Method of manufacturing a golf club face

Abstract

Embodiments of methods of manufacturing a face plate for a golf cub are generally described herein. In one exemplary embodiment, a method for manufacturing a golf club face plate comprises: providing a face plate material, and milling the face plate material in an elliptical pattern to form a central region comprising, a first elliptical outer edge and a transition region extending from the first elliptical outer edge to a second elliptical outer edge. In this exemplary embodiment, each point along the second elliptical outer edge is displaced outward from the first elliptical outer edge by a predetermined distance. Other embodiments herein may be described and claimed.

1 . A method for manufacturing a golf club face plate comprising: 
 providing a face plate material;    milling the face plate material in an elliptical pattern to form: 
 a central region comprising a first elliptical outer edge; and  
 a transition region extending from the first elliptical outer edge to a second elliptical outer edge;  
   wherein: 
 each point along the second elliptical outer edge is displaced outward from the first elliptical outer edge by a predetermined distance.  
   
     
     
         2 . The method of  claim 1 , wherein the central region comprises a thickness substantially similar to a thickness of the face plate material.  
     
     
         3 . The method of  claim 1 , wherein the central region comprises a thickness of about 0.13 inches to about 0.18 inches.  
     
     
         4 . The method of  claim 1 , wherein the predetermined distance is about 0.40 inches to about 1.20 inches.  
     
     
         5 . The method of  claim 1 , wherein milling the face plate material comprises using an end mill to mill the face plate material.  
     
     
         6 . The method of  claim 1 , wherein the central region comprises a major axis of about 0.65 inches to about 1.05 inches.  
     
     
         7 . The method of  claim 1 , wherein the central region comprises a minor axis of about 0.25 inches to about 0.45 inches.  
     
     
         8 . The method of  claim 1 , wherein an aspect ratio of the central region is about 1.4 to about 4.2.  
     
     
         9 . The method of  claim 1 , wherein an aspect ratio of the second elliptical outer edge is less than an aspect ratio of the central region.  
     
     
         10 . The method of  claim 1 , wherein milling the face plate material comprises using a cutting tool comprising a first cutting surface and a second cutting surface different from the first cutting surface.  
     
     
         11 . The method of  claim 10 , wherein the second cutting surface comprises a perpendicular configuration to a rotating axis of the cutting tool.  
     
     
         12 . The method of  claim 10 , wherein the first cutting surface creates an angle with respect to the second cutting surface of about 5 degrees to about 20 degrees.  
     
     
         13 . The method of  claim 1 , wherein the transition region comprises a non-linear transition between the first elliptical outer edge and the second elliptical outer edge.  
     
     
         14 . The method of  claim 1 , wherein the transition region comprises a non-linear transition having a convex configuration.  
     
     
         15 . The method of  claim 1 , wherein the transition region comprises a non-linear transition having a concave configuration.  
     
     
         16 . The method of  claim 1 , wherein the transition region comprises a frustrum-like region.  
     
     
         17 . The method of  claim 1 , wherein milling the face plate material further comprises milling the face place material in a single elliptical orbit.  
     
     
         18 . A method for manufacturing a golf club head: 
 providing a golf club head shell comprising an opening to receive a faceplate;    providing a faceplate; and    coupling the faceplate to the opening; 
 wherein, providing a faceplate further comprises: 
 milling a face plate material in an elliptical pattern to form:  
 a central region comprising a first elliptical outer edge; and  
 a transition region tapering from the first elliptical outer edge to a second elliptical outer edge;  
 wherein: 
 cross-section profiles of the transition region from the first elliptical outer edge to the second elliptical outer edge are substantially similar when the cross sectional profiles are taken along perpendicular directions that are collinear with a major axis and a minor axis of the second elliptical outer edge.  
 
 
   
     
     
         19 . The method of  claim 18 , wherein: 
 the central region comprises a major axis of about 0.65 inches to about 1.05 inches;    the central region comprises a minor axis of about 0.25 inches to about 0.45 inches;    an aspect ratio of the central region is about 1.4 to about 4.2; and    a thickness of the central region is about 0.13 inches to about 0.18 inches.    
     
     
         20 . The method of  claim 18 , wherein the transition region comprises a convex configuration.  
     
     
         21 . The method of  claim 18 , wherein the transition region comprises a concave configuration.  
     
     
         22 . A method for manufacturing a golf club: 
 providing a golf club head comprising a faceplate; and    coupling the golf club head to a shaft; 
 wherein, the faceplate comprises: 
 a first region comprising a first elliptical outer edge comprising a first aspect ratio, a first major axis, and a first minor axis; and  
 a second region extending from the first elliptical outer edge to a second elliptical outer edge, comprising a second aspect ratio, a second major axis, and a second minor axis, the second major axis being equal to the first major axis plus a predetermined distance, and the second minor axis being equal to the first minor axis plus the predetermined distance.  
 
   
     
     
         23 . The method of  claim 22 , wherein: 
 the first and second major axes are collinear with each other; and    the first and second minor axes are collinear with each other.    
     
     
         24 . The method of  claim 22 , wherein: 
 the first major axis is about 0.65 inches to about 1.05 inches;    the first minor axes is about 0.25 inches to about 0.45 inches; and    the aspect ratio of the first region is about 1.4 to about 4.2.    
     
     
         25 . The method of  claim 22 , wherein the second region comprises a non-linear transition from the first elliptical outer edge to the second elliptical outer edge.