Optimized Structural Support Members for Golf Club Heads

Publication ID: 24-11857851_0006_PTD

Published: October 28, 2025

Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Optimized Structural Support Members for Golf Club Heads,” Published Technical Disclosure No. 24-11857851_0006_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857851_0006_PTD

This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,851.

Summary of the Inventive Concept

This inventive concept introduces a system and method for optimizing structural support members in golf club heads, enhancing their durability and performance. The optimized support members reduce stress concentrations, improve fatigue life, and provide a more efficient manufacturing process.

Background and Problem Solved

The original patent, 'Support structures for golf club heads and methods of manufacturing improved support structures', provides a foundation for golf club head design and manufacturing. However, it has limitations in terms of support member design, which can lead to stress concentrations and reduced fatigue life. This new inventive concept addresses these limitations by introducing a curvature-based optimization algorithm and machine learning model to optimize support member geometries.

Detailed Description of the Inventive Concept

The inventive concept consists of a system comprising a curvature analysis module, design optimization module, stress simulation module, and fatigue life prediction module. The system optimizes the cross-sectional shape and area of each support member based on curvature analysis, simulates stress concentrations, and predicts fatigue life. The method for manufacturing a golf club head with improved structural support involves generating a digital model using CAD, optimizing the digital model using a curvature-based optimization algorithm, and manufacturing the optimized golf club head. The optimized support members have improved fatigue life, reduced stress concentrations, and are manufactured more efficiently.

Novelty and Inventive Step

The new claims introduce a novel curvature-based optimization algorithm, machine learning model, and fatigue life prediction module, which are not present in the original patent. These innovations provide a significant improvement in support member design, stress reduction, and fatigue life prediction, making the inventive concept non-obvious and novel.

Alternative Embodiments and Variations

Alternative embodiments of the inventive concept could include using different machine learning models, incorporating additional design parameters, or integrating the optimization system with existing CAD software. Variations could include applying the optimization algorithm to other golf club head components or extending the concept to other sports equipment.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential in the golf industry, particularly in the design and manufacturing of high-performance golf clubs. The optimized support members can provide a competitive advantage in terms of durability, performance, and manufacturing efficiency, appealing to golf club manufacturers, professional golfers, and recreational golfers.

CPC Classifications

Section	Class	Group
A	A63	A63B53/0487
A	A63	A63B53/0408
B	B22	B22F10/14
B	B22	B22F10/80
B	B33	B33Y10/00
A	A63	A63B53/0412

Section 103 Obviousness Analysis (PHOSITA)

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Field of Art

Sports equipment manufacturing, specifically golf club head design and advanced additive manufacturing techniques, involving computer-aided design (CAD), binder jet manufacturing, and structural optimization of complex geometrical components

Person of Ordinary Skill (PHOSITA) Profile

A mechanical engineer with expertise in CAD modeling, additive manufacturing, finite element analysis, and sports equipment design, possessing advanced computational design skills and understanding of material science principles related to structural optimization

Obviousness Rationale

A PHOSITA would recognize that the PTD's curvature-based optimization and machine learning approach represents a predictable extension of existing golf club head support structure design methodologies. The disclosed optimization techniques are a natural progression of computational design tools already employed in advanced manufacturing. The integration of stress simulation and fatigue life prediction modules represents an incremental improvement consistent with standard engineering design practices.

Obvious Combinations & Variations

Source Patent Element

Binder jet manufacturing method for creating golf club head support structures with curved splines

PTD Variation

Implementing a curvature analysis module to systematically optimize support member geometries

Obviousness Reasoning

A PHOSITA would recognize that computational optimization of existing manufacturing techniques is a standard design improvement using known machine learning and simulation tools

Source Patent Element

Support members extending at an angle from the sole portion of the golf club head

PTD Variation

Adding a stress simulation module to predict and minimize stress concentrations in those support members

Obviousness Reasoning

Finite element analysis and stress simulation are well-established techniques for refining structural designs, representing a predictable application of computational engineering principles

Source Patent Element

Manufacturing method involving powdered material deposition and sintering

PTD Variation

Integrating a machine learning model trained on existing golf club head design datasets to predict optimal geometries

Obviousness Reasoning

Machine learning applied to design optimization is a known technique in advanced manufacturing, representing an incremental improvement using standard computational approaches

Source Patent Element

Support structures without sharp corners or simple constant surface fillets

PTD Variation

Implementing a dynamic cross-sectional shape optimization algorithm based on curvature analysis

Obviousness Reasoning

Continuous geometric refinement using computational tools is a predictable evolution in advanced design methodologies

Source Patent Element

Golf club head support member manufacturing techniques

PTD Variation

Adding a fatigue life prediction module to monitor structural performance during use

Obviousness Reasoning

Predictive maintenance and performance monitoring are standard engineering practices in advanced computational design systems

35 U.S.C. § 103 Summary: Pursuant to 35 U.S.C. § 103, the variations disclosed in the Published Technical Disclosure render obvious any patent claims covering computational optimization of golf club head support structures, as the disclosed techniques represent predictable extensions of the foundational teachings in US Patent 11857851, utilizing standard engineering design methodologies and computational tools known to those skilled in the art.

Original Patent Information

Patent Number	US 11,857,851
Title	Support structures for golf club heads and methods of manufacturing improved support structures
Assignee(s)	Topgolf Callaway Brands Corp.