Golf club head and a method for manufacturing the same

Abstract

A golf club head has a metal base, face and tubular neck and a carbon-fiber cover. The face extends up vertically from one edge of the base. The tubular neck is integrally connected to the base and the face. The cover is made of a carbon-fiber material and is securely attached to the base and the face. Because the carbon-fiber material is lighter than metal, the area of the face is enlarged. In addition, the shock absorbing effect of the golf head club is also improved.

What is claimed is:  
     
         1 . A golf club head comprising: 
 a metal base;    a metal face extending up vertically from one edge of the base;    a tubular neck integrally connected to the base and the face; and    a cover made of a carbon-fiber material and securely attached to the base and the face.    
     
     
         2 . The golf club head as claimed in    claim 1   , wherein a lip extends vertically from an edge of the base to connect to the cover.  
     
     
         3 . The golf club head as claimed in    claim 1   , wherein a countersunk threaded hole is defined in the base.  
     
     
         4 . The golf club head as claimed in    claim 1   , wherein a threaded plug with an enlarged head and a threaded shaft is screwed into the countersunk threaded hole in the base.  
     
     
         5 . The golf club head as claimed in    claim 1   , wherein at least one bore is formed in a side of the cover.  
     
     
         6 . The golf club head as claimed in    claim 5   , wherein a weighted plug is inlaid in each bore in the cover.  
     
     
         7 . The golf club head as claimed in    claim 6   , wherein an annular recess is defined in an outer edge of each weighted plug.  
     
     
         8 . The golf club head as claimed in    claim 6   , wherein an annular rib is formed on an outer edge of each weighted plug.  
     
     
         9 . A method for manufacturing a golf club head, the method comprising the following steps: 
 a. integrally forming the body comprising a base and a face of metal in a casting molding process and forming a tubular neck of metal on the body by a forging process such that a cavity is defined between the base and the face;    b. spraying aluminum oxide sand onto an inner surface of the cavity and an outer edge around the cavity to increase a surface roughness of the body;    c. attaching a cover formed from multiple carbon-fiber layers to the body to cover the cavity; and    d. attaching the cover to the body in a hot-pressing mold process such that a golf club head with a carbon-fiber cover is made.    
     
     
         10 . The method for manufacturing a golf club head as claimed in    claim 9    further comprising a step of a thermal treatment to the body after the body is formed  
     
     
         11 . The method for manufacturing a golf club head as claimed in    claim 10    further comprising a step of grinding the body after the thermal treatment process to form the body to a desired shape and size.  
     
     
         12 . The method for manufacturing a golf club head as claimed in    claim 9   , wherein at least one bore is defined in the cover to receive a weighted plug.  
     
     
         13 . The method for manufacturing a golf club head as claimed in    claim 9   , wherein a countersunk through hole is defined in the base after the body is formed; 
 the through hole is tapped; and    a plug with a threaded shaft is screwed into the threaded hole.    
     
     
         14 . The method for manufacturing a golf club head as claimed in    claim 13   , wherein an air bag is inserted into the body with the cover through the threaded hole before the hot-pressing mold process is processed; 
 the air bag is inflated and expands to press against the inner surface of the cover and the body during the hot-pressing mold process to form the cover into a desired shape;    the air bag is taken out of the body after the cover has hardened; and    the threaded plug is screwed into the threaded hole in the base.    
     
     
         15 . The method for manufacturing a golf club head as claimed in    claim 9    further comprising a step of fine grinding to increase the smooth of a surface of the golf club head.  
     
     
         16 . The method for manufacturing a golf club head as claimed in    claim 15    further comprising a step of applying a lacquer coating to an outer surface of the gold club head to provide a protective coating on the golf club head.  
     
     
         17 . The method for manufacturing a golf club head as claimed in    claim 9   , wherein a lip is formed on an edge of the body to connect to the cover.