf club. The typical head
103 has
several parts: the hosel 104, where the head 103 connects to the shaft 102;
the face
105, which actually strikes the ball; the sole 106, which is the part closest
to the
ground; the back (not shown in Figure 2), which is on the side opposite the
face 105,
and the top 109. The sides 110 extend between the top 109 and the sole 106 at
both
the heel side and the toe side of the club head 103. The face 105 may be
formed to
include a separate face plate, e.g., forrued from metal, that is attached to a
framework
defined by the remainder of the club head.
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[09] The head 103 of the golf club is where all the energy of the swing is
transferred to the
golf ball. There are a variety of different types of golf club heads,
including, for
example: the heads of woods, irons, wood-type hybrid clubs, iron-type hybrid
clubs,
and putters.
[10] Woods or drivers have the largest heads of any golf club. Several of
these large clubs
are designed to propel the ball long distances, e.g., 300 yards or more with a
single
swing. The large head of a driver or other woods and the materials from which
they
are made, such as metals (e.g., steel, titanium, aluminum, and bronze),
fiberglass
reinforced resin composites, or carbon fiber-reinforced resin composites, are
balanced
to provide stability and light weight. The driver or wood head shape,
including wood-
type hybrid club heads, allows the weight in the head to move to points that
enhance
stability. The driver or wood head shape also allows the head to glide over
grass and
ground rather than digging into the turf.
[11] Irons are designed for a greater variety of shots than woods. Woods or
drivers tend to
be optimal for long to very long shots, whereas irons are used for shots that
range
from less than 300 yards down to 40 yards or less. Relatively recent
developments
with perimeter weighting and cavity back designs have made irons more
"forgiving"
and easier for the average golfer to hit.
[12] Putters are designed to strike the golf ball with a face that is
substantially
perpendicular to the intended ball path with a relatively gentle swing that
will cause
the ball to roll along the ground until it stops or falls into a hole. Putter
heads may be
found in a wide array of shapes -- blocks, blades, short, long, thick, thin,
etc.,
optionally with various patterns of lin.es found on the faces or even smooth
faces.
[13] The "number" cr name associated with a club generally is related to the
angle at
which the face 105 slopes back from vertical when the club is held in its
normal
position facing the ball. A higher number for the club represents a greater
degree of
slope awav from vertical, generally resulting in a higher, shorter shot as
compared
with lower numbered clubs.
[141 Tlce slope is important for propelling a golf ball with the desired
trajectory through the
air and for imparting spin. Typically, the greater the slope, the greater the
spin. A
rapid spin provides aerodynamic lift, causing a spinning ball to travel higher
and
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farther than one with no spin at all. The spinning ball is also less
influenced by small
gusts of wind, making for a more predictable shot. (3rooves in the face 105
will also
help provide spin.
[15] The grooves on the face of a golf head provide a bit of "bite" or
friction for the golf
ball as it slides up the face, helping it to spin more rapidly. In addition,
if grass is
trapped between the ball and club at impact, the water in the grass will be
squeezed
out by the force generated by the average swing. Similar to an automobile tire
tread,
the grooves on the club face give the water somewhere to go so that the ball
does not
slcid up the club face without spinning.
[16) Ideally, the sole of the golf club will help minimize the twisting of a
poor swing.
Woods and wood-type hybrid clubs have a relatively broad, flat sole with
rounded
edges to help the head glide over the surface of the grass without digging
into the turf.
Irons, on the other hand, tend to be hit so as to produce divots in the turf,
so the soles
of iron golf clubs (including iron-type hybrid clubs) typically are designed
to slice
through the turf evenly, without twisting or unexpected tagging to disrupt the
golfefs
shot.
[17] It is known to use fiber-reinforced resin composites in the construction
of golf club
shafts. Such reinforcing fibers include carbon fiber, polyamide fiber, glass
fiber,
boron fiber, alumina fiber, aramid fiber, Tyrannom fiber, and amorphous fiber.
The
fiber-reinforced resin composite may be used in layered structures, molded
structures,
and combinations thereof. Examples of the variety of uses of fibers in the
construction of golf club shafts include, but are not limited to, those
described in U.S.
Patent Nos. 4,157,181; 6,354,957; and 6,572,490; and U.S. Patent Publication
No.
2005/0107182. Each of these documents is entirely incorporated herein by
reference.
1181 Carbon fiber composite materials also are known for use in golf club
heads, including,
for example, as part of the crown or body of a wood-type club head structure.
Examples of patents illustrating such carbon composite containing club head
structures include: U.S. Patent Nos. 6,491,592 and 6,739,982. These patents
also are
entirely incorporated herein by reference.
[19] Carbon fiber is particularly preferable and used in golf club heads and
golf club shaft
structures due to its superior strength and modulus, or stiffiless. Carbon
fiber,
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however, is expensive and may be cost prohibitive. Fiber glass is a low cost
alternative to carbon fiber, but it has physical properties inferior to carbon
fiber.
Thus, a low cost altemative to carbon fiber would be desirable.
SUNIlVIARY
[20] This invention relates to golf clubs having heads and shafts, such as
putters, irons
(including all types of wedges), hybrid type clubs (both iron-type hybrid
clubs and
wood-type hybrid clubs), faiuway woods, drivers, and the like. One aspect of
the
invention is the use of basalt material, in particular basalt fiber, in the
design of
composite golf club shafts and heads. Basalt fiber is superior to fiber glass,
approaching the performance of carbon fiber materials, but at a much lower
cost.
[22) Golf clubs and golf club heads according to at least some example aspects
of this
invention may include: (a) a club shaft member constructed, at least in part,
from
basalt material and/or (b) a club head body member constructed, at least in
part, from
a basalt material. Optionally, if desired, the club shaft member and/or the
club head
body member may be of a multi-piece construction, and any one or more of these
multiple pieces may be formed from a basalt material without departing from
this
invention.
[22] Additional aspects of this invention relate to methods of making and/or
using golf
club shafts and/or golf club heads that include basalt material forming at
least a
portion of the club shaft and/or club head structure.
[231 'Another aspect of the invention relates to a light weight, optionally
tapered, tubular
structure that provides superior performance for a wide variety of
applications,
especially in golf club shafts, but also in other products such as fishing
rods, sld poles,
knitting needles, croquet mallets, racquets, bats, billiard cue sticks, tools,
tool handles,
etc.
DESCRIPTION OF THE DRAWINGS
[24] The foregoing Summary, as well as the following Detailed Description,
will be better
understood when read in conjunction with the accompanying drawings.
[25] Figure 1 depicts a typical golf club having a grip, shaft and head.
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[26] Figure 2 depicts a typical golf club head.
[27] Figure 3 depicts a putter type golf club.
[28] Figure 4 depicts an iron type golf club head.
[29] Figure 5 depicts a wood-type golf club head.
[30] Figures 6 through 6c depict various features of an elongated tubular
structure for
various potential products according to the invention.
DETAILED DESCRIPTION
1. General Description of Aspects of the Invention
1311 The following description and the accompanying figures disclose features
of golf club
shafts and golf club heads in accordance with the present invention (e.g.,
woods,
irons, hybrids, putters, etc.). Various examples of the use of basalt
materials in golf
club head and shaft structures in accordance with aspects of the present
invention will
now be described. However, the invention is not limited to any particular
design of
the golf club shaft or heads.
[32] Generally, in accordance with at least some example aspects of this
invention, basalt
material is used to replace metal in an overall club shaft or head structure
to save
weight (e.g., basalt fibers in a resin matrix typically are lighter than the
same volume
of metal, but the resulting basalt fiber-reinforced composite material remains
strong).
In a golf club head structure, for example, this "saved" weight can be moved
to
various desired locations in the club head structure, e.g., to the back and
bottom sides
of the club head structure, which improves the performance of the club to
strike the
golf ball well with improved accuracy and farther distance or helps the club's
"hit-
ability" (a lower and deeper center of gravity helps golfers get the ball
airborne and
helps prevent club head twist [increasing club head moment of inertia]); to
the toe
side of the club head structure (to provide a fade biased and/or hook
correcting club
he=_=d. structure); to the heel side of the club head structure (to provide a
draw biased
and/or slice correcting club head structure); around the club head perimeter,
etc.
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[33) In general, the basalt material can be used in a wide variety of
locations in a club
structure (e.g., as a basalt fiber-reinforced composite material). For
example, in
accordance with at least some examples of this invention, basalt fibers will
be used to
form at least a portion of the club head body (e.g., often engaged with a
steel,
aluminum, magnesium, or titanium alloy used as the face member). The basalt
material can be used, for example, as at least a portion of one or more of a
crown
member, a sole member, and/or a skirt or ribbon portion of the club head. In
many
instances, the entire rear portion of the club head (e.g., its "aft body'
rearward from a
face member) will be made from the basalt material (e.g., attached to a metal
[e.g., a
steel, aluminum, magnesium, or titanium metal or alloy material] face cup
including
the ball strildng surface). Club heads also could have a basalt material face
plate
member (e.g., as the ball striking face, as a frame member for holding a
separate ball
striking face, etc.). In one particular aspect of the invention, the basalt
material may
be used in a wood or hybrid type golf club structure, such as in a driver,
fairway
wood, and/or wood-type hybrid club head structure.
[34] Alternatively, if desired, the entire club head may be made of basalt
material, e.g., in
the form of a basalt fiber reinforced resin composite, which may be formed
into the
proper configuration by any desired method, including by conventional fiber-
reinforced material production techniques that are known and used in the art
(e.g.
compression molding, resin transfer molding RTM, vacuum assisted resin
transfer
molding VARTM, prepreg lay up, etc.). A metal cover or ball striking plate may
cover the face or fit into an opening provided in the face, if desired.
[35] Various examples of the production of golf clubs and other structures,
including
structures according to the present invention and results obtained using such
structures, are provided below. Those skilled in the art will recognize,
howr,ver, that
the scope of the present invention is in no way limited to these examples or
the results
achieved thereby.
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H. Detailed Description of Example Golf Club Heads and Other Structures
According to the Invention
A. Basalt - Basalt Fibers - Reinforced Resins
[36] Generally, basalt is a hard, dense, dark volcanic rock composed chiefly
of plagioclase,
pyroxene, and olivine, and often has a glassy appearance. Basalt has been
mainly
used as a crushed rock in construction, industrial and highway engineering.
Basalt
also can be made into fine, superfine, and ultra fine fibers. Techniques for
making or
spinning basalt into fibers are known in the art.
[37] Basalt fibers are superior to many other fibers in terms of thermal
stability, heat and
sound insulation properties, vibration resistance, and durability. Basalt
fiber products,
for example, can provide very low thermal conductivity and can withstand
worlcing
temperatures in excess of 816 T. Moreover, products made with basalt fibers
have
no toxic reaction with air or water, are non-combustible, explosion proof, and
have a
long service life. When in contact with other chemicals, basalt fibers produce
no
chemical reactions that may damage health, the environment, or the general
structural
integrity of the construction into which the basalt fiber is built. Basalt is
both allcali
and acid resistant
[38] Basalt fibers also provide good tensile strength in products. For
example, basalt
reinforcement rods made of a unidirectional composite of basalt fibers, used
to
replace steel rebar, can have a tensile strength of 1200 MPa.
[39] Basalt may be in the form of continuous or discontinuous fibers,
particles, flakes,
whiskers, filaments, ribbons, and rods. Basalt fibers, for example, generally
can have
diameters from approximately 9 gm to 23 - m. Discontinuous or chopped basalt
fibers, for example, generally can have a length of 1 cm to 5 cm.
[40] Basalt material may also be produced in the form of sheets, mats, felts,
grids, meshes,
woven members, braided members, lattice network members, textiles, or mixtures
thereof prepared from, for example, continuous or discontinuous fibers,
particles,
flakes, whiskers, filaments, ribbons, rods and combinations thereof.
[41] The invention will be generally described in terms of use of "basalt
material," which
is intended to refer to any suitable form of basalt, including, but not
limited to: basalt
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fibers: basalt fiber-reinforced materials (such as polymers, metals, composite
materials, and the like): structures containing basalt in the form of sheets,
mats, felts,
grids, meshes, woven members, braided members, lattice network members,
textiles,
or mixtures thereof; and the like.
[42] In a particular aspect of the invention, the basalt material is combined
with a suitable
polymer matrix to form a basalt reinforced polymer composite. As a more
specific
example, the basalt is used in the form of fibers to produce a basalt fiber-
reinforced
product by incorporating basalt fibers into a suitable polymer matrix.
[43] Any desired polymer matrix or base material may be used and reinforced
with basalt
materials, including basalt fibers, without departing from this invention. For
example,
the polymer matrix may comprise: thermosetting resins, such as epoxy resins,
phenol
or urea formaldehyde resins, polyurethane resins, polyester resins, vinyl
ester resins
and the like; and thermoplastic resins, such as polypropylene resins,
polyether ether
ketone resins, acrylonitrile-butadiene-styrene resins, nylon resins, etc.
Other
examples include, but are not limited to, polyphenylene sulfide, polysulfone,
polyethylene terephthalate, and polycarbonate resins.
[44] Prior to mixing with the polymer matrix, the basalt fibers can be treated
or coated
with a chemical sizing or treated to modify surface energy, e.g., to make them
more
compatible with the polymer matrix. The sizing treatment may include, for
example,
coating with epoxy or phenolic resins, treating with acid, atmospheric plasma,
corona
discharge, or the like.
[45] The invention will be generally described in terms of a resin, but any
suitable polymer
matrix may be used. Basalt fibers, for example, are mixed with the resin so as
to form
a basalt fiber-reinforced resin composition. Generally the reinforcement
composition
in the resin matrix may range from 5 wt% to 70 wt% reinforcement or
approximately
2 vol% to 50 vol% reinforcement. Generally more preferred the reinforcement
composition in the resin matrix may range from 30 wt% to 50 wt% reinforcement
or
anproximately 13 vol% to 27 vol% reinforcement, depending on the performance
requirements of the application and the form of the basalt material including,
for
example, sheets, mats, felts, grids, meshes, woven members, braided members,
lattice
network members, textiles, or mixtures thereof prepared from, for example,
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continuous or discontinuous fibers, particles, flakes, whiskers, filaments,
ribbons, rods
and combinations thereof.
roperty nits asalt -Glass Carbon on
ow cost modulus
Density IG g/cm3 .75 .6 1.8 1.9
ensile strength Pa) 1840 3450 890 750
lastic modulus Pa) 89 77 130 190
[46] The basalt fiber-reinforced resin composition may then be formed into the
head of -a
golf club, the shaft of a golf club, or into a tubular member. The basalt
fiber-
reinforced composite may form all or part of the shaft, head, and/or other
member, as
known in the art for use of other fiber-reinforced resin composites, such
carbon fiber-
and fiberglass-reinforced composites.
[47] In view of the above description of basalt materials, more specific
examples of golf
club structures and other structures according to the invention incorporating
such
composites are provided below.
B. Example Head Structures
[48] Golf club heads according to at least some example aspects of this
invention may
include a club head body member constructed, at least in part, from basalt
material.
Generally, in accordance with at least some examples of this invention, at
least a
portion of the club head may.be made from basalt material. For example; the
head
may be formed entirely or partially from a basalt material. Any or part of one
or more
of the hosel, face, sole, back, crown, top, and sides of the club head,
including the ball
striking face and/or a frame for holding the ball striking face, may be formed
entirely
or partially of a basalt material. Such heads may be constnicted in any
suitable
manner, including, for example, in conventional manners known and used in the
art
for forming club heads or portions thereof from prior art fiber-reinforced
composites
(such as carbon-fiber reinforced materials). As some more spe:.ific examples,
if
desired, the club head may be formed to include one or more of a crown member,
a
skirt member, a ribbon member, an aft body member, a face cup or other face
member, a hosel member, a sole plate member, a ball-striking member, etc. from
a
basalt material (e.g., a basalt fiber-reinforced material). The parts of the
head may be
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manufactured by integrally forming one or more of these parts as a unitary,
one-piece
construction; by forming multiple, sepatate parts and joining them together,
e.g.,
using an adhesive, cement, mechanical connectors, fusing techniques, etc.; or
the like.
1. Putter Structures
[49] One example aspect of this invention relates to putter structures that
include one or
more parts made, at least in part, from basalt material.
[50] Figure 3 illustrates an example of parts for a putter stracture 300 that
may be made
from basalt material in accordance with at least some examples of this
invention. The
head member 302, as illustrated in Figure 3, includes a face member 304 that
faces a
golf ball (or other ball) when the club head is used. The body member 302 in
this
illustrated example essentially is rectangular cubic shaped such that a back
member
306 is located opposite the face 304. Of course, a wide variety of sizes,
shapes, and
orientations of body member 302 and/or other putter head designs may be used
without departing from the invention, including, for example, mallet type
putter
heads, blade type butter heads, etc.
[51] Basalt material may be used for part of or the entirety of the head. For
example,
= basalt material may be used in face member 304, back member 306, and/or
shaft
mounting member (hosel member) 312. The body member 302 may be made of
basalt material and a faceplate, e.g., a metal or polymeric ball striking face
piece, may
be attached to the face member 304.
[521 If desired, in accordance with at least some examples of the invention,
the club head
302 may include weighted regions, e.g., located in the rear and/or toward the
heel and
toe regions of the club head 302. Weighted regions of this type can assist in
increasing the club head's moment of inertia, thereby reducing club head twist
during
a swing. Of course, the weighted regions may be provided in any desired manner
without departing from the invention, e.g., by attaching one or more separate
weight
elements 'to the club head stricture (e.g., in weight receiving receptacles),
by
integrally forming the weighted region into the remainder of the club head
structure,
by applying lead tape or other weighted adhesive material, by plasma spraying,
etc.
Also, the weighted regions may be provided in either or both of the club
head's
interior or exterior structure without departing from this invention.
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[53] Any desired type of shaft member 310 may be used in the putter structure
300 without
departing from the invention, including shaft members 310 of conventional
design
and made of conventional materials as are known and used in the art,
including, for
example, steel, titanium, aluminum, nickel, tungsten, magnesium, graphite,
polymers,
or composites, or combinations thereof (including alloys of the various metals
noted
above). Alternatively, if desired, either or both of the hosel or other shaft
mounting
member 312 and/or the shaft member 310 may be made, at least in part, from a
basalt
material.
[54] A grip element 314 may be positioned on the shaf1310 to provide a golfer
with a slip
resistant surface with which to grasp golf club shaft 310. The grip element
may be
attached to the shaft member 310 in any desired manner, including in
conventional
manners known and used in the art (e.g., via adhesives or cements, mechanical
connectors, etc.).
[55] As noted above, basalt materials, including basalt fiber-reinforced
materials may be
used in any type of putter structure, including, for example, one or more of
the various
parts of the example putters illustrated in U.S. Published Patent Appln. No.
2006/0052178, which document is entirely incorporated herein by reference.
2. Example Iron Type Golf Club Structures
[56] Putters are not the only types of golf clubs that can take advantage of
the weight
saving and other favorable properties of basalt materials. These materials
also can be
used, for example, in iron type golf club structures. Referring to Figure 4, a
golf club
400 in ar;cordance with at least some examples of this invention is
illustrated. This
exampl: golf club 400 includes a shaft member 410 and a golf club head member
402.
The golf club head member 402 of Figure 4 may be representative of any iron or
hybrid type golf club head, including, for example, 0 through 10 irons,
pitching
wedges, lob wedges, gap wedges, sand wedges, iron-type hybrid clubs, etc..
[57] The shaft member 410 of golf club 400 may be made of various materials,
such as one
or more of steel, titanium, graphite, or composite materials, as well as
combinations
thereof, including materials that are conventionally known and used in the
art. As
another example, if desired, the shaft member 410 may be made, at least in
part, frmm
a basalt material. Additionally, the shaft member 410 may be attached to the
club
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head 402 in any desired manner, including in conventional manners known and
used
in the art (e.g., via adhesives or cements at a hosel element 412 (which
itself may be
made, at least in part, from a basalt material), via threads or other
mechanical
connectors, etc.).
[58] A grip element (not shown but similar to the grip shown in Figure 3) may
be
positioned on the shaft member 410 to provide a golfer with a slip resistant
surface
with which to grasp golf club shaft member 410. The grip element may be
attached to
the shaft member 410 in any desired manner, including in conventional manners
known and used in the art (e.g., via adhesives or cements, mechanical
connectors,
etc.).
[591 As shown in Figure 4, the golf club head 402 includes a heel portion 408
and a toe
portion 404. The heel portion 408 is attached to and/or extends from a hosel
412
(e.g., as a unitary or integral one-piece construction) for connecting the
shaft member
410 to the golf club head 402. The golf club head 402 also includes a top
portion 414
and a sole portion 416. A striking face 418 is provided between the top
portion 414
and the sole portion 416, and between the toe portion 404 and the heel portion
408.
The striking face 418 provides a contact area for engaging and propelling a
golf ball
in an intended direction. The striking face 418 may include grooves 420 (e.g.,
generally horizontal grooves 420 extending across the face 418 in the
illustrated
example) for the removal of water and grass from the striking face 418 during
a ball
strike. Of course, any number of grooves and desired groove pattern may be
provided
(or even no groove pattern ,. if desired), without departing from this
invention.
[601 The golf club head 402 may be constructed from a wide variety of
different materials,
including materials known and used in the art, such as steel, titanium,
aluminum,
nickel, tungsten, magnesium, graphite, polymers, or composites, or
combinations
thereof (including alloys of the various metals noted above). Advantageously,
in
accordance with at least some examples of this invention, at least some
portion of the
club head structure (e.g., a major body portion thereof) will be formed from a
basalt
material. Also, the club head 402 may be made from any number of independent
pieces and/or by any construction technique, including; for example, casting,
forging,
and/or other methods known and used in the art.
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[61J The striking face 418 may be formed from a separate face plate attached
to the club
head 402 as is known in the art by any desired manner, e.g., fabricated as a
one piece
construction; welded, brazed, or soldered thereto; bonded thereto with cements
or
adhesives, etc.; coated or filled therein (e.g., as a molten metal or polymer
coating or
filling, etc.); etc. Also, the face plate may be made from the same or a
different
material as compared with the materials used for other parts of the club head
402. In
at least some examples of this invention, the face plate 418 and/or a frame
member to
which it is attached (e.g., forming at least a portion of the club head body
402) may be
formed from a basalt material, such as a basalt fiber-reinforced material.
[62] The use of basalt materials for at least some portions of the golf club
head 402 or
other portions of the golf club structure (such as hosel 412 or shaft member
410) can
assist in club design by enabling club designers and manufacturers to
selectively place
weight and move the center of gravity to positions so as to better affect the
ball flight.
For example, positioning the center of gravity of the club head 402 away from
the
strildng face 418 and toward the rear of the golf club head 404 may better
conform to
the play characteristics, style, and preferences of many golfers.
[63] If desired, in accordance with at least some examples of this invention,
weighted
regions may be provided at one or more locations in the overall club head
structure,
e.g., around the club head perimeter, at a low, rearward position, in the club
toe area
404, in the club heel area 408, along the club sole 416, etc. Weighting of
this type can
help increase the club head's moment of inertia characteristics and/or help
modify the
ball flight, e.g., in the various manners described above and in the manners
lmo.wn.in.:....::_
the art. Of course, the weighted regions may be provided in any desired manner
without departing from the invention, e.g., by attaching one or more separate
weight
elements to some portion of the club head structure (e.g., in weight receiving
receptacles), by integrally forming the weighted region into the remainder of
the club
head structure, by applying lead tape or other weighted adhesive material, by
plasma
spraying, by providing a rear "bridge member" as used in commercially
available
SLINQSHO'I' iron products available from NIKE, Inc., of Beaverton, Oregon, by
including one or more ireights on a bridge member, etc. Also, the weighted
regions
may be provided in either or both of the club head's interior or exterior
structure
without departing from this invention.
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[64] Again, as noted above, basalt materials, including basalt fiber-
reinforced materials,
may be used in any desired iron golf club structure, including cavity back
clubs,
perimeter weighted clubs, muscle back clubs, blade-type clubs, and the like.
As some
more specific and non-limiting examples, basalt materials may be used as one
or more
parts of the club head structures illustrated, for example, in U.S. Patent No.
6,918,840;
U.S. Patent No. 6,981,924; and U.S. Patent Publication No. 2005-0137024. Each
of
these documents is entirely incorporated herein by reference.
3. Example Wood Type Golf Club Structures
[65] Aspects of this invention are not limited to use with putters, irons,
and/or hybrid iron
type golf clubs and golf club heads. Figure 5 illustrates an example of a golf
club 500
in accordance with at least some examples of this invention. Notably, the
overall golf
club structure 500 of this example includes a golf club head 502, a hosel
region 512, a
shaft member 510 received in and/or inserted into and/or through the hosel
region
512, and a grip or handle member (not shown) attached to the shaft member 510.
Optionally, if desired, the hosel region 512 may be eliminated and the shaft
member
510 may be directly inserted into and/or otherwise attached to the head member
502
(e.g., through an opening provided in the top and optionally bottom of the
club head
502). Optionally, if desired, the hosel member may be located intemal to the
club
head structure 502.
[66] The shaft member 510 may be received in, engaged with, and/or attached to
the club
head 502 in any suitable or desired manner, including in conventional manners
known
and used in the art, without departing from the invention. * As more specific
examples,
the shaft member 510 may be engaged with the club head 502 via the hosel
member
512 or directly with the club head structure 502, e.g., via adhesives,
cements, welding,
soldering, mechanical connectors (such as threads, retaining elements, or the
like),
through a shaft-receiving sleeve or element extending into and/or within the
club head
body 502, etc. The shaft member 510 also may be made from any suitable or
desired
materials, including conventional materials known and used in the art, such as
graphite based materials, composite materials, steel materials (including
stainless
steel), aluminum materials, titanium materials, magnesium materials, other
metal or
metal alloy materials, polymeric materials, combinations of various materials,
and the
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like. If desired, either or both of the shaft member 510 and the hosel member
512
(when present) may be made from a basalt material.
[67] The grip or handle member (not shown) may be attached to, engaged with,
and/or
extend from the shaft member 510 in any suitable or desired manner, including
in
conventional manners known and used in the art, e.g., using adhesives or
cements; via
welding, soldering, adhesives, or the like; via mechanical connectors (such as
threads,
retaining elements, etc.); and/or in any other desired manner. As another
example, if
desired, the grip or handle member may be integrally formed as a unitary, one-
piece
construction with the shaft member 510. Additionally, any desired grip or
handle
member materials may be used without departing from this invention, including
rubber materials, leather materials, rubber or other materials including cord
or other
fabric material embedded therein, polymeric materials, metal materials, and
the like.
The grip or handle member also may be made, at least in part, from a basalt
material.
[68] The club head 500 may be constructed in any suitable or desired manner
and/or from
any suitable or desired materials without departing from this invention,
including in
conventional manners and/or fmm conventional materials known and used in the
art.
For example, in the example structure shown in Figure 5, the club head 502
includes a
sole member 507, a face member 508, at least one body member 509, and a crown
member 511. The body member(s) 509 may be formed, for example, as bands or
ribbons of material (e.g., optionally generally U-shaped bands or ribbons)
that extend
around from one side of the face member 508 to its other side and form at
least a
portion of the perimpter of the middle of the golf club head body 502 (e.g.,
such that
the overall club head structure 502 defines an at least partially hollow
interior
chamber (e.g., into which the shaft member 510 may be inserted and/or
secured)).
Any of the individual portions of the club head structure 502 described above
may be
made from multiple independent pieces, and/or two or more of these individual
portions may be integrally formed together, e.g., as unitary, one-piece
constructions,
without departing from this invention (e.g., the sole and/or crown members
additionally may form at least some portions of the club head body and/or face
members, etc). As other options, if desired, the overall club head structure
502 may
be comprised of a single, one-piece construction (optionally hollowed out) or
the face
member 508 may attach to a one or more piece club head "aft" body, etc.
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[69] The various individual parts that make up a club head structure 502, if
made from
multiple pieces, may be engaged and/or held together in any suitable or
desired
manner, including in conventional manners known and used in the art. For
example,
the various parts of the club head structure 502 may be joined and/or fixed
together
(directly or indirectly through intermediate members) by adhesives, cements,
welding,
soldering, or other bonding or fusing techniques; by mechanical connectors
(such as
threads, screws, nuts, bolts, or other connectors); and the like. If desired,
the side
edges of various parts of the club head structure 502 (e.g., the edges where
sole
member 507, face member 508, body members 509, and/or crown member 511
contact and join to one another) may include one or more raised ribs, tabs,
ledges, or
other engagement elements that fit into or onto corresponding grooves, slots,
surfaces,
ledges, or openings provided in or on the facing side edges to which they are
joined.
Cements, adhesives, mechanical connectors, or the like may be used in
combination
with the'raised rib/groove or other connecting structures descnbed above to
further
help secure the various parts of the club head structure 502 to one another.
[70] In at least some examples of the invention, the materials making up at
least some of
the various portions of the club structure 500 (e.g., at least some potion(s)
of the sole
507, the face plate 508, the body member(s) 509, the crown 511, the hosel 512,
the
shaft 510, etc.) may be formed from a basalt material, e.g., like the various
materials
described above. If desired, two or more of these parts may be integrally
formed as a
one-piece construction (e.g., if desired, the sole 507, the body member 509,
and/or the
crown 511 may be integrally formed as one piece with a separate face plate
member
. -;:...:. . .:.
engaged therewith). Also, any desired materials may be used for various
portions uf
the club head body 502 without departing from the invention, including, for
example,
aluminum, nickel, titanium, sleel, polymers, glasses, ceramics, rubbers,
and/or
combinations thereof. When at least some portion of the club head structure
502 is
formed from a basalt material, if desired, the shell wall. thickness may be
made
somewhat larger than the shell members of many conventional club heads, such
as
metallic shell walls.
[71] The use of basalt materials for at least some portions of the golf club
head 502 or
other portions of the golf club structure (such as hose1512 or shaft member
510) can
assist in club design by enabling club designers and manufacturers to
selectively place
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weight and move the center of gravity to positions so as to better affect the
ball flight.
For example, positioning the center of gravity of the club head 502 away from
the
striking face 508 and toward the rear and lower portions of the golf club head
502
may better conform to the play characteristics, style, and preferences of many
golfers.
[72] If desired, in accordance with at least some examples of this invention,
weighted
regions may be provided at one or more locations in the overall club head
structure
502, e.g., around the club head perimeter, at a low, rearward position, in the
club toe
area, in the club heel area, along the club sole 507, along the club body
member 509,
etc. Weighting of this type can help increase the club head's moment of
inertia
characteristics and/or help modify the ball flight, e.g., in the various
manners
described above and in the manners known in the art. Of course, the weighted
regions
may be provided in any desired manner without departing from the invention,
e.g., by
attaching one or more. separate weight elements to some portion of the club
head
structure (e.g., in weight receiving receptacles), by integrally forming the
weighted
region into the remainder of the club head structure, by applying lead tape or
other
weighted adhesive material, by plasma spraying, by providing movable -and/or
removable weights, etc. Also, the weighted regions may be provided in either
or both
of the club head's interior or exterior structure without departing from this
invention.
[73] The dimensions and/or other characteristics of a wood-type golf club head
stracture
according to examples of the invention may vary significantly without
departing from
the invention. Moreover, any desired type of wood-type golf club head
structare may
be provided, such as drivers, fairway woods, wood=type hybrid clubs, chipping
clubs,
aad the like. Any desired loft angles, head weights, lie angles, etc., also
may be used
without departing from the invention, e.g., if the club is designed as a 2-
wood, 3-
wood, 4-wood, 5-wood, 7-wood, 9-wood, 11-wood, etc.; to suit a user's
preferences
and/or swing characteristics; to provide the desired launch angle, carry
distance,
and/or other characteristics for the club; etc. Additionally, various
different shaft
characteristics (such as stiffness, flex point, kick point, etc.) may be used
to fiirther
allow change and control over the club's and the club head's feel and
characteristics.
[74] As noted above, basalt materials, including basalt fiber-reinforced
materials, way be
used in any desired wood type golf club structure, including drivers, fairway
woods,
wood-type. hybrid clubs, chipping clubs, and the like. As some more specific
and
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non-limiting examples, basalt materials may be used akin to the use of carbon-
fiber
materials as one or more parts of the club head structures descnbed, for
example, in
U.S. Patent Nos. 6,406,381; 6,739,983; 6,758,763; and 6,881,159 and U.S.
Published
Patent Appln. No. 2004/0034986. Each of these patent documents is entirely
incorporated herein by reference.
C. Example Shaft or Other Elongated Tubular Structures
[751 Another example aspect of this invention relates to golf club shaft
members (or other
tubular members, optionally tapered tubular members). Such members may be
constructed in any suitable manner without departing from this invention,
including in
manners that utilize, for example, prior art fiber-reinforced resin and
composite
production techniques. For example, the shaft may be prepared as a solid or
hollow
elongate tube wherein at least a portion of the elongate tube comprises basalt
material.
[76] In one aspect, as shown in Figure 6, a golf club shaft 600 may be
constructed as an
elongate tube member 602, optionally having a grip element 604 engaged
therewith.
As shown in Figure 6A, the elongate tube member 602 may have a core layer 606
and
at least a first layer 608 about the core layer 606. At least one of the core
layer 606
and the first layer 608 in this example structure contains basalt material. As
a more
specific example, the fiirst layer 608 in this structure 602 contains a basalt
material.
[77] As shown in Figure 6b, several layers of material may be used to form the
elongate
tube member 602. The elongate tube 602 may have a core layer 610, a fnst layer
612
about at -least a-portion of the core layer 610, and a second layer 614 about
at least a
portion of the core layer 610 or the first layer 612. At least on& of the core
layer 610,
fust layer 612, and second layer 614 in this example structure contains basalt
fiber.
1781 As still another example, as shown in Figure 6c, the elongate tube member
602 may
be a single solid elongate tube containing basalt fibers. Alternatively, if
desired, the
tube member 602 of Figure 6c may be a hollow tube constructed of a basalt
fiber
containing material.
[791 The basalt material may be provided used in any suitable or desired form.
For
example, basalt material may be formed. into fibers, meshes, sheets, webs,
fabrics,
weaves, textiles, tapes, rovings, prepregs, and the like and then rolled to
form the
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solid or hollow tapered tubular structure, like those shown in Figures 6
through 6c.
Alternatively, layers of basalt material may be applied by coating a core or
previous
layer (e.g., a steel, aluminunz, titanium, or other metal containing material
tube) with a
basalt material.
[80] Each layer may be the same or different without departing from the
invention. For
example, the amount of basalt material used, the type of resin used, or the
type of
layer structure (e.g., fibers, mesh, sheet, web, fabrics, weaves, textiles,
tapes, rovings,
prepregs and the like) used may be the same or different in each layer. Also,
different
materials may be used in the different layers (e.g., one or more metal layers
with one
or more basalt material layers, etc.). The layers may comprise the entire
length of the
tubular structure or a portion thereof.
[81] The fibers may be positioned unidirectional or multidirectional.
Generally, when
unidirectional, the fibers are aligned along the length of the tube or slanted
along the
length, although other arrangements are possible without departing from this
invention.
[82] The shaft may further contain an outer cover layer containing, for
example, at least
one of titanium, steel, stainless steel, aluminum, tungsten, nickel, copper,
zinc,
chromium, brass, bronze, magnesium, tin, gold, silver, alloys thereof, or
metallic
matrix composites. Such outer coatings are known in the art.
M. Conclusion
[83] Golf club heads and shafts in accordance with examples of the present
invention may
be incorporated into a set, e.g., sets including one or more of woods, irons,
hybrid
type golf clubs, and/or putLers. As a more specific example, aspects of the
present
invention may be used to provide a club set with increasing numbered woods
and/or
iron golf clubs, such as a driver and/or two or more of fairway woods, hybrid
type
clubs, a zero iron, a one iron, a two iron, a three iron, a four iron, a five
iron, a six
iron, a seven iron, au eight iron, a nine iron, a ten iron, a pitching wedge,
a lob wedge,
a gap wedge, a sand wedge, putters, etc. With at least some examples of the
present
invention, a golfer, a club designer, and/or a club fitter may select and/or
modify the
positiox, of the center of gravity for each golf club to meet the player's
unique
requirements, skill, or playing style.
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[84] As is readily apparent from the above description, this invention may be
used to
include basalt materials, having a wide variety of potential properties, in a
wide
variety of different locations, in a golf club structure (e.g., as part of the
head, striking
face, hosel, shafft, grip, etc.). The basalt material may be used on the club
head
exterior, on the interior, on both, and the basalt material may be visible,
partially
visible, filled, partially filled, hidden, partially hidden, etc.
[85] Aspects of the invention also include the use of basalt in various other
items requiring
high tensile strength and which should not be brittle. Examples include such
items as
fishing rods, ski poles, knitting needles, croquet mallets, racquets, baseball
bats,
billiard cues, tool handles, etc., and the like.
[86] While the invention has been described with respect to specific examples
including
presently preferred modes of carrying out the invention, those slalled in the
art will
appreciate that there are numerous variations and permutations of the above
descnbed
systems and methods. Thus, the spirit and scope of the invention should be
construed
broadly as set forth in the appended claims.
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