Golf Club Head With Foam Core

Abstract

A golf club head having improved properties such as structural rigidity and weight distribution comprises a core formed of a first material such as metallic or ceramic foam. The golf club head may be fabricated by intercalating a second material into the foam core to provide a composite core. The composite core is formed into at least a portion of a club head body. Optionally, a coating is applied to the composite core and, thereafter, the second material is pyrolized and removed.

1 . A method of making a golf club comprising:
 providing a sponge-like non-metallic material having a shape approximating at least a portion of a club head body;   depositing metal onto the sponge-like non-metallic material in order to form a metallic foam member; and   covering the metallic foam member with a coating.   
   
   
       2 . The method of  claim 1 , wherein the sponge-like non-metallic material is polymer. 
   
   
       3 . The method of  claim 2 , wherein said metal is nickel alloy. 
   
   
       4 . The method of  claim 1 , wherein the coating is a non-metallic material. 
   
   
       5 . The method of  claim 1 , wherein the sponge-like non-metallic material is open cell foam. 
   
   
       6 . A method of making a golf club comprising:
 providing a sponge-like non-metallic material in the shape of a club head preform;   depositing metal onto the club head preform; and   forming the club head perform into the shape of at least a portion of a club head body.   
   
   
       7 . The method of  claim 6 , further comprising covering said at least a portion of a club head body with a coating. 
   
   
       8 . The method of  claim 7 , wherein the coating is a non-metallic material. 
   
   
       9 . The method of  claim 6 , wherein the sponge-like non-metallic material is polymer and wherein said metal is nickel alloy. 
   
   
       10 . A method of manufacturing a golf club comprising:
 forming a club head pre-form from a first material chosen from the group consisting of a metallic foam and a ceramic foam;   intercalating said club head pre-form with a second material to form a foam composite core; and   forming said foam composite core into at least a portion of a club head body.   
   
   
       11 . The golf club of  claim 10 , wherein said second material has a decomposition temperature below the melting point of said first material. 
   
   
       12 . The method of  claim 10 , wherein said first material has a reticulated structure of interconnected voids. 
   
   
       13 . The method of  claim 10 , further comprising machining said foam composite core to provide said club head body with a substantially smooth outer surface. 
   
   
       14 . The method of  claim 13 , further comprising applying a coating to the substantially smooth outer surface of said club head body. 
   
   
       15 . The method of  claim 14 , wherein said coating comprises a metallic material. 
   
   
       16 . The method of  claim 15 , wherein said metallic material is electroplated to said foam composite core. 
   
   
       17 . The method of  claim 14 , wherein said coating comprises a fiber reinforced composite bonded to said foam composite core. 
   
   
       18 . The method of  claim 14 , wherein said coating comprises a polymer coating chosen from the group consisting of thermoset plastics and thermoplastics. 
   
   
       19 . The method of  claim 13 , further comprising:
 heating said foam composite core to decompose said second material; and   draining said decomposed second material from said foam composite core.   
   
   
       20 . The method of  claim 10 , wherein said second material is chosen from the group consisting of thermoplastics and waxes. 
   
   
       21 . The method of  claim 10 , wherein said first material is open cell foam. 
   
   
       22 . A method of manufacturing a golf club comprising:
 forming a club head pre-form from a first material chosen from the group consisting of a metallic foam and a ceramic foam;   intercalating said club head pre-form with a second material to form a foam composite core; and   applying a coating to said foam composite core to form at least a portion of a club head body having a substantially smooth outer surface.   
   
   
       23 . The golf club of  claim 22 , wherein said second material is denser than said first material. 
   
   
       24 . The method of  claim 22 , wherein said coating is formed of said second material and is applied in said intercalating of said club head pre-form. 
   
   
       25 . The method of  claim 22 , wherein said coating is applied separately from said intercalating of said club head pre-form. 
   
   
       26 . The method of  claim 22 , wherein said coating is a metallic material. 
   
   
       27 . The method of  claim 22 , wherein said coating is a fiber reinforced composite. 
   
   
       28 . At least a portion of a golf club head comprising:
 a foam core composed of a foam material chosen from the group consisting of a metallic foam and a ceramic foam, said foam material having an inherently irregular outer surface of peaks and valleys; and   a coating attached to an outer surface of said foam core, said coating filling the valleys between the peaks of said inherently irregular outer surface on said foam material.   
   
   
       29 . The golf club of  claim 28 , wherein said coating comprises a fiber reinforced composite. 
   
   
       30 . The golf club of  claim 28 , wherein said coating comprises a metallic material. 
   
   
       31 . The golf club of  claim 28 , wherein said coating comprises a material chosen from the group consisting of thermoset plastic and thermoplastic. 
   
   
       32 . The golf club of  claim 28 , wherein said foam core has a bulk density between 0.5 to 0.05 grams per cubic centimeter.