Method for manufacturing a golf club face

Abstract

A method of manufacturing a face plate for a golf club head is presented to provide face having substantial thickness variation for enhanced performance. The method includes the steps of providing a rolled sheet of metal material having an initial thickness and forming a blank having a prescribed outer shape from the material. The method also includes machining a second side of the blank such that the resulting face plate has a variable thickness. The machining is such that the plate has a first thickness less than or equal to the initial thickness, a second thickness less than the first thickness and a third thickness less than the second thickness. The machining is performed over a substantial portion of the surface area of the second side. Either a CNC lathe or milling machine may be used; however, for an axisymmetric face thickness a CNC lathe is preferred and for an asymmetric face thickness a CNC end mill is preferred. The club head may be a wood-type or iron, and titanium or steel alloys may be used.

1 - 20 . (canceled).  
   
   
       21 . A method of forming a face plate for a wood-type golf club head, comprising: 
 forming a face plate blank from a titanium alloy having a density of at least 4 g/cm 3 , wherein the face plate blank has a first volume delimited by a first surface, a second surface, and a periphery, and wherein the first surface has a first surface area delimited by the periphery; and    performing a computer numeric controlled milling process on the first surface, thereby forming a toe zone, a heel zone, and a central zone disposed between the toe zone and the heel zone, a transition between the central zone and the heel zone, and a transition between the central zone and the toe zone, wherein the toe zone has a maximum toe zone thickness of less than 2.5 mm, the heel zone has a maximum heel zone thickness of less than 2.5 mm, the central zone has a maximum central zone thickness between 3.2 to 4.5 mm, and the thickness of the central zone varies asymmetrically about a heel to toe axis;    wherein performing the computer numeric controlled milling processes comprises machining at least 80% of the first surface area and removing at least 25% of the first volume.    
   
   
       22 . A method as defined in  claim 21 , wherein machining the face plate blank comprises machining over 90% of the first surface area.  
   
   
       23 . A method as defined in  claim 22 , wherein machining the face plate blank comprises removing more than 40% of the first volume.