US20260166394A1
MULTI-PIECE GOLF CLUB HEAD
Publication
Application
Classifications
IPC Classifications
CPC Classifications
Applicants
Taylor Made Golf Company, Inc.
Inventors
Charles Chou, Mark Greaney, Stephen Kraus, Bryan Cheng, Kevin Cheng, Matthew Greensmith, Christopher Harbert, Todd Beach, Matthew D. Johnson, Garrett Vierhout, Brad Pluschkell, Brett Walker, Christopher Rollins, Joseph Felipe, Jennifer Luoma
Abstract
A golf club head and a method of making the golf club head including at least one significant aluminum alloy component and at least one significant non-metal component, and all the benefits afforded therefrom.
Figures
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001]This application is a continuation-in-part application of U.S. patent application Ser. No. 19/378,232, filed Nov. 3, 2025, which is a continuation-in-part application of U.S. patent application Ser. No. 19/054,744, filed Feb. 14, 2025, which is a continuation application of U.S. patent application Ser. No. 18/323,935, filed May 25, 2023, which claims the benefit of U.S. Provisional Patent Application No. 63/345,875, filed on May 25, 2022. This application also claims the benefit of U.S. Provisional Patent Application No. 63/740,603, filed on Dec. 31, 2024. Each of the foregoing applications is incorporated by reference herein in its entirety.
FIELD
[0002]This disclosure relates generally to golf clubs, and more particularly to a golf club head constructed of multiple parts adhesively bonded together.
BACKGROUND
[0003]In the early history of golf, golf club heads were made primarily of a single material, such as wood. Subsequently, golf club heads progressed away from a construction made primarily from wood to one made primarily of metal. Initial golf club heads made of metal were made of steel alloys. Over time, golf club heads started to be made of titanium alloys. Some, but not all, golf club head manufacturers have transitioned away from use of a single material to a multi-material and multi-piece construction. The use of multiple pieces and the use of multiple materials can provide various manufacturing and performance advantages. The multiple pieces of a multi-piece golf club head can be bonded together in a variety of ways, such as adhesive bonding and welding.
[0004]Often, the strength of the bond between bonded pieces of a multi-piece golf club head affects the durability of the golf club head and thus the performance of the golf club head over time. A weak bond tends to accelerate degradation of the bond as the golf club head is used to impact golf balls. Degradation in a bond between bonded pieces can lead to a diminution of the performance of the golf club head, such as via a reduction in stiffness and lack of proper load transfer, at best, and complete failure of the golf club head, at worst. Typically, the strike face of a driver-type golf club head undergoes several thousand collisions with a golf ball through its life-cycle. Each collision imparts a force onto the strike face in the range of 10,000 g to 20,000 g, where g is equal to the force per unit mass due to gravity. Repeated impacts, at such high forces, tends to cause degradation of the bonds forming the golf club head. Accordingly, a strong initial and durable bond between bonded pieces of a golf club head is desired.
[0005]Because welding generally provides a stronger initial bond and can exhibit a higher durability compared to other bonding techniques, the pieces of many conventional multi-piece golf club heads utilize materials, such as compatible metals, that are conducive to welding. However, many metals used to construct multi-piece golf club heads have a higher mass than non-metallic materials. Therefore, the mass available to for distribution around such golf club heads (otherwise known as discretionary mass), which can be utilized for promote the performance of golf club heads, can be limited. difficult. For this reason, providing a multi-piece golf club head, which has strong and durable bonds between the pieces of the golf club head and promotes an increase in discretionary mass, can be difficult.
SUMMARY
[0006]The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the shortcomings of golf club heads with a multi-piece construction, that have not yet been fully solved. Accordingly, the subject matter of the present application has been developed to provide a golf club head that overcomes at least some of the above-discussed shortcomings of conventional golf club heads. Disclosed herein is a golf club head. The golf club head comprises a hollow interior cavity, a first piece, defining at least a first portion of the hollow interior cavity, and a second piece, defining at least a second portion of the hollow interior cavity. The first piece is adhesively bonded to the second piece along a bonded joint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007]In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the subject matter and are not therefore to be considered to be limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:
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DETAILED DESCRIPTION
[0193]The following describes examples of golf club heads in the context of a driver-type golf club head having a multi-piece construction, but the principles, methods and designs described may be applicable, in whole or in part, to fairway wood golf club heads, utility golf club heads (also known as hybrid golf club heads), iron-type golf club heads, putters, and the like, because such golf club heads can also be made to have a multi-piece construction.
[0194]The inventive features include all novel and non-obvious features disclosed herein both alone and in novel and non-obvious combinations with other elements. As used herein, the phrase “and/or” means “and”, “or” and both “and” and “or”. As used herein, the singular forms “a,” “an,” and “the” refer to one or more than one, unless the context clearly dictates otherwise. As used herein, the term “includes” means “comprises.” The preferred embodiments of the invention accomplish the stated objectives by new and novel arrangements of elements and configurations, materials, and methods that are configured in unique and novel ways and which demonstrate previously unavailable but preferred and desirable capabilities. The description set forth below in connection with the drawings is intended merely as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, materials, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions, features, and material properties may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention. The present disclosure is described with reference to the accompanying drawings with preferred embodiments illustrated and described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout the disclosure and the drawings. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. All publications, patent applications, patents, and other references mentioned herein are incorporated herein by reference in their entireties. Further, while the disclosure is directed to the components and attributes of the golf club head, the disclosure also covers a method of creating a finished multi-piece golf club head having components attached to each other via bonding tape utilizing the disclosed components and steps. Even though the embodiments of this disclosure are particularly suited as large multi-piece construction golf club heads such as drivers, which often have a volume of 400 cc or greater, it should be immediately apparent that embodiments of the present disclosure are applicable to any multi-piece construction club heads as well, including, but not limited to, mini-drivers characterized by volumes of 250-350 cc and a loft of 13 degrees or less, fairway woods characterized by volumes of 140-249 cc, rescue club heads (often referred to as hybrid clubs) characterized by volumes of 80-160 cc, hollow-iron club heads, cap-back iron club heads, cavity back iron club heads, and putter club heads. Thus, the present invention may be applied to, or in conjunction with, any of the disclosure of: U.S. patent application Ser. No. 19/197,583, filed May 2, 2025 and published as U.S. Pub. No. 20250325883; U.S. patent application Ser. No. 19/013,451, filed Jan. 8, 2025 and published as U.S. Pub. No. 20250222313; U.S. patent application Ser. No. 19/040,820, filed Jan. 29, 2025 and published as U.S. Pub. No. 20250281803; U.S. patent application Ser. No. 19/011,537, filed Jan. 6, 2025 and published as U.S. Pub. No. 20250222320; U.S. patent application Ser. No. 18/414,128, filed Jan. 16, 2024 and published as U.S. Pub. No. 20250229145; U.S. patent application Ser. No. 18/827,140, filed Sep. 6, 2024 and published as U.S. Pub. No. 20240424356; U.S. patent application Ser. No. 19/345,718, filed Sep. 30, 2025; and U.S. patent application Ser. No. 19/030,258, filed Jan. 17, 2025; which are all incorporated herein by reference in their entirety. Further, the presently disclosed club heads may include any of the materials, configurations, and embodiments disclosed in U.S. patent application Ser. No. 19/007,332, filed Dec. 31, 2024 and published as U.S. Pub. No. 20250144480, U.S. patent application Ser. No. 18/957,619, filed Nov. 22, 2024, U.S. patent application Ser. No. 18/647,379, filed Apr. 26, 2024 and published as U.S. Pub. No. 20240293705, U.S. patent application Ser. No. 19/013,893, filed Jan. 8, 2025 and published as U.S. Pub. No. 20250213931, U.S. patent application Ser. No. 18/534,512, filed Dec. 8, 2023 and published as U.S. Pub. No. 20250161765, and U.S. patent application Ser. No. 17/564,077, filed Dec. 28, 2021 and published as U.S. Pub. No. 20220184469, which are incorporated herein by reference.
[0195]The following disclosure describes embodiments of golf club heads for metalwood type golf clubs. Several of the golf club heads incorporate features that provide the golf club heads and/or golf clubs with volume and/or dimensions and unique relationships providing improved performance associated with club head constructions that provide unique and preferential mass properties for a club head 2, as well as unique dimensional configurations and mass properties, unique face designs, higher coefficients of restitution (“COR”) and characteristic times (“CT”), and/or impart preferred launch conditions upon a golf ball, including, but not limited to, decreased backspin rates, relative to other golf club heads that have come before. The disclosure makes reference to the accompanying drawings which form a part hereof, wherein like numerals designate like parts throughout. The drawings illustrate specific embodiments, but other embodiments may be formed and structural changes may be made without departing from the intended scope of this disclosure. Directions and references (e.g., up, down, top, bottom, left, right, rearward, forward, heelward, toeward, etc.) may be used to facilitate discussion of the drawings but are not intended to be limiting. For example, certain terms may be used such as “up,” “down,”, “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships, particularly with respect to the illustrated embodiments. Such terms are not, however, intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Accordingly, the following detailed description shall not to be construed in a limiting sense and the scope of property rights sought shall be defined by the appended claims and their equivalents.
[0196]In some examples disclosed herein, the golf club head has a strike face formed of a non-metallic material, such as a fiber-reinforced polymeric material. A breakdown of the adhesive joint formed between a body of the golf club head and a non-metallic strike face component can cause characteristic time (CT) creep. USGA regulations require the CT of a golf club head to remain within the regulated limit regardless of the number of impacts the golf club head has with a golf ball. The CT of conventional driver-type golf club heads tends to increase after multiple impacts with a golf ball. The increase of CT due to impacts with a golf ball is known as CT creep. In certain examples disclosed herein, the golf club heads are configured to strengthen the adhesive joint formed between the body of the golf club heads and the non-metallic strike face component, such as by optimizing the surface structure of the golf club head for stronger adhesive bonds.
[0197]U.S. Patent Application Publication No. 2014/0302946 A1 ('946 App), published Oct. 9, 2014, which is incorporated herein by reference in its entirety, describes a “reference position” similar to the address position used to measure the various parameters discussed throughout this application. The address or reference position is based on the procedures described in the United States Golf Association and R&A Rules Limited, “Procedure for Measuring the Club Head Size of Wood Clubs,” Revision 1.0.0, (Nov. 21, 2003). Unless otherwise indicated, all parameters are specified with the club head in the reference position.
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[0199]For further details or clarity, the reader is advised to refer to the measurement methods described in the '946 App and the USGA procedure. Notably, however, the origin and axes associated with the club head origin coordinate system 185 used in this application may not necessarily be aligned or oriented in the same manner as those described in the '946 App or the USGA procedure. Further details are provided below on locating the club head origin coordinate system 185.
[0200]In some examples, the golf club heads described herein include driver-type golf club heads, which can be identified, at least partially, as golf club heads with strike faces that have a total surface area of at least 3,500 mm{circumflex over ( )}2, 3,600 mm{circumflex over ( )}2, 3,700 mm{circumflex over ( )}2, 3,800 mm{circumflex over ( )}2, 3,900 mm{circumflex over ( )}2, 4,000 mm{circumflex over ( )}2, and/or 4,100 mm{circumflex over ( )}2. Some embodiments limit the strike face total surface area to no more than 5,200 mm{circumflex over ( )}2, 5,100 mm{circumflex over ( )}2, 5,000 mm{circumflex over ( )}2, 4,900 mm{circumflex over ( )}2, 4,800 mm{circumflex over ( )}2, and/or 4,700 mm{circumflex over ( )}2. The total surface area of the strike face is the outermost area of the striking face, which can be the outermost area of a face insert in some examples. In certain examples, the total surface area of the strike face is the surface area of the surface of the striking face that is bounded on its periphery by all points where the face transitions from a substantially uniform bulge radius (i.e., face heel-to-toe radius of curvature) and a substantially uniform roll radius (i.e., face crown-to-sole radius of curvature) to the body of the golf club head. In certain examples, the strike face of the golf club head disclosed herein is defined in the same manner as in one or more of U.S. Patent Application Publication No. 2020/0139208, filed Oct. 22, 2019, U.S. Pat. No. 8,096,897, issued Jan. 17, 2012, U.S. Pat. No. 8,801,541, issued Aug. 12, 2014, and U.S. Pat. No. 8,012,039, issued Sep. 6, 2011, all of which are incorporated herein by reference in their entirety. In yet some examples, the strike face has a uniform bulge radius and a uniform roll radius, except for portions that have a higher lofted toe and a lower lofted heel, such as described in U.S. patent application Ser. No. 17/006,561, filed Aug. 28, 2020, U.S. Pat. No. 9,814,944, issued Nov. 14, 2017, U.S. Pat. No. 10,265,586, issued Apr. 23, 2019, and U.S. Patent Application Publication No. 2019/0076705, filed Oct. 15, 2018, which are incorporated herein by reference in their entirety.
[0201]Additionally, in certain examples, driver-type golf club heads include a center-of-gravity (CG) projection, parallel to a horizontal (y-axis), which is, in one example, at most 3 mm above or below a center face of the strike face, while in further embodiments it is at most 2 mm, 1 mm, 0 mm, −1.0 mm, or −2.0 mm. Another series of embodiments establishes a floor for the center-of-gravity (CG) projection such that it is at least-8.0 mm, while in further embodiments it is at least-7.0 mm, −6.0 mm, −5.0 mm, or −4.0 mm. The center-of-gravity (CG) projection is also interchangeably referred to as a balance point projection, or BP projection, often abbreviated as “BP proj.” As disclosed in U.S. Ser. No. 19/007,332, filed Dec. 31, 2024, and incorporated herein by reference in the entirety, the CG location preferentially affects the Z-axis gear effect. As seen in
[0202]The below-BP-Plane portion of the club head has a below-BP-Plane portion Izz about the CG z-axis, as well as a below-BP-Plane portion Ixx about the CG x-axis. The above-BP-Plane portion of the club head has an above-BP-Plane portion Izz about the CG z-axis, as well as an above-BP-Plane portion Ixx about the CG x-axis. The above-BP-Plane portion Izz is at least 15% greater than the below-BP-Plane portion Izz in one embodiment, and the percentage is increased to at least 17.5%, 20%, 22.5%, or 25% in additional embodiments. However, another series of embodiments caps this relationship such that the above-BP-Plane portion Izz is no more than 35%, 32.5%, 30%, or 27.5% greater than the below-BP-Plane portion Izz. The above-BP-Plane portion Ixx is at least 7.5% greater than the below-BP-Plane portion Ixx in one embodiment, and the percentage is increased to at least 10% or 12.5% in additional embodiments. However, another series of embodiments caps this relationship such that the above-BP-Plane portion Ixx is no more than 25%, 22.5%, 20%, or 17.5% greater than the below-BP-Plane portion Ixx.
[0203]If the projected CG point on the ball striking club face is closer to the sole than the geometric center, when the golf club is swung such that the club head impacts a golf ball at the origin 205, the impact is “off center” from the projected CG point, creating torque that causes the body of the golf club head to rotate (or twist) about the CG x-axis. The rotation of the club face creates a “z-axis gear effect.” More specifically, the rotation of the club head about the CG x-axis tends to induce a component of spin on the ball. In particular, the backward rotation of the face that occurs as the golf ball is compressed against the face during impact causes the ball to rotate in a direction opposite to the rotation of the face, much like two gears interfacing with one another. Thus, the backward rotation of the club face during impact creates a component of forward rotation in the golf ball. This effect is termed the “z-axis gear effect.” Because the loft of a golf club head also creates a significant amount of backspin in a ball impacted by the golf club head, the forward rotation resulting from the z-axis gear effect is typically not enough to completely eliminate the backspin of the golf ball, but instead reduces the backspin from that which would normally be experienced by the golf ball. In general, the forward rotation (or topspin) component resulting from the z-axis gear effect is increased as the impact point of a golf ball moves upward from (or higher above) the projected CG point on the ball striking club face, and having a large club head and face may promote strikes high on the face. Additionally, the effective loft of the golf club head that is experienced by the golf ball and that determines the launch conditions of the golf ball can be different than the static loft of the golf club head. The difference between the golf club head's effective loft at impact and its static loft angle at address is referred to as “dynamic loft” and can result from a number of factors. In general, however, the effective loft of a golf club head is increased from the static loft as the impact point of a golf ball moves upward from (or higher than) the projected CG point on the ball striking club face. Thus, a club head with a low CG, or relatively small Zup value, and associated low projected CG point has preferred z-axis gear effect particularly when combined with an increased face height Hss that tends to promote impacts higher on the face. In a further embodiment the static loft angle is at 8-15 degrees, while in another embodiment it is 9-14 degrees, and in yet a further embodiment it is 9-13 degrees.
[0204]The trajectory of a golf ball hit by a club head having a projected CG that coincides with the geometric center of the striking surface typically includes a low launch angle and a significant amount of backspin. The backspin on the ball causes it to quickly rise in altitude and obtain a more vertical trajectory, “ballooning” into the sky. Consequently, the ball tends to quickly lose its forward momentum as it is transferred to vertical momentum, eventually resulting in a steep downward trajectory that does not create a significant amount of roll. Even though some backspin can be beneficial to a golf ball's trajectory by allowing it to “rise” vertically and resist a parabolic trajectory, too much backspin can cause the golf ball to lose distance by transferring too much of its forward momentum into vertical momentum.
[0205]In contrast, the trajectory of a golf ball hit by a large club head having a lower center of gravity has a higher launch angle and less backspin relative to the club head having a projected CG that coincides with the geometric center of the striking surface, and the trajectory includes less “ballooning” but still has enough backspin for the ball to have some rise and to generally maintain its launch trajectory longer than a ball with no backspin. As a result, the golf ball carries further because the horizontal momentum of the golf ball is greater, which also increases the roll-out upon landing.
[0206]As seen in
[0207]Adjusting the location of the discretionary mass in a golf club head, the shape of the club head, and/or multi-component and multi-material construction can provide the desired Delta1 value. For instance, Delta1 can be manipulated by varying the mass in front of the CG (closer to the face) with respect to the mass behind the CG. That is, by increasing the mass behind the CG with respect to the mass in front of the CG, Delta1 can be increased. In a similar manner, by increasing the mass in front of the CG with the respect to the mass behind the CG, Delta1 can be decreased. The shape of the body may include any of the embodiments disclosed in U.S. patent application Ser. No. 18/653,254, filed May 2, 2024 and published as U.S. Pub. No. 20240350872, and Ser. No. 18/822,842, filed Sep. 3, 2024 and published as U.S. Pub. No. 20250058182, and U.S. Pat. No. 10,463,929, issued Nov. 5, 2019, which are incorporated herein by reference. Additionally, one embodiment the club head avoids the high CG locations by incorporating a low-density material in at least a portion of the crown, which may be metallic or non-metallic. As such, one particular embodiment has an average crown density of less than 4 g/cc, while in another embodiment the average crown density is less than 3 g/cc, and in yet another embodiment the average crown density is less than 2 g/cc. In one particular embodiment at least 50% of the crown area is composed of non-metallic material. In another embodiment at least 75% of the crown area is composed of non-metallic material. In another embodiment at least 50% of the exposed surface area of the club head located above the height of the origin 205 is formed of non-metallic materials, while in an even further embodiment the non-metallic surface area located above the height of the origin 205 is at least 7500 mm2, and in another embodiment the mass of the non-metallic portions located above the height of the origin is 25-50 grams, while the mass is 30-45 grams in another embodiment. In another embodiment at least 50% of the exposed surface area of the club head located below the height of the origin 205 is formed of non-metallic materials, while in an even further embodiment the non-metallic surface area located below the height of the origin 205 is at least 7500 mm2, and in another embodiment the mass of the non-metallic portions located below the height of the origin 205 is 15-50 grams, while the mass is 20-45 grams in another embodiment.
[0208]As seen in
[0209]Simply maximizing or minimizing one attribute of a club head's mass properties generally produces a club head that is difficult for a novice golfer to maneuver and return to a square position. Such surprising and unique relationships include variations of Delta1, Delta2, CG angle, moments of inertia, volume, face dimensions, bulge, roll, and club head dimensions, as well as unique and unexpected ratios of such variables that box in unexpected characteristics to achieve the goals disclosed herein.
[0210]Another unexpected ratio that is a good indicator of the feel and difficulty a novice golfer is going to have controlling the club head throughout the swing, while avoiding the previously explained unstable feeling associated with mis-hits struck far from the geometric center of the face, is a delta2-hosel-axis ratio of the hosel axis moment of inertia (Ih) to the Delta2 value. In one embodiment the delta2-hosel-axis ratio is at least 24 kg·mm, while in further embodiments it is at least 25, 26, or 27 kg·mm. Another series of embodiments caps the delta2-hosel-axis ratio to no more than 31, 30, 29, or 28 kg·mm.
[0211]In one particular embodiment the hosel axis moment of inertia (Ih) is at least 900 kg·mm2, while in further embodiments it is at least 920, 940, 960, 980, or 1000 kg·mm2, while in yet another embodiment it is no more than 1100 kg·mm2, and in an even further embodiments it is no more than 1090, 1080, 1070, 1060, 1050, 1040, or 1030 kg·mm2. Likewise, in another preferred series of embodiments an Ih-to-Zup ratio of the hosel axis moment of inertia (Ih) to the Zup value is at least 34 kg·mm, while in a further embodiment it is at least 36 kg·mm, and in yet another embodiment it is at least 38 kg·mm, and in still another embodiment it is at least 40 kg·mm. In an even further series of embodiments the Ih-to-Zup ratio is no more than 45 kg·mm, while in another embodiment it is no more than 44 kg·mm, and in yet a further embodiment it is no more than 43 kg·mm, and in yet a further embodiment it is no more than 42 kg·mm. The disclosed ratios and ranges unexpectedly produce preferred launch conditions while not sacrificing playability and feel of the golf club in the hands of a novice golfer.
[0212]An extreme forward CG location in a large club head depths Dch club head often results in a feeling of club head instability upon mis-hits struck far from the origin 205, due in part to moments of inertia that are too small for the size of the club head. While a degree of club head twisting is sensed by a novice golfer using a golf club head having a club head depths Dch of 115 mm or less, when a golf ball is struck at the extreme toe or heel portion of the face, it is significantly more noticeable when using a club head having a club head depths Dch of 120 mm or more, particularly on shots struck high on the face or low on the face, which is virtually unperceivable to a novice golfer using a club head having a club head depths Dch of 115 mm or less.
[0213]In one particular embodiment the club head depths Dch is at least 120, 121, 122, 123, or 124 mm, and the Ixx value is at least 360 kg·mm2, while in further embodiments the Ixx value is at least 370, 380, 390, 400, or 410 kg·mm2. Another series of embodiments introduces new limits on the Ixx value range to ensure the desired z-axis gear effect is not reduced or negated. For instance, in one embodiment the Ixx value is no more than 455 kg·mm2, while in further embodiments the Ixx value is no more than 445, 435, or 425 kg·mm2. A ratio of the Ixx value to the Izz value is also critical to achieving the goals. Thus, in one embodiment the Ixx-Izz ratio is at least 0.68, and in further embodiments is at least 0.69, 0.70, or 0.71. Another series of embodiments caps the Ixx-Izz ratio to no more than 0.75, 0.74, 0.73, or 0.72. In another particular embodiment Iyy value is at least 265 kg·mm2, while in a further embodiment the Iyy value is at least 275 kg·mm2, and in yet another embodiment the Iyy value is at least 285 kg·mm2. Another series of embodiments introduces new limits on the Iyy value range to promote a natural feeling when the club head is moved throughout the range of motion of a golf swing by a novice golfer. For instance, in one embodiment the Iyy value is no more than 325 kg·mm2, while in another embodiment the Iyy value is no more than 315 kg·mm2, and in yet another embodiment the Iyy value is no more than 305, or 295 kg·mm2. In another particular embodiment the Izz value is at least 560 kg·mm2 thereby reducing the feeling of the club head spinning open or closed when mis-hits are struck on the extreme toe or heel size of the face, while in a further embodiment the Izz value is at least 570 kg·mm2, and in yet another embodiment the Izz value is at least 580, or 590 kg·mm2. Another series of embodiments introduces new limits on the Izz value range so that a novice golfer does not feel as though they need to introduce additional rotation of their hands and the grip to square the face at impact with the golf ball. For instance, in one embodiment the Izz value is no more than 700 kg·mm2, while in another embodiment the Izz value is no more than 650 kg·mm2, and in yet another embodiment the Izz value is no more than 625, or 600 kg·mm2. Still further embodiments of the club head may incorporate any of the ratios, relationships, and/or features disclosed in U.S. patent application Ser. No. 18/202,025, filed May 25, 2023, which is incorporated by reference herein.
[0214]Additionally, the location of the CG may be used to further the goal of assisting the novice golfer maneuver the club head throughout the swing and promote the return to the square position at impact with the golf ball. In one such example the CGx value is less than 0 mm, meaning the CG is located on the toe side of the origin 205 and thus the CGx value is negative, while in further embodiments the CGx value is less than-0.5 mm, −1.0 mm, −1.5 mm, −2 mm, −2.5 mm, or −3.0 mm. Another series of embodiments establishes a floor for the CGx value with it being no less than −7 mm, −6 mm, −5 mm, or −4 mm. In a further embodiment the CGx value is negative and within 30% of the absolute value of the BP projection distance multiplied by negative one, while in further embodiments the percentage is reduced to 25%, 20%, 15%, or 10%. In yet another embodiment the CGx value is negative, but greater than the absolute value of the BP projection distance multiplied by negative one. However, having a large GCx value, either negative or positive, may negatively influence performance, reduce impact efficiency, produce an undesirably feel when a ball is struck a significant distance from the origin 205, and result in a tendency of the golfer to have the face open, or closed, at impact (i.e. difficult to reliably bring the face to square during the swing).
[0215]As previously explained, Delta1 is a measure of how far rearward in the club head the CG is located behind a vertical plane containing the shaft axis, also referred to as the VSAP, further a center face progression CFP, also referred to as CFY, is a measure of how far the geometric face center, or origin, is in front of the VSAP, and the CGy value is the sum of Delta1 and CFP. As noted with several other variables, the center face progression CFP is particularly important when the maximum club head depth Dch is large, meaning at least 120 mm, 121 mm, 122 mm, 123 mm, or 124 mm. In one such embodiment the CFP is no more than 44% of Delta1, and/or the CFP is no more than 35.5% of Delta2. In a further embodiment the CFP is no more than 43.5% of Delta1; while further embodiments establish a floor for the relationship whereby the CFP is at least 41%, 41.5%, 42%, 42.5%, or 43% of Delta1. Similarly, in further embodiments the CFP is no more than 35.25%, 35%, or 34.75% of Delta2; while additional embodiments establish a floor for the relationship whereby CFP is at least 33%, 33.5%, 34%, or 34.5% of Delta2. In an even further embodiment the CFP is no more than 14 mm, and in additional embodiments the CFP is no more than 13.9 mm, 13.8 mm, or 13.7 mm. A further series of embodiments establishes a floor whereby the CFP is at least 12 mm, 12.5 mm, 13 mm, or 13.5 mm. The CFP influences the mass properties of the club head, but also must achieve a delicate balance with the mass properties to achieve a club head that is easy to control. This is achieved in part by carefully controlling the magnitudes of the BP projection, Delta1, Delta2, and/or Zup.
[0216]For example, in one embodiment the Delta2 value is at least 13 times the absolute value of the BP projection, while in further embodiments it is at least 13.1, 13.2, or 13.3 times the absolute value of the BP projection. Further, the difference between the Delta2 value and the Delta1 value, referred to as the Delta2-1 differential, is critical variable to control, often in association with other relationships. For example, in one embodiment the absolute value of the BP projection is less than 40% of the Delta2-1 differential, and in further embodiments the percentage is reduced to less than 39% or 38%. A further series of embodiments establishes a floor for the relationship whereby the absolute value of the BP projection is at least 30%, 31%, or 32% of the Delta2-1 differential. In another embodiment the Delta2-1 differential is less than 10 mm, and in additional embodiments is less than 9.5 mm, 9 mm, 8.5 mm, or 8 mm. While another series of embodiments establishes a floor for this relationship whereby the Delta2-1 differential is at least 5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, or 7.5 mm. Delta2, and the relationships associated therewith, may be used to manipulate impact location with a golf ball. For example, increasing Delta2 produces more toe droop during the golf swing, meaning there is a tendency of the toe to be more downward or closer to the ground at impact with a golf ball, which promotes a higher impact location on the strike face, which promotes an increased launch angle and/or lower spin on the golf ball after impact. However, simply maximizing Delta2 would produce a poor performing club head, as impact efficiency decreases as the impact location gets further from the origin 205. The unique relationships disclosed herein produce a club head that benefits most amateur golfers in ease of use, returning the club face to square at impact, and promoting impacts higher on the strike face, while still improving the performance in terms of resistance to twisting on off-center impacts and face performance via COR, weighted average COR, BP COR, and/or other performance factors disclosed herein.
[0217]A Zup-Delta1 ratio is a ratio of the Zup value to the Delta1 value, which in one embodiment is less than 0.815, which is further embodiments is reduced to less than 0.805 or 0.795. Another series of embodiments establishes a floor for this relationship whereby the Zup-Delta1 ratio is at least 0.65, 0.675, 0.7, 0.725, or 0.75. In another embodiment the CGy value is less than 47 mm, and is less than 46.5 mm, 46 mm, or 45.5 mm in additional embodiments. The CGy value is at least 40 mm in a further embodiment, at is at least 41 mm, 42 mm, 43 mm, or 44 mm in further embodiments. Additionally, the Delta1 value is less than 33 mm in an embodiment, and is less than 32.5 mm, 32 mm, or 31.5 mm in further embodiments. In another series of embodiments the Delta1 value is at least 27 mm, 27.5 mm, 28 mm, or 28.5 mm. The delicate balancing of pros and cons associated with mass distribution, construction, and CG placement, is also influenced by the CGz value to achieve a desired z-axis gear effect and launch characteristics, which in some embodiments is less than −3.5 mm, −3.75 mm, −4 mm, −4.25 mm, or −4.5 mm. Another series of embodiments establishes a floor for the CGz value whereby it is no less than −7 mm, −6.5 mm, −6 mm, −5.5 mm, or −5 mm. This is also true for the value of Zup, which is less than 27 mm in an embodiment, and in further embodiments is less than 26.5 mm, 26.25 mm, 26 mm, 25.75 mm, 25.5 mm, or 25.25 mm. In another series of embodiment the Zup value is at least 23 mm, 23.5 mm, 24 mm, or 24.5 mm.
[0218]In yet another embodiment the golf club head may include any of the ratios, products, relationships, and/or embodiments found in U.S. patent application Ser. No. 18/595,140, filed Mar. 4, 2024, Ser. No. 18/376,179, filed Oct. 3, 2023, Ser. No. 13/839,727, filed Mar. 15, 2013, and Ser. No. 18/379,512, filed Oct. 12, 2023, which are incorporated by reference herein.
[0219]Another important influencer of z-axis gear effect is the curvature of the face. Bulge and roll are golf club face properties that are generally used to compensate for gear effect. The term “bulge” on a golf club head refers to the rounded properties of the golf club face from the heel to the toe of the club face. The term “roll” on a golf club head refers to the rounded properties of the golf club face from the crown to the sole of the club face. The roll radius R refers to the radius of a circle having an arc that corresponds to the arc along the z-axis of the ball striking club face. Curvature is the inverse of radius and is defined as 1/R, where R is the radius of the circle having an arc corresponding to the arc along the z-axis of the ball striking club face. As an example, a roll with a curvature of 0.0050 mm−1 corresponds to a roll with a radius of 200 mm. The process for measure bulge and roll is disclosed later herein.
[0220]The roll of the golf club head can contribute to the amount of backspin that the golf ball acquires when it is struck by the club head at a point on the club face either above or below the projected CG of the club head. For example, shots struck at a point on the club face above the projected CG have less backspin than shots struck at or below the projected CG. If the roll radius of the club head is decreased, there will be a decreased variance between backspin for shots struck above the projected CG of the golf club face and shots struck below the projected CG of the ball striking club face. A Zup-to-Roll ratio is a ratio of the Zup value to the roll, and in an embodiment the Zup-to-Roll ratio is less than 0.13, while in further embodiments it is less than 0.128, 0.126, or 0.124. Another series of embodiments establishes a floor for this relationship whereby the Zup-to-Roll ratio is at least 0.1, 0.125, 0.15, 0.175, 0.12, or 0.122. The bulge radius also influences the performance and is at least 30% greater than the roll radius in one embodiment, while further embodiments increase the percentage to at least 35%, 40%, or 45% greater than the roll. In another embodiment the roll radius is less than 250 mm, while in additional embodiments it is less than 240 mm, 230 mm, 220 mm, or 210 mm. However, another series of embodiments introduces a floor for the roll whereby the roll is at least 180 mm, 185 mm, 190 mm, 195 mm, or 200 mm.
[0221]Taking advantage of the roll to influence z-axis gear effect is particularly important in club heads having large club head depths Dch, head heights, Hch, face heights, Hss, moments of inertia, and/or the disclosed relationships. One such embodiment has a roll-to-FH ratio of the roll (mm) to the face height Hss (mm) of less than 4.25, thereby promoting preferred z-axis gear effect, launch conditions, and trajectory. In a further embodiment the roll-to-FH ratio is no more than 4.05, while in an even further embodiment it no more than 3.95. Another series of embodiments discovers that a lower limit of this roll-to-FH ratio promotes preferred z-axis gear effect, launch conditions, and trajectory associated with large club head depths Dch club heads. For instance, in one embodiment the roll-to-FH ratio is at least 3.25, while in another embodiment the roll-to-FH ratio is at least 3.5, and in yet a further embodiment the roll-to-FH ratio is at least 3.75. The roll-to-FH ratio achieves both a visually attractive face when standing over a ball at address, and also yields preferred spin and trajectory.
[0222]Often the Delta1 values of the club heads having large club head depths Dch are not ideal. In one present embodiment, preferred z-axis gear effect and trajectory are achieved in a large club head depths Dch club head when the Delta1 value is less than 62% of the face height Hss, while in a further embodiment the Delta1 value is less than 61.5% of the face height Hss, and in yet a further embodiment the Delta1 value is less than 61% of the face height Hss, or even when it is less than 60.5%. In a further series of embodiments preferred performance is achieved when the Delta1 value lies within a tight range of relationships to face height Hss. For instance in one embodiment the Delta1 value is at least 57% of the face height Hss, while in a further embodiment the Delta1 value is at least 58% of the face height Hss, or even at least 59%. Similarly, in another embodiment the Delta2 value is less than 82.5% of the face height Hss, while in further embodiments the percentage is reduced to less than 80.5%, 78.5%, or 77%. Another series of embodiments sets a floor for the relationship whereby the Delta2 value is at least 60% of the face height Hss, which in further embodiments is increased to at least 65% or 70%. In another embodiment the face height Hss is at least 49 mm, which is increased in additional embodiments to at least 50 mm or 51 mm. In another series of embodiments the face height Hss is capped whereby it is no more than 56 mm, 55 mm, 54 mm, or 53 mm.
[0223]The method used to obtain the bulge and roll values in the present disclosure is the optical comparator method. The club face includes a series of score lines which traverse the width of the club face generally along the X-axis of the club head. In the optical comparator method, the club head is mounted face down and generally horizontal on a V-block mounted on an optical comparator. The club head is oriented such that the score lines are generally parallel with the X-axis of the optical comparator. Measurements are then taken at the geometric center point on the club face. Further measurements are then taken 20 millimeters away from the geometric center point of the club face on either side of the geometric center point 5a and along the X-axis of the club head, and 30 millimeters away from the geometric center point of the club face on either side of the center point and along the X-axis of the club head. An arc is fit through these five measure points, for example by using the radius function on the machine. This arc corresponds to the circumference of a circle with a given radius. This measurement of radius is what is meant by the bulge radius, or just simply bulge.
[0224]To measure the roll, the club head is rotated by 90 degrees such that the Z-axis of the club head is generally parallel to the X-axis of the machine. Measurements are taken at the geometric center point of the club face. Further measurements are then taken 15 millimeters away from the geometric center point and along the Z-axis of the club face on either side of the center point, and 20 millimeters away from the geometric center point and along the Z-axis of the club face on either side of the geometric center point. An arc is fit through these five measurement points. This arc corresponds to the circumference of a circle with a given radius. This measurement of radius is what is meant by the roll radius, or just simply roll.
[0225]As previously expressed, aerodynamic drag associated with a large club head depth Dch is significant compared to a smaller golf club head, to the point that it not only may reduce the swing speed but also impacts a golfers ability to consistently return the club face to the square position at the time of impact with the golf ball. Therefore, the club head may incorporate any of the aerodynamic features, contours, and elements described in U.S. patent application Ser. No. 18/800,504, filed Aug. 12, 2024, Ser. No. 18/814,646, filed Aug. 26, 2024, Ser. No. 18/911,709, filed Oct. 10, 2024, Ser. No. 18/207,276, filed Jun. 8, 2023, and U.S. Pat. No. 10,463,929, issued Nov. 5, 2019, and others disclosed herein, which are incorporated herein by reference. Additionally, as explained in detail in U.S. Pat. No. 10,569,144, issued Feb. 25, 2020, which is incorporated herein by reference, preferential aerodynamic shaping of the body, and particularly the crown, tend to result in a high center of gravity, and thus a large Zup dimension. Further, as explained above, traditional large club head depth Dch club heads have produced a moment of inertia about the golf club head CG z-axis, Izz, that is less than ideal. An embodiment of the present invention unexpectedly discovered that a unique relationship of the Zup value relative to ½ of the maximum club head height Hch provides a preferred balance of aerodynamic performance, launch characteristic performance, forgiveness, and feel, provided a sufficient Izz is maintained. One embodiment achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5 mm, while in another embodiment the differential is less than −6 mm, and in still a further embodiment the differential is less than −7 mm. The preferred balance of aerodynamic performance, launch characteristic performance, forgiveness, and feel, are further provided in embodiments with sufficient Izz; for example, one embodiment has an Izz value of at least 550 kg·mm2 and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5.0 mm. In a further embodiment the Izz value is at least 575 kg·mm2 and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5.0 mm; while in yet another embodiment the Izz value is at least 585 kg·mm2 and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −6.0 mm. Another series of embodiments identifies a floor for the differential and a ceiling for the Izz value that lead to desirable improvements and avoid diminishing returns, here the differential between the Zup value and ½ the value of the maximum club head height Hch that is greater than −12.0 mm and the Izz value is no more than 615 kg·mm2, while in a further embodiment the differential is greater than −10 mm and the Izz value is no more than 600 kg·mm2.
[0226]In some examples, the CG projection is toe-ward of the geometric center of the strike face. Moreover, in some examples, driver-type golf club heads have a relatively high moment of inertia about a vertical axis (e.g., a CG z-axis passing through the CG and parallel with the z-axis of the club head origin coordinate system 185) (e.g. Izz>400 kg-mm{circumflex over ( )}2 and preferably Izz>450 kg-mm{circumflex over ( )}2, and more preferably Izz>500 kg-mm{circumflex over ( )}2, but less than 600 kg-mm{circumflex over ( )}2 in certain implementations), a relatively high moment of inertia about a horizontal axis (e.g., a CG x-axis passing through the CG and parallel with the x-axis of the club head origin coordinate system 185) (e.g. Ixx>250 kg-mm{circumflex over ( )}2 and preferably Ixx>300 kg-mm{circumflex over ( )}2 or 320 kg-mm{circumflex over ( )}2, and more preferably Ixx>350 kg-mm{circumflex over ( )}2, more preferably Ixx>375 kg-mm{circumflex over ( )}2, more preferably Ixx>385 kg-mm{circumflex over ( )}2, more preferably Ixx>400 kg-mm{circumflex over ( )}2, more preferably Ixx>415 kg-mm{circumflex over ( )}2, more preferably Ixx>430 kg-mm{circumflex over ( )}2, more preferably Ixx>450 kg-mm{circumflex over ( )}2, but no more than 590 kg mm2 in some examples), and preferably a ratio of Ixx/Izz>0.70. More details about inertia Izz and Ixx can be found in U.S. Patent Application Publication No. 2020/0139208, published May 7, 2020, which is incorporate herein by reference in its entirety.
[0227]According to certain examples, a summation of Ixx and Izz is greater than 780 kg-mm{circumflex over ( )}2, 800 kg-mm{circumflex over ( )}2, 820 kg-mm{circumflex over ( )}2, 825 kg-mm{circumflex over ( )}2, 850 kg-mm{circumflex over ( )}2, 860 kg-mm{circumflex over ( )}2, 875 kg-mm{circumflex over ( )}2, 900 kg-mm{circumflex over ( )}2, 925 kg- mm{circumflex over ( )}2, 950 kg-mm{circumflex over ( )}2, 975 kg-mm{circumflex over ( )}2, or 1000 kg-mm{circumflex over ( )}2, but less than 1,100 kg-mm{circumflex over ( )}2. For example, the summation of Ixx and Izz can be between 740 kg-mm{circumflex over ( )}2 and 1,100 kg-mm{circumflex over ( )}2, such as around 869 kg-mm{circumflex over ( )}2. Ixx is at least 65% of Izz in some examples, even more preferably Ixx is at least 68% of Izz in some examples. In some example, a golf club head mass may range from 190 grams to 210 grams, preferably between 195 grams and 205 grams, even more preferably no more than 203 grams. The golf club head mass includes the mass of any FCT system and fastener to tighten the FCT system, but not the shaft of the golf club head or the grip of the golf club head. A maximum distance from a leading edge to a trailing edge of the club head as measured parallel to the y-axis is preferably is between 112 mm and 127 mm, preferably between 115 mm and 127 mm, even more preferably between 119 mm and 127 mm.
[0228]The larger inertia values and lower CG projection e.g. no more than 3 mm above center face can be achieved by including a forward weight and/or a rearward weight as discussed in more detail below. The forward weight can be a single forward weight or two or more forward weights. The forward weight can be located proximate to an imaginary vertical plane passing through the y-axis, or the forward weight can be offset to either a toe or a heel side of the imaginary vertical plane passing through the y-axis or both a toe and a heel side of the imaginary vertical plane passing through the y-axis of the golf club head. The forward weight can be separately formed and threadedly attached, welded, or bonded to the golf club head, or the forward weight can be a thickened region of the golf club head or in some cases the forwarded weight could be molded or over-molded into a forward portion of a golf club head. See below and U.S. Pat. No. 10,220,270, issued Mar. 5, 2019, which is incorporated herein by reference in its entirety, for further discussion on the various locations of forward and rearward weights. A forward weight is forward of a center of gravity of the golf club head and a rearward weight is rearward of a center of gravity of the golf club head.
[0229]In some examples, the golf club heads described herein have a delta-1 value that is no more than 25 mm, preferably between 20 mm and 25 mm. The delta-1 of the driver-type golf club head is a distance, along the y-axis of the head center face origin coordinate system 185, between the CG of the golf club head and an XZ plane, passing through the x-axis and the z-axis of the head center face origin coordinate system 185 and passing through the hosel axis 191. In certain examples, the Ixx of the golf club head is at least 335 kg·mm2 and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 345 kg mm2 and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 355 kg mm2 and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 365 kg·mm2 and the delta 1 is no more than 25 mm, or the Ixx of the golf club head is at least 375 kg mm2 and the delta 1 is no more than 25 mm.
[0230]In some examples, the golf club heads described herein have a delta-1 value that is between 20 mm and 35 mm. In certain examples, the Ixx of the golf club head is at least 335 kg·mm2 and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 345 kg·mm2 and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 355 kg mm2 and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 365 kg·mm2 and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 375 kg·mm2 and the delta 1 is between 23 mm and 32 mm, the Ixx of the golf club head is at least 385 kg mm2 and the delta 1 is between 24 mm and 32 mm, the Ixx of the golf club head is at least 395 kg mm2 and the delta 1 is between 25 mm and 32 mm, or the Ixx of the golf club head is at least 405 kg mm2 and the delta 1 is between 27 mm and 32 mm.
[0231]Referring to
[0232]The strike face 145 extends along the forward portion 112 from the sole portion 117 to the crown portion 119, and from the toe portion 114 to the heel portion 116. Moreover, the strike face 145, and at least a portion of an interior surface 166 of the forward portion 112, opposite the strike face 145, is planar in a top-to-bottom direction. As further defined, the strike face 145 faces in the generally forward direction. In some examples, the strike face 145 is co-formed with the body 102. In such examples, a minimum thickness of the forward portion 112 at the strike face 145 is between 1.5 mm and 2.5 mm and a maximum thickness of the forward portion 112 at the strike face 145 is less than 3.7 mm. An interior surface 166 of the forward portion 112, opposite the strike face 145, is not chemically etched and has an alpha case thickness of no more than 0.30 mm, in some examples.
[0233]Referring to
[0234]As shown in
[0235]Referring to
[0236]In certain examples, the width TPLW of the top plate-opening recessed ledge 147A is greater than 4.5 mm (e.g., greater than 5.0 mm in some examples and greater than 5.5 mm in other examples, but less than 8.0 mm, preferably less than 7.0 mm in some examples). In some examples, a ratio of the width TPLW to a maximum height of the strike plate 143 is between 0.08 and 0.15. In the same or different examples, a ratio of the width TPLW to a maximum height of the plate opening 149 is between 0.07 and 0.15, such as 0.1, where in some examples the maximum height of the plate opening 149 is between 50-60 mm, such as 53 mm.
[0237]According to some examples, the thickness TPLT of the top plate-opening recessed ledge 147A is between a minimum value of 0.8 mm and a maximum value of 1.7 mm (e.g., between 0.9 mm and 1.6 mm in some examples and between 0.95 mm and 1.5 mm in other examples). As shown, the thickness TPLT is greater away from the inner periphery of the ledge 147A than at the inner periphery of the ledge 147A. Accordingly, the thickness TPLT varies along the width TPLW of the ledge 147A in some examples. For example, as shown, the thickness TPLT tapers or decreases in a crown-to-sole direction (e.g., toward a center of the plate opening 149). In some examples, the top ledge thickness TPLT of the top plate-opening recessed ledge 147A varies such that a maximum value of the top ledge thickness TPLT is between 30% and 60% greater than a minimum value of the top ledge thickness TPLT. In certain examples, a ratio of the thickness TPLT to a thickness of the strike plate is between 0.2 and 1.2. According to certain examples, a ratio of the width TPLW to the thickness TPLT is between 2.6 and 10.
[0238]The bottom plate-opening recessed ledge 147B has a width (BPLW) and a thickness (BPLT). The width BPLW is defined as the distance from the inner periphery of the ledge 147B defining the plate opening 149 to the furthest extent of the adhering surface of the ledge 147B away from the inner periphery. The thickness BPLT is defined as the thickness of the material defining the adhering surface of the ledge 147B.
[0239]In certain examples, the width BPLW of the bottom plate-opening recessed ledge 147B is greater than 4.5 mm (e.g., greater than 5.0 mm in some examples and greater than 5.5 mm in other examples, but less than 8.0 mm, preferably less than 7.0 mm in some examples). In some examples, a ratio of the width BPLW to a maximum height of the strike plate 143 is between 0.08 and 0.15. In the same or different examples, a ratio of the width BPLW to a maximum height of the plate opening 149 is between 0.07 and 0.15, such as 0.1, where in some examples the maximum height of the plate opening 149 is between 50-60 mm, such as 53 mm.
[0240]According to some examples, the thickness BPLT of the bottom plate-opening recessed ledge 147B is between 0.8 mm and 1.7 mm (e.g., between 0.9 mm and 1.6 mm in some examples and between 0.95 mm and 1.5 mm in other examples). As shown, the thickness BPLT is greater away from the inner periphery of the ledge 147B than at the inner periphery of the ledge 147B. Accordingly, the thickness BPLT varies along the width BPLW of the ledge 147B in some examples. For example, as shown, the thickness BPLT decreases in a sole-to-crown direction (e.g., toward a center of the plate opening 149). In some examples, the bottom ledge thickness BPLT of the bottom plate-opening recessed ledge 147B varies such that a maximum value of the bottom ledge thickness BPLT is between 30% and 60% greater than a minimum value of the bottom ledge thickness BPLT. In certain examples, a ratio of the thickness BPLT to a thickness of the strike plate is between 0.2 and 1.2. According to certain examples, a ratio of the width BPLW to the thickness BPLT is between 2.6 and 10.
[0241]As shown, the strike plate 143 is attached to the body 102 by fixing the strike plate 143 in seated engagement with at least the top plate-opening recessed ledge 147A and the bottom plate-opening recessed ledge 147B. When joined to the top plate-opening recessed ledge 147A and the bottom plate-opening recessed ledge 147B in this manner, the strike plate 143 covers or encloses the plate opening 149. Moreover, in some examples, the top plate-opening recessed ledge 147A and the strike plate 143 are sized, shaped, and positioned relative to the crown portion 119 of the golf club head 100 such that the strike plate 143 abuts the crown portion 119 when seatably engaged with the top plate-opening recessed ledge 147A. The strike plate 143, abutting the crown portion 119, defines a topline of the golf club head 100. Moreover, in some examples, the visible appearance of the strike plate 143 contrasts enough with that of the crown portion 119 of the golf club head 100 that the topline of the golf club head 100 is visibly enhanced. Because the strike plate 143 is formed separately from the body 102, the strike plate 143 can be made of a material that is different than that of the body 102. In one example, the strike plate 143 is made of a fiber-reinforced polymeric material, such as described hereafter.
[0242]Notably, the TPLW, TPLT, BPLW, and BPLT dimensions help to control the local stiffness of the club head and to ensure sufficient bonding area to bond the strike plate to the body 102. The modulus of the strike plate if formed from a fiber-reinforced polymeric material will be much different than the modulus of the body if formed from a metal material such that the stiffness or compliance of the two are different, and during impact the strike plate and the body will move at different rates due to the different moduli unless precautions are taken in the design to account for the stiffness differences. The recess 190, and the TPLW, TPLT, BPLW, and BPLT dimensions, all play a role in controlling the overall compliance and rate with which the face and body move during impact. Additionally, TPLW and BPLW contribute to ensuring sufficient bond area and face performance. Too little bond area and the bonded joint will fail, too much bond area and the face will not perform i.e. the coefficient of restitution will not be optimized, and in some examples too much bond area will result in the face peeling away from the club head due to the differences in stiffness. Thus, TPLW, TPLT, BPLW, and BPLT dimensions contribute to the overall performance of the club head and to the avoidance of bonded joint failure. In some examples, the bond area will range from 850 mm2 to 1800 mm2, preferably between 1,300 mm2 to 1, mm2. In some examples, a ratio of the bond area to the inner surface area of the strike plate (rear surface area of the strike plate) will range from 21% to 45%. In some examples, a total bond area of the strike plate will be less than a total bond area of the crown insert. In some examples, a ledge width TPLW and/or BPLW will be less than a ledge width of the forward crown-opening recessed ledge 168A (front-back as measured along the y-axis).
[0243]The forward portion 112 includes a sidewall 146 that defines a depth of the plate-opening recessed ledge 147 and defines a radially outer periphery of the plate-opening recessed ledge 147 away from a center of the plate opening 149. The sidewall 146 is angled (e.g., acute, obtuse, or perpendicular) relative to the plate-opening recessed ledge 147. In some examples, the angle defined between the sidewall 146 and the plate-opening recessed ledge 147 is between 70° and 120°. In certain examples, the angle defined between the sidewall 146 and the plate-opening recessed ledge 147 is greater than 90°. The body 102 further includes a transition portion between the plate-opening recessed ledge 147 and the sidewall 146. In some examples, the transition portion defines a radiused surface, which couples together the surfaces of the plate-opening recessed ledge 147 and the sidewall 146.
[0244]Referring to
[0245]In some examples, the strike plate may have a maximum face plate height of no more than 65 mm as measured along the z-axis through the club head origin, preferably no more than 60 mm and no less than 40 mm, even more preferably between 44 mm and 56 mm. In some instance, the strike plate formed of fiber-reinforced polymeric material may have a front surface area of no more than 5,000 mm2, and in further embodiments no more than 4,800 mm2, 4,600 mm2, 4,400 mm2, or 4,200 mm2. In another embodiment the front surface area is at least 3,200 mm2, 3,400 mm2, or 3,600 mm2. According to certain examples, the strike face 145 has a first bulge radius of no more than 320 mm, 300 mm, 280 mm, 260 mm, or 240 mm; while in a further embodiment it is at least 195 mm, 205 mm, or 215 mm. Further, in another embodiment a first roll radius is no more than 290 mm, and in further embodiments no more than 270 mm, 250 mm, or 230 mm; while in a further embodiment it is at least 195 mm, 205 mm, or 215 mm. In one embodiment the roll radius is within X mm of the bulge radius, where X is a value selected from 50, 45, 40, 35, or 30; and in further embodiments the roll radius is less than the bulge radius. The bulge radius, the roll radius, and the relationship to one another influence the CT creep rate, particularly within the disclosed size variations of the strike face and when bonding tape 174 is used to join components of the golf club head. Further, the roll radius plays a significant roll in the distance variation associated with an impact location high on a face versus the an impact location low on the face.
[0246]In some embodiments the golf club head 100 includes a body 102, a crown insert 108 (or crown panel) attached to the body 102 at a top of the golf club head 100, and a sole insert 110 (or sole panel) attached to the body 102 at a bottom of the golf club head 100 (see, e.g.
[0247]The cup 104 is cup-shaped. More specifically, as shown in
[0248]The ring 106 is not circumferentially closed or does not form a continuous annular or circular shape. Instead, the ring 106 is circumferentially open and in some embodiments defines a substantially semi-circular shape. Thus, as defined herein, the ring 106 is termed a ring because it has a ring-like shape, and, when joined to the cup 104, forms a circumferentially closed or annular shape with the cup 104.
[0249]In the illustrated embodiment the cup 104 is formed separately from the ring 106 and the ring 106 is subsequently joined to the cup 104; however the ring 106 may be integrally formed with the cup 104. Accordingly, in the illustrated embodiment the body 102 has at least a two-piece construction where the cup 104 defines one piece of the body 102 and the ring 106 define another piece of the body 102; however in other embodiments they are integral, and in further embodiments the ring 106 is not present and an aft-body component, or components, are joined to the cup 104 to create the golf club head, which in some embodiments may cover a ring 106. Accordingly, in the illustrated embodiment a seam is defined at each of the toe-side joint 112A and the heel-side joint 112B where the cup 104 and the ring 106 are adjoined. The cup 104 and the ring 106 may be formed separately, or integrally together, using any of various manufacturing techniques. In one example, the cup 104 and the ring 106 are formed using a casting process, a forging process, an additive manufacturing process, a metal injection molding process, an injection molding process, or thermo forming methods such as blow molding, thermoforming, rotational molding, compression molding, and extrusion; and/or combinations thereof. Any of the disclosed components, can be made by stamping, forging, metal-injection-molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM. Thus, any references to cup in this disclosure may be replaced with stamped cup, forged cup, milled cup, metal-injection-molding (MIM) cup, metal additive manufacturing (metal AM) cup, and/or freeform injection molded cup, and combinations thereof. For example, a cup may be both a milled cup, as well as any of the other variation, as would be the case of a cup that is forged and then milled, or cast and then milled, and thus may be referred to as a forged-milled cup and/or a cast-milled cup. Likewise, duplicative but in the interest of eliminating any confusion, the front body portion 4602 may be both a milled front body portion 4602, as well as any of the other variation, as would be the case of a front body portion 4602 that is forged and then milled, or cast and then milled, and thus may be referred to as a forged-milled front body portion 4602 and/or a cast-milled front body portion 4602. Further, the milling may be further defined by the extent of the total surface area of an individual component that is milled, the extent of the interior exposed surface area (that exposed to the interior of the club head) that is milled, and/or the extent of the externally exposed surface area (that exposed to the external environment) that is milled. For instance the simplest embodiment is a 100% milled total surface area of the cup 104, and/or front body portion 4602, whereby every surface has been milled, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% milled total surface area. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% milled total surface area. Another embodiment has at least 50% milled interior exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled interior exposed surface area. Another embodiment has at least 50% milled externally exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled externally exposed surface area.
[0250]Forging of the cup 104 and/or front body portion 4602 components, which often have very thin areas and relatively thick areas, induces residual stresses due to plastic deformation and temperature gradients during the cooling process. Subsequent milling removes material and relieves some of the residual stresses. However, subsequent milling may also introduce new residual stresses, particularly if the machining process generates significant heat, and depending on the material and final thickness of the area being milled. Further, titanium alloy has poor thermal conductivity and higher strength compared to aluminum alloy, which can make it more prone to machining issues. For instance, during milling of titanium alloys the heat generated tends to remain more localized, which can lead to localized thermal stresses. Further, titanium alloys have a tendency to work-harden during machining, which can also contribute to the development of new residual stresses. The cup 104, and/or front body portion 4602, is exposed to severe stress upon impact with a golf ball, and controlling residual improves durability and facilitates improved performance. Any of the disclosure relating to the cup 104, and its variations and embodiments, applies equally to the later disclosed front body portion 4602, and its variations and embodiments, and likewise any disclosure relating to the front body portion 4602, and its variations and embodiments, applies equally to the cup 104, and its variations and embodiments. Potential manufacturing techniques, designs, constructions, and relationships are further disclosed in U.S. Ser. No. 63/740,603, filed Dec. 31, 2024, U.S. Ser. No. 19/007,332, filed Dec. 31, 2024, U.S. Ser. No. 18/662,372, filed May 13, 2024, and U.S. Ser. No. 18/827,140, filed Sep. 6, 2024, which are incorporated herein by reference in their entirety.
[0251]In embodiments where the cup 104 and the ring 106 are formed separately, the cup 104 and the ring 106 can be made of different materials. For example, the cup 104 can be made of a first material and the ring 106 can be made of a second material where the second material is different than the first material. The first material has a first material density and the second material has a second material density. In one embodiment the second material density is at least 30% less than the first material density. In another embodiment the second material density is no more than 55% less than the second material density.
[0252]Referring to
[0253]To help strengthen and stiffen the toe-side joint 112A and the heel-side joint 112B, complementary mating elements can be incorporated into or coupled to the engagement surfaces. In the illustrated example, the cup 104 includes a toe projection 154A protruding from the toe ring-engagement surface 150A and a heel projection 154B protruding from the heel ring-engagement surface 150B. In contrast, in the illustrated example, the ring 106 includes a toe receptacle 156A formed in the toe cup-engagement surface 152A and a heel receptacle 156B formed in the heel cup-engagement surface 152B. The toe projection 154A mates with (e.g., is received within) the toe receptacle 156A and the heel projection 154B mates with (e.g., is received within) the heel receptacle 156B as the engagement surfaces abut each other to form the joints. Although in the illustrated example, the toe projection 154A and the heel projection 154B form part of the cup 104 and the toe receptacle and the heel receptacle 156B form part of the ring 106, in other examples, the mating elements can be reversed such that the toe projection 154A and the heel projection 154B form part of the ring 106 and the toe receptacle and the heel receptacle 156B form part of the cup 104. Additionally, different types of complementary mating elements, such as tabs and notches, can be used in addition to or in place of the projections and receptacles.
[0254]In some examples, the toe-side joint 112A and the heel-side joint 112B are located a sufficient distance from the strike face 145 to avoid potential failures due to severe impacts undergone by the golf club head 100 when striking a golf ball. For example, each one of the toe-side joint 112A and the heel-side joint 112B can be spaced at least 20 mm, at least 30 mm, at least 40 mm, at least 50 mm, at least 60 mm, and/or from 20 mm to 70 mm rearward of the center face 183 of the strike face 145, as measured along a y-axis (front-to-back direction) of the club head origin coordinate system 185. Referring to
[0255]Referring to
[0256]The cup 104 additionally includes a forward crown-opening recessed ledge 168A and a forward sole-opening recessed ledge 170A. The ring 106 includes a rearward crown-opening recessed ledge 168B and a rearward sole-opening recessed ledge 170B. The forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B form a sole-opening recessed ledge 170 of the golf club head 100. Moreover, in some examples, the sole-opening recessed ledge 170 is non-planar or curved. The ledges are offset inwardly, toward the interior cavity 113, from the exterior surfaces of the body 102 surrounding the ledges by distances corresponding with the thicknesses of the crown insert 108 and the sole insert 110. In some examples, the offset of the ledges from the exterior surfaces of the body 102 is approximately equal to the corresponding thicknesses of the crown insert 108 and the sole insert 110, such that the inserts are flush with the corresponding surrounding exterior surfaces of the body 102 when attached to the ledges. However, in some examples, the crown insert 108 and the sole insert 110 need not be flush with (e.g., can be raised or recessed relative to) the surrounding exterior surface of the body 102 when seatably engaged with the corresponding ledges. In some examples, a thickness of the sole insert 110 is greater than a thickness of the crown insert 108. Moreover, the sole insert 110 is made up of a first quantity of stacked plies, each made of a fiber-reinforced polymeric material, and the crown insert 108 is made up of a second quantity of stacked plies, each made of a fiber-reinforced polymeric material. In some examples, the first quantity of stacked plies is greater than the second quantity of stacked plies.
[0257]When the cup 104 and the ring 106 are joined, the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B collectively define a crown-opening recessed ledge 168 of the body 102, and the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B collectively define a sole-opening recessed ledge 170 of the body 102. The inner periphery of the forward crown-opening recessed ledge 168A defines the forward section 162A of the crown opening 162 and the inner periphery of the rearward crown-opening recessed ledge 168B defines the rearward section 162B of the crown opening 162. Likewise, the inner periphery of the forward sole-opening recessed ledge 170A defines the periphery of the forward section 164A of the sole opening 164 and the inner periphery of the rearward sole-opening recessed ledge 170B defines the periphery of the rearward section 164B of the sole opening 164. Accordingly, the inner periphery of the crown-opening recessed ledge 168 defines the periphery of the crown opening 162 and the inner periphery of the sole-opening recessed ledge 170 defines the periphery of the sole opening 164.
[0258]Referring to
[0259]The crown insert 108 and the sole insert 110 of the illustrated embodiments are formed separately from each other and separately from the body 102, however the crown insert 108 and the sole insert 110 may be integrally formed as a single unit thereby creating an aft-body which may enclose the ring and bond to the body 102, or it may simply bond to the body 102 without the presence of the ring 106, or with the presence of a ring 106. Accordingly, the crown insert 108 and the sole insert 110 are attached to the body 102 as shown in
[0260]The crown insert 108 and the sole insert 110 can have any of various shapes. Referring to
[0261]Referring to
[0262]According to some examples, a ratio of a peak crown height of the crown portion 119 to a peak skirt height of the skirt portion 121 ranges between about 0.45 to 0.59, preferably 0.49-0.55, and in one example the skirt height is about 34 mm and the peak crown height is about 65 mm, which results in a ratio of peak skirt height to peak crown height of about 0.52. A peak skirt height typically ranges between 28 mm and 38 mm, preferably between 31 mm and 36 mm. A peak crown height typically ranges between 60 mm and 70 mm, preferably between 62 mm and 67 mm. It is desirable to limit a difference between the peak crown height and the peak skirt height to no more than 40 mm, preferably between 27 mm and 35 mm. It is desirable for the peak skirt height to be the same as or greater than a Z-up value for the golf club head i.e. the vertical distance along a z-axis from the ground plane 181 to the center of gravity. It is desirable for the peak crown height to be two times (2×) larger than a Z-up value for the golf club head. A greater peak skirt height may help with better aerodynamics and better air flow attachment especially for faster swing speeds. Likewise, if the difference between the peak crown height and peak skirt height is too great there will be a greater likelihood of the flow separating early from the golf club head i.e. increased likelihood of turbulent flow.
[0263]The construction and material diversity of the golf club head 100 enables the golf club head 100 to have a desirable center-of-gravity (CG) location and peak crown height location. In one example, a y-axis coordinate, on the y-axis of the club head origin coordinate system 185, of the location (PCH) of the peak crown height is between about 26 mm and about 42 mm. In the same or a different example, a distance parallel to the z-axis of the club head origin coordinate system 185, from the ground plane 181, when the golf club head 100 is in the address position, of the location (PCH) of the peak crown height ranges between 60 mm and 70 mm, preferably between 62 mm and 67 mm as described above. According to some examples, a y-axis coordinate, on the y-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 ranges between 25 mm and 50 mm, preferably between 32 mm and 38 mm, more preferably between 36.5 mm and 42 mm, an x-axis coordinate, on the x-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 ranges between −10 mm and 10 mm, preferably between −6 mm and 6 mm, and more preferably between −7 mm and 7 mm, and a z-axis coordinate, on the z-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 is less than 2 mm, such as ranges between −10 mm and 2 mm, preferably between −7 mm and −2 mm.
[0264]Additionally, the construction and material diversity of the golf club head 100 enables the golf club head 100 to have desirable mass distribution properties. Referring to
[0265]According to some examples, a first vector distance (V1) from a center-of-gravity of the rearward mass (RMCG) to a CG of the driver-type golf club head is between 49 mm and 64 mm (e.g., 55.7 mm), a second vector distance (V2) from a center-of-gravity of the forward mass (FMCG) to the CG of the driver-type golf club head is between 22 mm and 34 mm (e.g., 29.0 mm), and a third vector distance (V3) from the CG of the rearward mass (RMCG) to the CG of the forward mass (FMCG) is between 75 mm and 82 mm (e.g., 79.75 mm). In certain examples, V1 is no more than 56.3 mm. In some examples, V2 is no less than 23.7 mm, preferably no less than 25 mm, or even more preferably no less than 27 mm. Some additional values of V1 and V2 relative to Zup and CGy values for various examples of the golf club head 100 are provided in Table 1 below. As defined herein, Zup measures the center-of-gravity of the golf club head 100 relative to the ground plane 181 along a vertical axis (e.g., parallel to the z-axis of the club head origin coordinate system 185) when the golf club head 100 is in the proper address position on the ground plane 181. CGy is the coordinate of the center-of-gravity of the golf club head 100 on the y-axis of the club head origin coordinate system 185.
| TABLE 1 | ||||
|---|---|---|---|---|
| Example | Zup | CGy | V1 | V2 |
| 1 | 26 mm | 37 mm | 55.7 mm | 29.0 mm |
| 2 | 30 mm | 37 mm | 56.3 mm | 31.8 mm |
| 3 | 22 mm | 37 mm | 55.2 mm | 27.3 mm |
| 4 | 25 mm | 32 mm | 61.0 mm | 23.7 mm |
| 5 | 25 mm | 40 mm | 52.7 mm | 30.76 mm |
[0266]In another embodiment of the above examples, Zup is ±10% of the indicated value, CGy is ±15% of the indicated value, V1 is ±15% of the indicated value, and V2 is ±15% of the indicated value. Any tables and/or examples and/or embodiments disclosed herein that give exact values, are to be interpreted as also disclosing an embodiment where each of the values is ±10% of the value indicated, and in further embodiments each of the values is ±7.5%, ±5%, ±2.5%, or ±0%, thereby disclosing distinct upper values for each, distinct lower values for each, as well as closed ranges having upper and lower limiting values.
[0267]With reference to the values in Table 1 above, in a new example 1A the club head mass is 197-202 grams, a Zup is 25-27 mm, a Delta2 is 36-39 mm, and a BP Projection is −1 mm to 3 mm, regardless of the configuration of repositionable weights; while in a first repositionable weight configuration a 1st CGy value is 37-40 mm, a 1st Delta1 is 23.5-26 mm, a 1st Ixx is 320-380 kg mm2, and a 1st Izz is 500-550 kg·mm2; while in a second repositionable weight configuration a 2nd CGy value is 30-33 mm, a 2nd Delta1 is 19-22 mm, a 2nd Ixx is 270-310 kg mm2, and a 2nd Izz is 450-490 kg·mm2.
[0268]A further new example 1B introduces two additional repositionable weight configurations, such as the embodiments of
[0269]In one embodiment, such as the embodiments of
[0270]In one embodiment a total repositionable mass, which is a sum total mass of all the repositionable weights, is less than 60 grams; and less than 57, 54, 51, 48, 45, 42, 39, 36, 33, or 30 grams in additional embodiments. In a further series of embodiments the total repositionable mass is at least 20, 22, 24, or 26 grams.
[0271]Referring still to the embodiments of
[0272]In one embodiment the ring repositionable weight has a RRP mass, which in embodiments having multiple ring repositionable weights is a sum of the RRP mass of each individual ring repositionable weight, and the RRP mass is greater than a mass of the ring 106, or ring mass. In further embodiments the RRP mass is at least 5%, 10%, 15%, or 20% greater than the ring mass. Another series of embodiments limits the RRP mass such that it is no more than 70%, 60%, 50%, or 40% greater than the ring mass.
[0273]In another embodiment a cup weight separation distance, abbreviated CWSP, is a distance from a center of gravity of the first cup weight 173 to a center of gravity of the second cup weight, and the CWSP is greater than the Zup value. In additional embodiments the cup weight separation distance is at least 110%, 120%, or 130% of the Zup value. In another series of embodiments the cup weight separation distance no more than 275%, 250%, or 225% of the Zup value.
[0274]Referring now to
[0275]In another embodiment the RRWSD is no more than 75% of the FRWSD, and the percentage is reduces in further embodiments to no more than 65%, 55%, or 45%. Another embodiment establishes a floor whereby the RRWSD is no at least 7.5% of the FRWSD.
[0276]One embodiment, such as that seen in
[0277]The setback of the toe cup weight 173T and the heel cup weight 173H significantly influences performance of the golf club head. In one embodiment the heel cup weight CGy coordinate 173H-CGy is less than 350% of the center face progression CFP, seen in
[0278]In one embodiment the heel cup weight CGy coordinate 173H-CGy is less than 100% of the club head CGy, which in additional embodiments is reduced to 95%, 90%, or 85%. In another embodiment the heel cup weight CGy coordinate 173H-CGy is at least 50% of the club head CGy, which is increased in additional embodiments to 55%, 60%, or 65%. Similarly, in one embodiment the toe cup weight CGy coordinate 173T-CGy is less than 100% of the club head CGy, which in additional embodiments is reduced to 95%, 90%, or 85%. In another embodiment the toe cup weight CGy coordinate 173T-CGy is at least 50% of the club head CGy, which is increased in additional embodiments to 55%, 60%, or 65%.
[0279]In another embodiment the heel cup weight CGy coordinate 173H-CGy is at least 60% of Zup, and in additional embodiments at least 65%, 70%, 75%, or 80%. The heel cup weight CGy coordinate 173H-CGy is no more than 185% of Zup in one embodiment, which is reduced in further embodiments to no more than 175%, 165%, 155%, 145%, or 135%. In another embodiment the toe cup weight CGy coordinate 173T-CGy is at least 60% of Zup, and in additional embodiments at least 65%, 70%, 75%, or 80%. The toe cup weight CGy coordinate 173T-CGy is no more than 185% of Zup in one embodiment, which is reduced in further embodiments to no more than 175%, 165%, 155%, 145%, or 135%.
[0280]The elevation of the center of gravity of a toe cup weight 173T and a heel cup weight 173H above the ground plane (i.e. their individual Zup values), or alternatively the distance of the toe cup weight CG 173T-CG and heel cup weight CG 173H-CG below the face center horizontal plane FCHP (i.e. their individual CGz coordinates) significantly influences performance of the golf club head. This is also true for the elevation of the center of gravity of a toe ring mass element 159T and a heel ring mass element 159H above the ground plane (i.e. their individual Zup values), or alternatively the distance of the toe ring mass element CG 159T-CG and the heel ring mass element CG 159H-CG below the face center horizontal plane FCHP (i.e. their individual CGz coordinates) significantly influences performance of the golf club head.
[0281]In one embodiment the toe cup weight Zup 173T-CG-Zup is at least 40% of the toe ring mass element Zup 159T-CG-Zup, while additional embodiments increase the percentage to 50%, 60%, or 70%. Another embodiment caps the relationship such that the toe cup weight Zup 173T-CG-Zup is less than 100% of the toe ring mass element Zup 159T-CG-Zup, which is reduced to 90% and 80% in additional embodiments. Similarly, in one embodiment the heel cup weight Zup 173H-CG-Zup is at least 40% of the heel ring mass element Zup 159H-CG-Zup, while additional embodiments increase the percentage to 50%, 60%, or 70%. Another embodiment caps the relationship such that the heel cup weight Zup 173H-CG-Zup is less than 100% of the heel ring mass element Zup 159H-CG-Zup, which is reduced to 90% and 80% in additional embodiments.
[0282]In one embodiment the toe ring mass element Zup 159T-CG-Zup is at least 70% of the RRWSD, which is increased to at least 80%, 90%, or 100% in additional embodiments. A ceiling is established in another embodiment whereby the toe ring mass element Zup 159T-CG-Zup is no more than 150% of the RRWSD. Similarly, in one embodiment the heel ring mass element Zup 159T-CG-Zup is at least 70% of the RRWSD, which is increased to at least 80%, 90%, or 100% in additional embodiments. A ceiling is established in another embodiment whereby the heel ring mass element Zup 159T-CG-Zup is no more than 150% of the RRWSD.
[0283]In one embodiment the toe cup weight Zup 173T-CG-Zup is at least 25% of the RRWSD, which is increased to at least 30%, 35%, or 40% in additional embodiments. A ceiling is established in another embodiment whereby the toe cup weight Zup 173T-CG-Zup is no more than 100% of the RRWSD. Similarly, in one embodiment the heel cup weight Zup 173H-CG-Zup is at least 25% of the RRWSD, which is increased to at least 30%, 35%, or 40% in additional embodiments. A ceiling is established in another embodiment whereby the heel cup weight Zup 173H-CG-Zup is no more than 100% of the RRWSD.
[0284]The relationship between the roll radius of the face and the toe ring mass element Zup 159T-CG-Zup and/or the heel ring mass element Zup 159H-CG-Zup is also a major driver of performance, particularly with respect to the impact of dynamic lofting and preferred z-axis gear effect. In one embodiment the toe ring mass element Zup 159T-CG-Zup is at least 7.5% of the roll radius in millimeters, which in further embodiments increases to at least 8.5%, 9.5%, 10.5%, or 11.5%. Another series of embodiments caps the relationship such that the toe ring mass element Zup 159T-CG-Zup is no more than 15.5%, 14.5%, or 13.5% of the roll radius. Similarly, in one embodiment the heel ring mass element Zup 159H-CG-Zup is at least 7.5% of the roll radius in millimeters, which in further embodiments increases to at least 8.5%, 9.5%, 10.5%, or 11.5%. Another series of embodiments caps the relationship such that the heel ring mass element Zup 159H-CG-Zup is no more than 15.5%, 14.5%, or 13.5% of the roll radius. The disclosure and relationships of this paragraph also apply to embodiments having a single ring mass element, as seen in
[0285]The relationship between the roll radius of the face and distance of the ring mass element from the origin is also a major driver of performance, particularly with respect to the impact of dynamic lofting and preferred z-axis gear effect. Specifically, the toe ring mass element CGy 159T-CGy and/or the heel ring mass element CGy 159H-CGy are at least 40% of the roll radius in millimeters, while in further embodiments the percentage is increased to at least 42% or 44%. A further body caps the relationship such that the toe ring mass element CGy 159T-CGy and/or the heel ring mass element CGy 159H-CGy is no more than 65% of the roll radius in millimeters.
[0286]Likewise, the relationship between the roll radius of the face and the front-rear repositionable weight separation distance FRWSD is also a major driver of performance, particularly with respect to the impact of dynamic lofting and preferred z-axis gear effect. Specifically, the front-rear repositionable weight separation distance FRWSD is at least 30% of the roll radius in millimeters, while in further embodiments the percentage is increased to at least 32% or 34%. A further body caps the relationship such that the front-rear repositionable weight separation distance FRWSD is no more than 65% of the roll radius in millimeters. These relationships apply equally to embodiments having multiple ring mass elements and multiple cup weights, as well as embodiments having a single mass element and a single cup weight, such as that illustrated in
[0287]The relationship between the roll radius of the face and distance of the toe cup weight 173T and a heel cup weight 173H from the origin is also a major driver of performance, particularly with respect to the impact of dynamic lofting and preferred z-axis gear effect. Specifically, in one embodiment the heel cup weight CGy coordinate 173H-CGy and/or the toe cup weight CGy coordinate 173T-CGy is at least 9.5% of the roll radius in millimeters, which is increase in additional embodiments to at least 10.5% or 11.5%. A limit is introduced in another embodiment wherein the heel cup weight CGy coordinate 173H-CGy and/or the toe cup weight CGy coordinate 173T-CGy is no more than 25% of the roll radius in millimeters. A limit is introduced in another embodiment wherein the heel cup weight CGy coordinate 173H-CGy and/or the toe cup weight CGy coordinate 173T-CGy is no more than 150% of the club head Zup, which is reduced in further embodiments to no more than 140%, 130%, 120%, or 110%.
[0288]In another embodiment the cup weight separation distance, abbreviated CWSP, is at least 19% of the bulge radius in millimeters, which is increased in further embodiments to at least 21%, 23%, or 25%. Another embodiment limits the relationship whereby the CWSP is no more than 35%, 33%, 31%, or 29% of the bulge radius in millimeters.
[0289]In one embodiment the cup weight separation distance, abbreviated CWSP, is at least 200% of the ring repositionable weight separation distance, abbreviated RRWSD, while in further embodiments the CWSP is at least 225%, 250%, or 275% of the RRWSD. In another embodiment the CWSP is no more than 600%, 550%, or 500% of the RRWSD.
[0290]This is also impacted by the elevation of the club head center of gravity Zup and the toe ring mass element Zup 159T-CG-Zup and/or the heel ring mass element Zup 159H-CG-Zup. In one embodiment the toe ring mass element Zup 159T-CG-Zup is ±25% of the club head Zup, which is reduced in further embodiments to ±20%, ±15%, ±10%, or ±5%. In one embodiment the heel ring mass element Zup 159H-CG-Zup is ±25% of the club head Zup, which is reduced in further embodiments to ±20%, ±15%, ±10%, or ±5%.
[0291]The cup 104 has a rearwardmost cup point 105, seen in
[0292]In one embodiment the heel cup weight CG Zup 173H-CG-Zup is ±10% of the toe cup weight CG Zup 173T-CG-Zup, which in further embodiments is reduced to ±7.5%, ±5%, or ±2.5%; and in one embodiment they are not equal, and in a further embodiment the toe cup weight CG Zup 173T-CG-Zup is greater than the heel cup weight CG Zup 173H-CG-Zup.
[0293]In one embodiment the absolute value of the heel cup weight CGx coordinate 173H-CGx is ±20% of the absolute value of the toe cup weight CGx coordinate 173T-CGx, which in further embodiments is reduced to ±17.5%, ±15%, ±12.5%, ±10%, ±7.5%, ±5%, or ±2.5%; and in one embodiment they are not equal, and in a further embodiment the toe cup weight CGz coordinate 173T-CGz is greater than the heel cup weight CGz coordinate 173H-CGz, yet in another embodiment both the toe cup weight CGz coordinate 173T-CGz and the heel cup weight CGz coordinate 173H-CGz are negative (i.e. below the FCHP).
[0294]In one embodiment the absolute value of the heel ring mass element CGx coordinate 159H-CGx is ±20% of the absolute value of the toe ring mass element CGx coordinate 159T-CGx, which in further embodiments is reduced to ±17.5%, ±15%, ±12.5%, ±10%, ±7.5%, ±5%, or ±2.5%; and in one embodiment they are not equal, and in a further embodiment the toe ring mass element CGz coordinate 159T-CGz is greater than the heel ring mass element CGz coordinate 159H-CGz, yet in another embodiment both the toe ring mass element CGz coordinate 159T-CGz and the heel ring mass element CGz coordinate 159H-CGz are negative (i.e. below the FCHP).
[0295]As seen in
[0296]As seen in
[0297]References to a mass or a center of gravity of a repositionable ring weight includes all components that may be removed from the golf club head during repositioning of the weight; in other words, if the repositionable ring weight includes multiple components, such as a ME fastener 159A and a ME weight collar 159B as seen in
[0298]The crown insert 108 has a crown-insert outer surface that defines an outward-facing surface or exterior surface of the crown portion 119. Similarly, the sole insert 110 has a sole-insert outer surface that defines an outward-facing surface or exterior surface of the sole portion 117. As defined herein, the crown-insert outer surface and the sole-inert outer surface includes the combined outer surfaces of multiple crown inserts and multiple sole inserts, respectively, if multiple crown inserts or multiple sole inserts are used. In one example, a total surface area of the sole-insert outer surface is smaller than a total surface area of the crown-insert outer surface. According to one example, the total surface area of the crown-insert outer surface is at least 9,482 mm2. In one example, the total surface area of the sole-insert outer surface is at least 8,750 mm2 and the sole insert has a maximum width, parallel to a heel-to-toe direction, of at least between 80 mm and 120 mm. The total surface area of the crown-insert outer surface can range between 5,300 mm{circumflex over ( )}2 to 11,000 mm{circumflex over ( )}2, preferably between 9,200 mm{circumflex over ( )}2 and 10,300 mm{circumflex over ( )}2, preferably between 5,300 mm{circumflex over ( )}2 and 7,000 mm{circumflex over ( )}2. The total surface area of the sole-insert outer surface can range between 4,300 mm{circumflex over ( )}2 to 10,200 mm{circumflex over ( )}2, preferably between 7,700 mm{circumflex over ( )}2 and 9,900 mm{circumflex over ( )}2, preferably between 4,300 mm{circumflex over ( )}2 and 6,600 mm{circumflex over ( )}2.
[0299]Preferably the total surface area of the sole-insert outer surface is greater than the total surface area of the sole-insert outer surface in the instance when at least a portion of the sole is formed of a composite material. A ratio of total surface area of the crown-insert outer surface formed of composite material to the total surface area of the sole-insert outer surface formed of composite material may be at least 2:1 in some examples, in other instance the ratio may be between 0.95 and 1.5, more preferably between 1.03 and 1.4, even more preferably between 1.05 and 1.3. In this instance a composite material will generally have a density between about 1 g/cc and about 2 g/cc, and preferably between about 1.3 g/cc and about 1.7 g/cc.
[0300]In some embodiments, the total exposed composite surface area in square centimeters multiplied by the CGy in centimeters and the resultant divided by the volume in cubic centimeters may range from 1.22 to 2.1, preferably between 1.24 and 1.65, even more preferably between 1.49 and 2.1, and even more preferably 1.7 and 2.1.
[0301]Moreover, the total mass of the crown insert 108 is less than a total mass of the sole insert 110 in some examples. According to some examples, where the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material and the body 102 is made of a metallic material, a ratio of a total exposed surface area of the body 102 to a total exposed surface area (e.g., the surface area of the outward-facing surfaces) of the crown insert 108 and the sole insert 110 is between 0.95 and 1.25 (e.g., 1.08). The crown insert 108, whether a single piece or split into multiple pieces, has a mass of 9 grams and the sole insert 110, whether a single piece or split into multiple pieces, has a mass of 13 grams, in some examples. Moreover, in certain examples, the crown insert 108 is about 0.65 mm thick and the sole insert 110 is about 1.0 mm thick. However, in certain examples, the minimum thickness of the crown portion 119 is less than 0.6 mm. According to some examples, an areal weight of the crown portion 119 of the golf club head 100 is less than 0.35 g/cm2 over more than 50% of an entire surface area of the crown portion 119 and/or at least part of the crown portion 119 is formed of a non-metal material with a density between about 1 g/cm3 to about 2 g/cm3. These and other properties of the crown insert 108 and the sole insert 110 can be found in U.S. Patent Application Publication No. 2020/0121994, published Apr. 23, 2020, which is incorporated herein by reference in its entirety. In certain examples, an areal weight of the sole portion 117 is less than about 0.35 g/cm2 over more than about 50% of an entire surface area of the sole portion 117. In certain examples, an areal weight of the crown insert 108 is less than an areal weight of the sole insert 110. At least 50% of the crown portion 119 has a variable thickness that changes at least 25% along at least 50% of the crown portion 119, in certain examples.
[0302]The cup 104 of the body 102 also includes the hosel 120, which defines the hosel axis 191 extending coaxially through a bore 193 of the hosel 120 (see, e.g.,
[0303]The FCT system 123 may include a fastener 125 that is accessible through a lower opening 195 formed in a sole region of the cup 104. An additional example of the FCT system 123 is shown in association with the golf club head 400 of
[0304]Referring to
[0305]
[0306]In a traditional process, the face plate is formed from a flat sheet of metal having a uniform thickness. Such a sheet of metal is typically rolled along one axis to reduce the thickness to a certain uniform thickness across the sheet. This rolling process can impart a grain direction in the sheet that creates a different material properties in the rolling axis direction compared to the direction perpendicular to the rolling direction. This variation in material properties can be undesirable and can be avoided by using the disclosed casting methods instead to create face portion.
[0307]Furthermore, because a conventional face plate starts off as a flat sheet of uniform thickness, the thickness of the whole sheet has to be at least as great as the maximum thickness of the desired end product face plate, meaning much of the starting sheet material has to be removed and wasted, increasing material cost. By contrast, in the disclosed casting methods, the face portion is initially formed much closer to the final shape and mass, and much less material has to be removed and wasted. This saves time and cost.
[0308]Still further, in a conventional process, the initial flat sheet of metal has to be bent in a special process to impart a desired bulge and roll curvature to the face plate. Such a bending process is not needed when using the disclosed casting methods.
[0309]The unique thickness profiles illustrated in
[0310]By using casting methods, large numbers of the disclosed club heads can be manufacture faster and more efficiently. For example, 50 or more heads can be cast at the same time on a single casting tree, whereas it would take much longer and require more resources to create the novel face thickness profiles on face plates using a conventional milling methods using a lathe, one at a time.
[0311]In one particular embodiment, an average face density is less than 4 g/cc, while in another embodiment the average face density is less than 3.75, 3.5, 3.25, or 3 g/cc, and in yet another embodiment the average face density is less than 2 g/cc. In one particular embodiment, at least 50% of the face area is composed of non-metallic material. Such non-metallic materials may be on the outer, or striking side, of the face, or may be on the interior side of the face to provide support or reinforcing without actually coming in contact with the golf ball.
[0312]In
[0313]The second ring 608 can itself have a variable thickness profile, such that the thickness of the second ring 608 varies as a function of the circumferential position around the center 602. Similarly, the variable blend zone 606 can have a thickness profile that varies as a function of the circumferential position around the center 602 and provides a transition in thickness from the maximum thickness ring 604 to the variable and less thicknesses of the second ring 608. For example, the variable blend zone 606 to a second ring 608 can be divided into eight sectors that are labeled A-H in
[0314]One example of the face portion 600 can have the following thicknesses: 3.1 mm at center 602, 3.3 mm at ring 604, the second ring 608 can vary from 2.8 mm in zone A to 2.2 mm in zone C to 2.4 mm in zone E to 2.0 mm in zone G, and 1.8 mm in the heel and toe zones 610.
[0315]According to one example, the ring 604 can be about 8 mm away from the center 602 and the ring 608 can be about 19 mm away from the center 602. The thickness of the face portion 600 at the center 602 can be between 2.8 mm and 3.0 mm. The thickness of the face portion 600 along the ring 604 can be between 2.9 mm and 3.1 mm. The thickness of the face portion 600 along the ring 608 proximate zone A can be between 2.35 mm and 2.55 mm, proximate zone C can be between 2.3 mm and 2.5 mm, proximate zone E can be between 2.1 mm and 2.3 mm, and proximate zone G can be between 2.6 mm and 2.8 mm. The thickness of the face portion 600 at approximately 35 mm away from the center 602 can be between 1.7 mm and 1.9 mm.
[0316]According to yet another example, the thickness of the face portion 600 at the center 602 is between 2.95 mm and 3.35 mm, at about 9 mm away from the center 602 is between 3.3 mm and 3.65 mm, at about 16 mm away from the center 602 is between 2.95 mm and 3.36 mm, and at about 28 mm away from the center 602 is between 2.03 mm and 2.27 mm. The thickness of the face portion 600 greater than 28 mm away from the center 602 can be between 1.8 mm and 1.95 mm on a toe side of the face portion 600 and between 1.83 mm and 1.98 mm on a heel side of the face portion 600.
[0317]
[0318]One example of the face portion 700 can have the following thicknesses: 3.9 mm at center 702, 4.05 mm at ring 704, 3.6 mm in zone A, 3.2 mm in zone B, 3.25 mm in zone C, 2.05 mm in zone D, 3.35 mm in zone E, 2.05 mm in zone F, 3.00 mm in zone G, 2.65 mm in zone H, and 1.9 mm at perimeter ring 710.
[0319]
[0320]To the heel side, the thicknesses are offset by set amount (e.g., 0.15 mm) to be slightly thicker relative to their counterpart areas on the toe side. A thickening zone 820 (dashed lines) provides a transition where all thicknesses gradually step up toward the thicker offset zone 822 (dashed lines) at the heel side. In the offset zone 822, the ring 823 is thicker than the ring 806 on the heel side by a set amount (e.g., 0.15 mm), and the ring 825 is thicker that the ring 808 by the same set amount. Blend zones 824 and 826 gradually decrease in thickness moving radially outwardly, and are each thicker than their counterpart blend zones 807 and 810 on the toe side. In the thickening zone 820, the inner ring 804 gradually increases in thickness moving toward the heel.
[0321]One example of the face portion 800 can have the following thicknesses: 3.8 mm at the center 802, 4.0 mm at the inner ring 804 and thickening to 4.15 mm across the thickening zone 820, 3.5 mm at the second ring 806 and 3.65 mm at the ring 823, 2.4 mm at the third ring 808 and 2.55 mm at the ring 825, 2.0 mm at the fourth ring 811, and 1.8 mm at the perimeter ring 814.
[0322]The targeted offset thickness profile shown in
[0323]As shown in
[0324]In some examples, the slot 171 is offset from the strike face 145 by an offset distance, which is the minimum distance between a first vertical plane passing through a center of the strike face 145 and the slot at the same x-axis coordinate as the center of the strike face 145, between about 5 mm and about 50 mm, such as between about 5 mm and about 35 mm, such as between about 5 mm and about 30 mm, such as between about 5 mm and about 20 mm, or such as between about 5 mm and about 15 mm.
[0325]Although not shown, the cup 104 and/or the ring 106 may include a rearward slot, with a configuration similar to the slot 171, but oriented in a forward-to-rearward direction, as opposed to a heel-to-toe direction. The cup 104 includes a rearward slot, but no slot 171 in some examples, and both a rearward slot and the slot 171 in other examples. In one example, the rearward slot is positioned rearwardly of the slot 171. The rearward slot can act as a weight track in some implementations. Moreover, the rearward track can be offset from the strike face 145 by an offset distance, which is the minimum distance between a first vertical plane passing through the center of the strike face 145 and the rearward track at the same x-axis coordinate as the center of the strike face 145, between about 5 mm and about 50 mm, such as between about 5 mm and about 40 mm, such as between about 5 mm and about 30 mm, or such as between about 10 mm and about 30 mm.
[0326]In certain embodiments, the slot 171, as well as the rearward slot if present, has a certain slot width, which is measured as a horizontal distance between a first slot wall and a second slot wall. For the slot 171, as well as the rearward slot, the slot width may be between about 5 mm and about 20 mm, such as between about 10 mm and about 18 mm, or such as between about 12 mm and about 16 mm. According to some embodiments, a depth of the slot 171 (i.e., the vertical distance between a bottom slot wall and an imaginary plane containing the regions of the sole portion 117 adjacent opposing slot walls of the slot 171) may be between about 6 mm and about 20 mm, such as between about 8 mm and about 18 mm, or such as between about 10 mm and about 16 mm.
[0327]Additionally, the slot 171, as well as the rearward slot if present, has a certain slot length, which can be measured as the horizontal distance between a slot end wall and another slot end wall. For both the slot 171 and rearward slot, their lengths may be between about 30 mm and about 120 mm, such as between about 50 mm and about 100 mm, or such as between about 60 mm and about 90 mm. Additionally, or alternatively, the length of the slot 171 may be represented as a percentage of a total length of the strike face 145. For example, the slot 171 may be between about 30% and about 100% of the length of the strike face 145, such as between about 50% and about 90%, or such as between about 60% and about 80% mm of the length of the strike face 145.
[0328]In some examples, the slot 171 is a feature to improve and/or increase the coefficient of restitution (COR) across the strike face 145. With regards to a COR feature, the slot 171 may take on various forms such as a channel or through slot. The COR of the golf club head 100 is a measurement of the energy loss or retention between the golf club head 100 and a golf ball when the golf ball is struck by the golf club head 100. Desirably, the COR of the golf club head 100 is high to promote the efficient transfer of energy from the golf club head 100 to the ball during impact with the ball. Accordingly, the COR feature of the golf club head 100 promotes an increase in the COR of the golf club head 100. Generally, the slot 171 increases the COR of the golf club head 100 by increasing or enhancing the flexibility of the strike face 145. In some examples of the golf club heads disclosed herein, the COR is at least 0.8 for at least 25% of the strike face within the central region, as defined below.
[0329]Further details concerning the slot 171 as a COR feature of the golf club head 100 can be found in U.S. patent application Ser. Nos. 13/338,197, 13/469,031, 13/828,675, filed Dec. 27, 2011, May 10, 2012, and Mar. 14, 2013, respectively, U.S. patent application Ser. No. 13/839,727, filed Mar. 15, 2013, U.S. Pat. No. 8,235,844, filed Jun. 1, 2010, U.S. Pat. No. 8,241,143, filed Dec. 13, 2011, U.S. Pat. No. 8,241,144, filed Dec. 14, 2011, all of which are incorporated herein by reference.
[0330]The slot 171 can be any of various flexible boundary structures (FBS) as described in U.S. Pat. No. 9,044,653, filed Mar. 14, 2013, which is incorporated by reference herein in its entirety. Additionally, or alternatively, the golf club head 100 can include one or more other FBS at any of various other locations on the golf club head 100. The slot 171 may be made up of curved sections, or several segments that may be a combination of curved and straight segments. Furthermore, the slot 171 may be machined or cast into the golf club head 100. Although shown in the sole portion 117 of the golf club head 100, the slot 171 may, alternatively or additionally, be incorporated into the crown portion 119 of the golf club head 100.
[0331]In some examples, the slot 171 is filled with a filler material. However, in other examples, the slot 171 is not filled with a filler material, but rather maintains an open, vacant, space within the slot 171. The filler material can be made from a non-metal, such as a thermoplastic material, thermoset material, and the like, in some implementations. The slot 171 may be filled with a material to prevent dirt and other debris from entering the slot and possibly the interior cavity 113 of the golf club head 100 when the slot 171 is a through-slot. The filler material may be any relatively low modulus materials including polyurethane, elastomeric rubber, polymer, various rubbers, foams, and fillers. The filler material should not substantially prevent deformation of the golf club head 100 when in use as this would counteract the flexibility of the golf club head 100.
[0332]According to one embodiment, the filler material is initially a viscous material that is injected or otherwise inserted into the slot 171. Examples of materials that may be suitable for use as a filler to be placed into a slot, channel, or other flexible boundary structure include, without limitation: viscoelastic elastomers; vinyl copolymers with or without inorganic fillers; polyvinyl acetate with or without mineral fillers such as barium sulfate; acrylics; polyesters; polyurethanes; polyethers; polyamides; polybutadienes; polystyrenes; polyisoprenes; polyethylenes; polyolefins; styrene/isoprene block copolymers; hydrogenated styrenic thermoplastic elastomers; metallized polyesters; metallized acrylics; epoxies; epoxy and graphite composites; natural and synthetic rubbers; piezoelectric ceramics; thermoset and thermoplastic rubbers; foamed polymers; ionomers; low-density fiber glass; bitumen; silicone; and mixtures thereof. The metallized polyesters and acrylics can comprise aluminum as the metal. Commercially available materials include resilient polymeric materials such as Scotchweld™ (e.g., DP-105™) and Scotchdamp™ from 3M, Sorbothane™ from Sorbothane, Inc., DYAD™ and GP™ from Soundcoat Company Inc., Dynamat™ from Dynamat Control of North America, Inc., NoViFlex™ Sylomer™ from Pole Star Maritime Group, LLC, Isoplast™ from The Dow Chemical Company, Legetolex™ from Piqua Technologies, Inc., and Hybrar™ from the Kuraray Co., Ltd. In some embodiments, a solid filler material may be press-fit or adhesively bonded into a slot, channel, or other flexible boundary structure. In other embodiments, a filler material may poured, injected, or otherwise inserted into a slot or channel and allowed to cure in place, forming a sufficiently hardened or resilient outer surface. In still other embodiments, a filler material may be placed into a slot or channel and sealed in place with a resilient cap or other structure formed of a metal, metal alloy, metallic, composite, hard plastic, resilient elastomeric, or other suitable material.
[0333]Referring to
[0334]In some examples, as shown, the weight port 175, and thus the weight 173, is located in the sole portion 117 of the golf club head 100. Moreover, according to certain examples, the weight port 175 and the weight 173 are located closer to the heel portion 116 than the toe portion 114. In one example, the weight port 175 and the weight are located closer to the heel portion 116 than the slot 171. The weight 173 has a mass between about 3 g and about 23 g (e.g., 6 g) in some examples.
[0335]Referring to
[0336]Referring to
[0337]Referring to
[0338]In some examples, the cantilevered portion 161 extends downward from the rearwardmost point of the ring 106 toward the ground plane 181, and a portion of the cantilevered portion 161 extends to an elevation that is less than 80% of the Zup value, and the percentage is reduces in further embodiments to 70%, 60%, or 50%; when the golf club head 100 is in the address position. According to certain examples, a ratio of the peak crown height to a vertical distance from the peak crown height to a lowest surface of the cantilevered portion 161 of the ring 106 is at least 6.0, at least 5.0, at least 4.0, or more preferably at least 3.0. Alternatively, or additionally, in some examples, a vertical cantilevered extension distance from the peak skirt height of the skirt portion to a lowermost surface of the cantilevered portion 161 of the ring 106, when the golf club head 100 is in the address position, is no less than 15 mm, and in additional embodiments is no less than 20 mm or 25 mm. In a further embodiment the vertical cantilevered extension distance is no more than 40 mm, and in further embodiments is no more than 35 mm or 30 mm.
[0339]The toe arm portion 163A and the heel arm portion 163B define a toe side of the skirt portion 121 and a heel side of the skirt portion 121, respectively, as well as part of the toe portion 114 and heel portion 116, respectively, of the golf club head 100. The cantilevered portion 161 extends downwardly away from the toe arm portion 163A and the heel arm portion 163B, while the toe arm portion 163A and the heel arm portion 163B extend forwardly away from the cantilevered portion 161. Accordingly, the cantilevered portion 161 is closer to the ground plane 181 than the toe arm portion 163A and the heel arm portion 163B when the golf club head 100 is in the address position. In other words, referring to
[0340]In some examples, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is different than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100. More specifically, in one example, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is greater than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100.
[0341]According to certain examples, as shown in
[0342]Referring to
[0343]The mass element 159 may be partially received by a mass receptable 157, which may be formed in the ring 106, as seen in
[0344]One embodiment, such as that of
[0345]In one embodiment the mass receptacle 157 attached to the cantilevered portion 161 of the ring 106. The mass receptacle 157 can include a threaded aperture, with internal threads, that threadably engages the mass element 159 to secure the mass element 159 to the cantilevered portion 161. In another embodiment the ME fastener 159A may extend through the mass receptable and engage the ring 106, thereby serving to also secure the mass receptacle 157 to the ring 106. Alternatively, the mass receptacle 157 may be welded, brazed, or adhesively attached to the cantilevered portion 161 in some examples and adhered to the cantilevered portion 161 in other examples, which includes being adhered by the VP bonding tape 174. In certain examples, the mass receptacle 157 is co-formed with the cantilevered portion 161. The mass receptable 157 may be a cylindrical insert as illustrated in
[0346]As seen in
[0347]The above disclosure regarding the relationships of the average masses applies equally to any pair of collars. For instance, a first pair of collars has an average first pair mass, where the first pair of collars are selected from the first ME collar, the second ME collar, the first cup weight collar, and the second cup weight collar. A second pair of collars has an average second pair mass, where the second pair of collars are selected from the first ME collar, the second ME collar, the first cup weight collar, and the second cup weight collar, and the second pair of collars do not include the collars of the first pair of collars. In an embodiment the average first pair mass is at least 3, 4, 5, or 6 grams greater than the average second pair mass. While in another embodiment the average first pair mass is no more than 12, 10, or 8 grams greater than the average second pair mass. In another embodiment a total collar mass is a sum of the first ME collar mass, the second ME collar mass, the first cup weight collar mass, and the second cup weight collar mass, and the total collar mass is less than 50 grams; and less than 47, 44, 41, 38, 35, 33, or 29 grams in additional embodiments. In a further series of embodiments the total collar mass is at least 20, 22, 24, or 26 grams.
[0348]Referring again to the embodiments of
[0349]In another embodiment a cup collar separation distance is a distance from a center of gravity of the first cup weight collar 173 to a center of gravity of the second cup weight collar 173, and the weight collar separation distance is greater than the Zup value. In additional embodiments the weight collar separation distance is at least 110%, 120%, or 130% of the Zup value. In another series of embodiments the weight collar separation distance no more than 275%, 250%, or 225% of the Zup value.
[0350]Referring now to
[0351]In some examples, the cantilevered portion 161 is close to the ground plane 181 when the golf club head 100 is in the address position. According to certain examples, a ratio of the peak crown height to a vertical distance from the peak crown height to a lowest surface of the cantilevered portion 161 of the ring 106 is at least 6.0, at least 5.0, at least 4.0, or more preferably at least 3.0. Alternatively, or additionally, in some examples, a vertical distance from the peak skirt height of the skirt portion to a lowermost surface of the cantilevered portion 161 of the ring 106, when the golf club head 100 is in the address position, is no less than between 20 mm and 30 mm.
[0352]The toe arm portion 163A and the heel arm portion 163B define a toe side of the skirt portion 121 and a heel side of the skirt portion 121, respectively, as well as part of the toe portion 114 and heel portion 116, respectively, of the golf club head 100. The cantilevered portion 161 extends downwardly away from the toe arm portion 163A and the heel arm portion 163B, while the toe arm portion 163A and the heel arm portion 163B extend forwardly away from the cantilevered portion 161. Accordingly, the cantilevered portion 161 is closer to the ground plane 181 than the toe arm portion 163A and the heel arm portion 163B when the golf club head 100 is in the address position. In other words, referring to
[0353]In some examples, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is different than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100. More specifically, in one example, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is greater than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100.
[0354]According to certain examples, as shown in
[0355]Referring to
[0356]In one example, the mass element 159 includes external threads. The golf club head 100 can additionally include a mass receptacle 157 attached to the cantilevered portion 161 of the ring 106. The mass receptacle 157 can include a threaded aperture, with internal threads, that threadably engages the mass element 159 to secure the mass element 159 to the cantilevered portion 161. The mass receptacle 157 is welded to the cantilevered portion 161 in some examples and adhered to the cantilevered portion 161 in other examples. In certain examples, the mass receptacle 157 is co-formed with the cantilevered portion 161. The cantilevered portion 161 also includes a mass pad 155 (see, e.g.,
[0357]The outer peripheral shape of one or both of the mass element 159 and the weight 173 in the illustrated examples is circular. Accordingly, an orientation of one or both of the mass element 159 and the weight 173 is rotatable about a central axis of the mass element 159 and the weight 173, respectively, in any of various orientations between 0-degrees and 360-degrees. However, in other examples, the outer peripheral shape of at least one or both of the mass element 159 and the weight 173 is non-circular, such as ovular, triangular, trapezoidal, square, and the like. For example, as shown in
[0358]The construction and material diversity of the golf club head 100 enables flexibility of the position of the weight 173 (e.g., first weight or forward weight) relative to the position of the mass element 159 (e.g., second weight or rearward weight). In some examples, the relative positions of the weight 173 and the mass element 159 can be similar to those disclosed in U.S. patent application Ser. No. 16/752,397, filed Jan. 24, 2020. Referring to
[0359]In certain examples, the sole portion 117 of the golf club head 100 includes an inertia generating feature 177 that is elongated in a lengthwise direction. The lengthwise direction is perpendicular or oblique to the strike face 145. According to some examples, the inertia generating feature 177 includes the same features and provides the same advantages as the inertia generator disclosed in U.S. patent application Ser. No. 16/660,561, filed Oct. 22, 2019, which is incorporated herein by reference in its entirety. In the illustrated examples, the sole insert 110 forms at least a portion of the inertia generating feature 177. More specifically, in some examples, the sole insert 110 forms all or a majority of the inertia generating feature 177. The cantilevered portion 161 of the ring 106 also forms part, such as a rearmost part, of the inertia generating feature 177 in certain examples. The inertia generating feature 177 helps to increase the inertia of the golf club head 100 and lower the center-of-gravity (CG) of the golf club head 100.
[0360]The inertia generating feature 177 includes a raised or elevate platform that extends from a location rearwardly of the hosel 120 to a location proximate the rearward portion 118 of the golf club head 100. The inertia generating feature 177 includes a substantially flat or planar surface that is raised above (or protrudes from, depending on the orientation of the golf club head 100) the surrounding external surface of the sole portion 117. In certain examples, at least a portion of the inertia generating feature 177 is raised above the surrounding external surface of the sole portion 117 by at least 1.5 mm, at least 1.8 mm, at least 2.1 mm, or at least 3.0 mm. The inertia generating feature 177 also has a width that is less than an entire width (e.g., less than half the entire width) of the sole portion 117. In view of the foregoing, the inertia generating feature 177 has a complex curved geometry with multiple inflection points. Accordingly, the sole insert 110, which defines the inertia generating feature 177, has a complex curved surface that has multiple inflection points.
[0361]Referring to
[0362]The CT properties of the golf club heads disclosed herein can be defined as CT values within a central region of the strike face 145. The central region, is forty millimeter by twenty millimeter rectangular area centered on a center of the strike face and elongated in a heel-to-toe direction. The center of the strike face 145 can be a geometric center of the strike face 145 in some examples. Within the central region, the strike face 145 has a characteristic time (CT) of no more than 257 microseconds. In some examples, the CT of at least 60% of the strike face, within the central region, is at least 235 microseconds. According to some examples, the CT of at least 35% of the strike face, within the central region, is at least 240 microseconds.
[0363]The CT of the strike face 145, at the geometric center of the strike face, has an initial CT value. The initial CT value is the CT value of the strike face 145 before any impacts with a standard golf ball. As defined herein, an impact with the standard golf ball is an impact of the standard golf ball when the golf ball is traveling at a velocity of 52 meters per second. According to some examples, the initial CT value is at least 244 microseconds. In certain examples, the driver-type golf club heads disclosed herein, including the golf club head 100, are configured such that after 500 impacts of a standard golf ball at the geometric center of the strike face 145, the CT of the strike face at any point within the central region is less than 256 microseconds and the CT at the geometric center of the strike face is no more than five microseconds different than (e.g., greater than) the initial CT value.
[0364]In certain examples, the driver-type golf club heads disclosed herein, including the golf club head 100, are configured such that after 1,000, 1,500, 2,000, 2,500, or 3,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face at any point within the central region is less than 256 microseconds. According to some examples, after 2,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at any point within the central region is no more than seven microseconds or nine microseconds different that the initial CT value. Moreover, in certain examples, after 2,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at the geometric center of the strike face is no less than 249 microseconds and no more than ten microseconds different than the initial CT value. According to some examples, after 3,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at any point within the central region is no more than nine microseconds or thirteen microseconds different that the initial CT value. In certain examples, such as those where the strike face 145 is made of a metallic material, an inward face progression of the strike face 145 is less than 0.01 inches after 500 impacts of the standard golf ball at the geometric center of the strike face.
[0365]Referring to
[0366]Unlike the golf club head 100, however, the strike face 245 of the golf club head 200 in
[0367]Additionally, unlike the golf club head 100, the cup 204 includes a weight track 279 in the sole portion 217 of the golf club head 200. The weight track 279 extends lengthwise in a heel-to-toe direction along the sole portion 217. In examples where the cup 204 also includes the slot 271, such as shown, the weight track 279 is substantially parallel to the slot 271 and offset from the slot 271 in a front-to-rear direction. The weight track 279 includes at least one ledge that extends lengthwise along the length of the weight track 279. In the illustrated example, the weight track 279 includes a forward ledge 297A and a rearward ledge 297B, which are spaced apart from each other in the front-to-rear direction. The weight 273, which positioned within the weight track 279, is selectively clampable to the ledge or ledges of the weight track 279 to releasably fix the weight 273 to the weight track 279. In the illustrated example, the weight 273 is selectively clampable to both the forward ledge 297A and the rearward ledge 297B. When unclamped to the one or more ledges of the weight track 279, the weight 273 is slidable along the one or more ledges, as shown by directional arrows in
[0368]According to one example, the weight 273 includes a washer 273A, a nut 273B, and a fastening bolt 273C that interconnects with the washer 273A and the nut 273B to clamp down on the ledges 297A, 297B of the weight track 279. The washer 273A has a non-threaded aperture and the nut 273B has a threaded aperture. The fastening bolt 273C is threaded and passes through the non-threaded aperture of the washer 273A to threadably engage the threaded aperture of the nut 273B. Threadable engagement between the fastening bolt 273C and the nut 273B allows a gap between the washer 273A and the nut 273B to be narrowed, which facilitates the clamping of the ledge or ledges between the washer 273A and the nut 273B, or widened, which facilitates the un-clamping of the ledge or ledges from between the washer 273A and the nut 273B. The fastening bolt 273C can be rotatable relative to both the washer 273A and the nut 273B or form a one-piece monolithic construction and be co-rotatable with one of the washer 273A and the nut 273B.
[0369]To reduce the weight of the golf club head 200 and the depth of the weight track 279, the fastening bolt 273C is short. For example, the length of the fastening bolt 273C, when the weight 273 is clamped on the ledges 297A, 297B, extends no more than 3 mm past the nut 273B (or the washer 273A if the position of the nut 273B and the washer 273A are reversed). In some examples, the entire length of the fastening bolt 273C is no more than 15% greater than the combined thicknesses of the washer 273A, the nut 273B, and one of the ledges 297A, 297B.
[0370]As shown, an outer peripheral shape of the washer 273A is non-circular, such as trapezoidal or rectangular. Similarly, the outer peripheral shape of the nut 273B can be non-circular, such as trapezoidal or rectangular. Alternatively, as shown, the outer peripheral shape of the nut 273B is circular and the outer peripheral shape of the washer 273A is non-circular.
[0371]Referring to
[0372]Additionally, like the golf club head 200, the golf club head 300 includes a strike plate 343, defining a strike face 145, that is formed separate from and attached to the cup 304. The strike plate 343 is made of a fiber-reinforced polymer in some examples and includes a base portion 347 and a cover 349 applied onto the base portion 347. The base portion 347 is thicker compared to the cover 349, the base portion 347 is made of a fiber-reinforced polymer, and the cover 349 is made of a fiber-less polymer in some examples. The cover 349 is made of polyurethane in certain examples. Also, the cover 349 includes grooves 351 or scorelines formed in the fiber-less polymer. The surface roughness of the portion of the cover 349 that defines the strike face 345 is greater than the surface roughness of the body 302. Accordingly, in view of the foregoing, the golf club head 300 shares some similarities with the golf club head 100 and the golf club head 200.
[0373]Unlike the illustrated examples of the cup 104 of the golf club head 100 and the cup 204 of the golf club head 200, however, the cup 304 has a multi-piece construction. More specifically, the cup 304 includes an upper cup piece 304A and a lower cup piece 304B. The upper cup piece 304A is formed separately from the lower cup piece 304B. Accordingly, the upper cup piece 304A and the lower cup piece 304B are joined or attached together to form the cup 304. Because the upper cup piece 304A and the lower cup piece 304B are formed separately, the upper cup piece 304A can be made of a material that is different than that of the lower cup piece 304B. The cup 304 includes a hosel 320 where a portion of the hosel 320 is formed into the upper cup piece 304A and another portion of the hosel 320 is formed into the lower cup piece 304B.
[0374]According to some examples, the upper cup piece 304A is made of a material that is different than that of the lower cup piece 304B. For example, the upper cup piece 304A can be made of a material with a density that is lower than the material of the lower cup piece 304B. In one example, the upper cup piece 304A is made of a titanium alloy and the lower cup piece 304B is made of a steel alloy. According to another example, the upper cup piece 304A is made of an aluminum alloy and the lower cup piece 304B is made of a steel alloy or a tungsten alloy, such as 10-17 density tungsten. Such configurations help to increase the mass of the cup 304 and lower the center-of-gravity (CG) of the cup 304 and the golf club head 300 compared to the single-piece cup 104 of the golf club head 100. In alternative configurations, according to some examples, the upper cup piece 304A is made of an aluminum alloy and the lower cup piece 304B is made of a titanium alloy. These later configurations help to lower the overall mass of the cup 304. According to some examples, the upper cup piece 304A and the lower cup piece 304B are made using different manufacturing techniques. For example, the upper cup piece 304A can be made by stamping, forging, and/or metal-injection-molding (MIM) and the lower cup piece 304B can be made by another one or a different combination of stamping, forging, and/or metal-injection-molding (MIM). Various examples of combinations of materials and mass properties for the upper cup piece 304A and the lower cup piece 304B are shown in Table 2 below.
| TABLE 2 | |||||||
|---|---|---|---|---|---|---|---|
| Material | Density (g/cc) | Mass (g) | CG (z-axis) (mm) | Mass (g) | Delta-CG | Delta-CG | |
| Example | Upper | Lower | Upper | Lower | Upper | Lower | Upper | Lower | Combined | Combined | Total Head |
| 1 | Ti-64 | Ti-64 | 4.4 | 4.4 | 37.5 | 37.5 | 15 | −15 | 75 | 0 | 0 |
| 2 | Ti-64 | Steel | 4.4 | 7.8 | 37.5 | 66.5 | 15 | −15 | 104.0 | −4.2 | −2.2 |
| 3 | Al-7075 | Steel | 2.8 | 7.8 | 23.9 | 66.5 | 15 | −15 | 90.3 | −7.1 | −3.2 |
| 4 | Al-7075 | W-10 | 2.8 | 10 | 23.9 | 85.2 | 15 | −15 | 109.1 | −8.4 | −4.6 |
| 5 | Al-7075 | Ti-64 | 2.8 | 4.4 | 23.9 | 37.5 | 15 | −15 | 61.4 | −3.3 | −1.0 |
| 6 | Al-7075 | Al-7075 | 2.8 | 2.8 | 23.9 | 23.9 | 15 | −15 | 47.7 | 0.0 | 0.0 |
In another embodiment of the above examples, each density is ±5% of the indicated value, each mass is ±15% of the indicated value, and each Delta-CG value is ±15% of the indicated value.
[0375]As shown, the cup 304 includes a port 375 that receives and retains the weight 373. The port 375 is configured to retain the weight 373 in a fixed location on the sole portion of the golf club head 300. However, in other examples, the port 375 can be replaced with a weight track, similar to the weight track 279 of the golf club head 200, such that the weight 373 can be selectively adjustable and moved into any of various positions along the weight track. In this manner, a weight track, and a corresponding ledge or ledges of the weight track, can form part of one piece of a multi-piece cup.
[0376]Although the cup 304 is shown to have a two-piece construction, in other examples, the cup 304 has a three-piece construction or constructed with more than three pieces. According to one instance, the cup 304 has a crown-toe piece, a crown-heel piece, and a sole piece. The crown-toe piece and the crown-heel piece are made of titanium alloys and the sole piece is made of a steel alloy in certain implementations. The titanium alloy of the crown-toe piece can be the same as or different than the titanium alloy of the crown-heel piece.
[0377]Referring to
[0378]Furthermore, the golf club head 400 additionally includes a weight 473 attached to the cup 404 via a fastener 479. As shown, the cup 404 includes a port 475 that receives and retains the weight 473. The port 475 is configured to retain the weight 473 in a fixed location on the sole portion of the golf club head 400. However, in other examples, the port 475 can be replaced with a weight track, similar to the weight track 279 of the golf club head 200, such that the weight 473 can be selectively adjustable and moved into any of various positions along the weight track. In this manner, a weight track, and a corresponding ledge or ledges of the weight track, can form part of the cup 404.
[0379]Also, like the golf club head 100, the golf club head 200, and the golf club head 300, the golf club head 400 additionally includes a mass element 459 and a mass receptacle 457. However, unlike some examples, of the receptacles of the previously discussed golf club heads, the mass receptacle 457 of the golf club head 400 forms a one-piece monolithic construction with a cantilevered portion 461 of the ring 406. Accordingly, in certain examples, the mass receptacle 457 is co-cast with the ring 406. The mass receptacle 457 includes an opening or recess that is configured to nestably receive the mass element 459. The mass element 459 can be made of a material, such as tungsten, that is different (e.g., denser) than the material of the ring 406. The mass element 459 is bonded, such as via an adhesive, to the ring 406 to secure the mass element 459 within the mass receptacle 457. In some examples, the mass element 459 includes prongs 463 that engage corresponding apertures in the mass receptacle 457 when bonded to the ring 406. Engagement between the prongs 463 and the corresponding apertures of the mass receptacle 457 help to strengthen and stiffen the coupling between the mass element 459 and the ring 406.
[0380]Referring to
[0381]In some examples, the height HR of the lowest surface (and in some examples, an entirety) of the toe arm portion 463A at the toe portion 414 of the golf club head 400 is different than the height HR of the lowest surface (and in some examples, an entirety) of the heel arm portion 463B at the heel portion 416 of the golf club head 400. More specifically, in one example, the height HR of the lowest surface of the toe arm portion 463A at the toe portion 414 of the golf club head 400 is greater than the height HR of the lowest surface of the heel arm portion 463B at the heel portion 416 of the golf club head 100.
[0382]According to certain examples, the width WR of the toe arm portion 463A of the ring 406 at the toe portion 414 is less than the width WR of the heel arm portion 463B of the ring 406 at the heel portion 416. According to some additional examples, a thickness (TR) of the ring 406 can vary along the ring 406 in a forward-to-rearward direction. For example, in some examples, the thickness TR of the ring 406 varies from a minimum thickness to a maximum thickness in a forward-to-rearward direction. In certain examples, as shown, the thickness TR of the toe arm portion 463A of the ring 406 at the toe portion 414 is less than the thickness TR of the heel arm portion 463B of the ring 406 at the heel portion 416.
[0383]The golf club heads disclosed herein, including the golf club head 100, the golf club head 200, and the golf club head 300, each has a volume, equal to the volumetric displacement of the golf club head, that is between 390 cubic centimeters (cm3 or cc) and about 600 cm3. In more particular examples, the volume of each one of the golf club heads disclosed herein is between about 350 cm3 and about 500 cm3 or between about 420 cm3 and about 500 cm3. The total mass of each one of the golf club heads disclosed herein is between about 145 g and about 245 g, in some examples, and between 185 g and 210 g in other examples.
[0384]The golf club heads disclosed herein have a multi-piece construction. For example, with regards to the golf club head 100, the cup 104, the ring 106, the crown insert 108, and the sole insert 110 each comprises one piece of the multi-piece construction. Because each piece of the multi-piece construction is separately formed and attached together, each piece can be made of a material different than at least one other of the pieces. Such a multi-material construction allows for flexibility of the material composition, and thus the mass composition and distribution, of the golf club heads.
[0385]The following properties of the golf club heads disclosed herein proceeds with reference to the golf club head 100. However, unless otherwise noted, the properties described with reference to the golf club head 100 also apply to the golf club head 200, the golf club head 300, and the golf club head 400. The golf club head 100 is made from at least one first material, having a density between 0.9 g/cc and 3.5 g/cc, at least one second material, having a density between 3.6 g/cc and 5.5 g/cc, and at least one third material, having a density between 5.6 g/cc and 20.0 g/cc. In a first example, the cup 104 is made of the third material, the ring 106 is made of the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this first example, according to one instance, the cup 104 is made of a steel alloy, the ring 106 is made of a titanium alloy, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. In a second example, the cup 104 is made of the second and third material, the ring 106 is made of the first or the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this second example, according to one instance, the cup 104 is made of a steel alloy and a titanium alloy, the ring 106 is made of a titanium alloy, aluminum alloy, or plastic, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. In a third example, according to one instance, the cup 104 is made of an aluminum alloy, the ring 106 is made of an aluminum alloy or plastic, the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a titanium alloy. In a fourth example, according to one instance, the cup 104 is made of an aluminum alloy, the ring 106 is made of an aluminum alloy or plastic, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a fiber-reinforced polymeric material. In a fifth example, according to one instance, the cup 104 is made of a titanium alloy, the ring 106 is made of an aluminum alloy or plastic, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a titanium alloy. In a sixth example, according to one instance, the cup 104 is made of a titanium alloy, the ring 106 is made of an aluminum alloy or plastic, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a fiber-reinforced polymeric material. In a seventh example, according to one instance, the cup 104 is made of a fiber-reinforced polymeric material, the ring 106 is made of an aluminum alloy or fiber-reinforced polymeric material, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a fiber-reinforced polymeric material. In an eighth example, according to one instance, the cup 104 is made of a fiber-reinforced polymeric material, the ring 106 is made of an aluminum alloy or fiber-reinforced polymeric material, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a titanium alloy. In a nineth example, according to one instance, the cup 104 is made of an anodized aluminum alloy having a variable oxide thickness, the ring 106 is made of an aluminum alloy or fiber-reinforced polymeric material, the crown insert 108 and/or the sole insert 110 are made of a fiber-reinforced polymeric material, and the strike plate 143 is a titanium alloy or a fiber-reinforced polymeric material.
[0386]According to some examples, the at least one first material has a first mass no more than 55% of the total mass of the golf club head 100 and no less than 25% of the total mass of the golf club head 100 (e.g., between 50 g and 110 g). In certain examples, the first mass of the at least one first material is no more than 45% of the total mass of the golf club head 100 and no less than 30% of the total mass of the golf club head 100. The first mass of the at least one first material can be greater than the second mass of the at least one second material. Alternatively, or additionally, the first mass of the at least one first material can be within 10 g of the second mass of the at least one second material.
[0387]In some examples, the at least one second material has a second mass no more than 65% of the total mass of the golf club head 100 and no less than 20% of the total mass of the golf club head 100 (e.g., between 40 g and 130 g). According to certain examples, the second mass of the at least one second material is no more than 50% of the total mass of the golf club head 100. The second mass of the at least one second material is less than two times the first mass of the at least one first material in certain examples. The second mass of the at least one second material is between 0.9 times and 1.8 times the first mass of the at least one first material in some examples. In one example, the second mass of the at least one second material is less than 0.9 times, or less than 1.8 times, the first mass of the at least one first material.
[0388]The at least one third material has a third mass equal to the total mass of the golf club head 100 less the first mass of the at least one first material and the second mass of the at least one second material. In one example, the third mass of the at least one third material is no less than 5% of the total mass of the golf club head 100 and no more than 50% of the total mass of the golf club head 100 (e.g., between 10 g and 100 g). According to another example, the third mass of the at least one third material is no less than 10% of the total mass of the golf club head 100 and no more than 20% of the total mass of the golf club head 100.
[0389]According to one example, the cup 104 of the body 102 of the golf club head 100 is made from the at least one first material and the at least one first material is a first metal material that has a density between 4.0 g/cc and 8.0 g/cc. In this example, the ring 106 of the body 102 of the golf club head 100 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc. According to certain implementations, the first metal material of the cup 104 is a titanium alloy and/or a steel alloy and the material of the ring 106 is an aluminum alloy and/or a magnesium alloy. In some implementations, the first metal material of the cup 104 is a titanium alloy and/or a steel alloy and the material of the ring 106 is a non-metal material, such as a plastic or polymeric material. Accordingly, in some examples, the ring 106 is made of any of various materials, such as titanium alloys, aluminum alloys, and fiber-reinforced polymeric materials.
[0390]The ring 106, in some examples, is made of one of 6000-series, 7000-series, or 8000-series aluminum, which can be anodized to have a particular color the same as or different than the cup 104. According to some examples, the ring 106 can be anodized to have any one of an array of colors, including blue, red, orange, green, purple, etc. Contrasting colors between the ring 106 and the cup 104 may help with alignment or suit a user's preferences. In one example, the ring 106 is made of 7075 aluminum. According to some examples, the ring 106 is made of a fiber-reinforced polycarbonate material. The ring 106 can be made from a plastic with a non-conductive vacuum metallizing coating, which may also have any of various colors. Accordingly, in certain examples, the ring 106 is made of a titanium alloy, a steel alloy, a boron-infused steel alloy, a copper alloy, a beryllium alloy, composite material, hard plastic, resilient elastomeric material, carbon-fiber reinforced thermoplastic with short or long fibers. The ring 106 can be made via an injection molded, cast molded, physical vapor deposition, or CNC milled technique.
[0391]As described herein, the ring (e.g., the ring 106) of any of the club heads disclosed herein can comprise various different materials and features, and be made of different materials and have different properties than the cup (e.g., the cup 104), which is formed separately and later coupled to the ring. In addition to or alternative to other materials described herein, the ring can comprise metallic materials, polymeric materials, and/or composite materials, and can include various external coatings.
[0392]In some embodiments, the ring comprises anodized aluminum, such as 6000, 7000, and 8000 series aluminum. In one specific example, the ring comprises 7075 grade aluminum. The anodized aluminum can be colored, such as red, green, blue, gray, white, orange, purple, pink, fuchsia, black, clear, yellow, gold, silver, or metallic colors. In some embodiments, the ring can have a color that contrasts from a majority color located on other parts of the club head (e.g., the crown insert, the sole insert, the cup, the rear weight, etc.).
[0393]Taken a step further, the cup 104, the ring 106, the cup 304, and/or the front body portion 4602, or any of their disclosed equivalents, may also receive a final finish or coating such as an anodizing, and therefore may be a forged-milled-anodized cup 104, a cast-milled-anodized cup 104, a forged-milled-anodized ring 106, a cast-milled-anodized ring 106, a cast-milled-anodized cup 304, or a cast-milled-anodized front body portion 4602. Anodizing is an electrochemical process that thickens and toughens the natural oxide layer on the surface of aluminum alloy. It converts the outer layer of aluminum metal into aluminum oxide (Al2O3)—a hard, corrosion-resistant, and porous coating that can also hold dyes for coloring. Type I anodizing comprises chromic acid and produces a thin soft coating, whereas Type II anodizing comprises sulfuric acid and is the most common type of anodizing, but is generally only suitable for decorative finishes, finally Type III anodizing is referred to as hard anodizing comprising sulfuric acid and low temperature to produce a thick, wear-resistant coating. Type I, II, and III can be thought of as different levels of anodizing, mainly defined by the chemical process and resulting coating thickness/hardness. The three main levels of anodizing-Type I, Type II, and Type III-differ in their electrolytes, coating thickness, hardness, and performance characteristics. Type I anodizing, also known as chromic acid anodizing, uses a chromic acid electrolyte to produce a thin oxide layer (about 0.5-7.6 micrometers thick). This coating provides good corrosion protection but has low wear resistance and hardness, typically around Rockwell C 20-30 or 200-300 HV on the Vickers Harness scale. Type II anodizing, performed in a sulfuric acid electrolyte, forms a medium-thickness layer (roughly 5-25 micrometers) with moderate hardness and wear resistance, generally in the range of Rockwell C 25-50 or 250-400 HV on the Vickers Harness scale. It can be dyed in many colors and is widely used for decorative, architectural, and general-purpose applications. Type III anodizing, or hardcoat anodizing, also uses sulfuric acid but at low temperatures and higher current densities to produce a thick, dense oxide layer (25-100 micrometers) with very high hardness, typically Rockwell C 51-70 or 400-600 HV on the Vickers Harness scale.
[0394]In one embodiment the cup 104, the ring 106, the cup 304, and/or the front body portion 4602 incorporates a first area having a first area anodizing oxide thickness, and a second area having a second area anodizing oxide thickness that is different than the first area anodizing oxide thickness. In one embodiment the first area anodizing oxide thickness is at least 15 micrometers, while the second area anodizing oxide thickness is less than the first area anodizing oxide thickness. In a further embodiments the first area anodizing oxide thickness is at least 20, 25, 30, 35, 40, 45, or 50 micrometers; while additional embodiments limit the first area anodizing oxide thickness to no more than 110, 100, 90, or 80 micrometers. In one embodiment the cup 104, the ring 106, the cup 304, and/or the front body portion 4602 is first formed via forging or casting, then at least a portion is milled, then the entire component is anodized, and then the oxide layer is removed in the regions that will be in contact with the bonding tape 174 and/or adhesive. The extreme hardness associated with Type III anodizing is ideal for wear resistance in certain areas of the club head, such as forward portions of the sole that often contact the ground and the leading edge, which contacts the tee. Thus, one embodiment limits the area to a high durability surface area associated with (a) an oxide layer of 25-100 micrometers, (b) a hardness of the anodized component within the high durability surface area is greater than Rockwell C 30, or (c) a hardness of the anodized component within the high durability surface area is greater than 400 HV on the Vickers Harness scale, and the high durability surface area is no more than 7000 mm{circumflex over ( )}2, and in further embodiments no more than 6500 mm{circumflex over ( )}2, 6000 mm{circumflex over ( )}2, 5500 mm{circumflex over ( )}2, or 5000 mm{circumflex over ( )}2. Another series of embodiments establishes a floor such that the high durability surface area is at least 500 mm{circumflex over ( )}2, 750 mm{circumflex over ( )}2, 1000 mm{circumflex over ( )}2, 1250 mm{circumflex over ( )}2, or 1500 mm{circumflex over ( )}2.
[0395]In one embodiment at least a portion of the front body portion 4602 and/or any of the disclosed cup variations has a forward component average anodizing oxide thickness and a maximum forward component hardness; while at least a portion of any of the ring variations, or metal alloy components that attach to the forward component, has a rear component average anodizing oxide thickness and a maximum rear component hardness. A forward-to-rear oxide thickness differential is a difference between the forward component average anodizing oxide thickness and the rear component average anodizing oxide thickness; and in one embodiment the forward-to-rear oxide thickness differential is at least 5 μm (micrometer), while in further embodiments the forward-to-rear oxide thickness differential is at least 10 μm or 15 μm. In another embodiment the forward-to-rear oxide thickness differential is no more than 100 μm, which is reduces in further embodiments to no more than 85 μm, 70 μm, 55 μm, 40 μm, or 25 μm.
[0396]Similarly, a forward-to-rear component hardness differential is a difference between the maximum forward component hardness and the maximum rear component hardness; and in one embodiment the forward-to-rear component hardness differential is no more than 20 HRB (Rockwell Hardness, B scale) despite the forward-to-rear oxide thickness differential is at least 5, 10, or 15 μm; while in further embodiments the forward-to-rear component hardness differential is no more than 15, 10, 5, or 2.5 HRB. In fact in one embodiment the forward-to-rear component hardness differential in HRB units is less than the forward-to-rear oxide thickness differential in micrometer units.
[0397]For instance the simplest embodiment is a 100% milled total surface area of the cup 104, and/or front body portion 4602, whereby every surface has been milled, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% milled total surface area for the individual component. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% milled total surface area for the individual component. Another embodiment has at least 50% milled interior exposed surface area for the individual component, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled interior exposed surface area for the individual component. Another embodiment has at least 50% milled externally exposed surface area for the individual component, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled externally exposed surface area for the individual component.
[0398]It is important to appreciate that regardless of whether an oxide layer is present or not, at least a portion of the front body portion 4602 and/or any of the disclosed cup variations has a maximum forward component hardness; and similarly regardless of whether an oxide layer is present or not, at least a portion of any of the disclosed ring variations, or metal alloy components that attach to the forward component, has a maximum rear component hardness. The hardness, strength, and elastic modulus (rigidity/stiffness) of the components requires a unique tuning in order to produce a high performance golf club head, particularly one containing large portions composed of nonmetallic materials. For perspective, typically a titanium golf driver head typically has a Rockwell hardness of about 95-115 HRB, a Yield Strength (0.2% offset) of at least 770 MPa, an Elastic Modulus of at least 105 GPa, and a Shear Modulus of at least 40 GPa, depending on alloy and heat treatment.
[0399]Conversely, in one embodiment of the present invention a substrate associated with the maximum forward component hardness and/or the maximum rear component hardness is an aluminum alloy and the component hardness is less than 95 HRB, and in further embodiments is less than 92.5 HRB or 90 HRB. Another embodiment establishes a floor for the aluminum alloy component hardness such that the component hardness is at least 60 HRB, and in further embodiments is at least 65, 70, 75, 80, or 85 HRB. One skilled in the art will appreciate the differences and challenges that must be overcome when incorporating such an aluminum alloy component, or components, into a high performance golf club head in light of the drastically different material properties compared to those of the typical titanium golf driver head.
[0400]In a further embodiment the aluminum alloy component is a forged front body portion 4602 or a forged cup having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged front body portion 4602 or a forged cup has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a forged front body portion 4602 or a forged cup having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged front body portion 4602 or a forged cup having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0401]In a further embodiment the aluminum alloy component is a forged rear body component, which may include any of the disclosed ring variations, or metal alloy components that attach to the forward component, having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged rear body component has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a rear body component having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged rear body component having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0402]In a further embodiment the aluminum alloy component is a forged-milled front body portion 4602 or a forged-milled cup having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged-milled front body portion 4602 or a forged-milled cup has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a forged-milled front body portion 4602 or a forged-milled cup having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged-milled front body portion 4602 or a forged-milled cup having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0403]In a further embodiment the aluminum alloy component is a forged-milled rear body component, which may include any of the disclosed ring variations, or metal alloy components that attach to the forward component, having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged-milled rear body component has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a forged-milled rear body component having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged-milled rear body component having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0404]The addition of the “-milled” terminology in the prior disclosure may be defined in the claims to include any of the disclosed milling embodiments, which as previously noted may be further defined by the extent of the total surface area of an individual component that is milled, the extent of the interior exposed surface area (that exposed to the interior of the club head) if the individual components that is milled, and/or the extent of the externally exposed surface area (that exposed to the external environment) of the individual component that is milled. For instance the simplest embodiment is a 100% milled total surface area of the cup 104, and/or front body portion 4602, whereby every surface has been milled, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% milled total surface area. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% milled total surface area. Another embodiment has at least 50% milled interior exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled interior exposed surface area. Another embodiment has at least 50% milled externally exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled externally exposed surface area.
[0405]In a further embodiment the aluminum alloy component is a forged-milled-anodized front body portion 4602 or a forged-milled-anodized cup having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged-milled-anodized front body portion 4602 or a forged-milled-anodized cup has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a forged-milled-anodized front body portion 4602 or a forged-milled-anodized cup having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged-milled-anodized front body portion 4602 or a forged-milled cup having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0406]In a further embodiment the aluminum alloy component is a forged-milled-anodized rear body component, which may include any of the disclosed ring variations, or metal alloy components that attach to the forward component, having a Yield Strength (0.2% offset) of no more than 550 MPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Yield Strength (0.2% offset) is no more than 525 MPa. Another series of embodiments sets a floor such that the forged-milled-anodized rear body component has a Yield Strength (0.2% offset) of at least 425 MPa, which is increased in further embodiments to at least 450 MPa or 475 MPa. Even further, the aluminum alloy component is a forged-milled-anodized rear body component having an Elastic Modulus of no more than 90 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Elastic Modulus is no more than 85, 80, or 75 GPa. Still even further, the aluminum alloy component is a forged-milled-anodized rear body component having a Shear Modulus of no more than 35 GPa, which is significantly less than the typical titanium golf driver head, while in another embodiment the Shear Modulus is no more than 32.5, 30, or 27.5 GPa. An additional embodiment sets a floor for the Elastic Modulus such that it is at least 55 GPa in one embodiment, and is increased to at least 60, 65, or 70 GPa in further embodiments. Similarly, an additional embodiment sets a floor for the Shear Modulus such that it is at least 17.5 GPa in one embodiment, and is increased to at least 20, 22.5, or 25 GPa in further embodiments.
[0407]The addition of the “-anodized” terminology in the prior disclosure may be defined in the claims to include any of the disclosed anodized embodiments, which may be further defined by the extent of the total surface area of an individual component that is anodized, the extent of the interior exposed surface area (that exposed to the interior of the club head) of the individual component that is anodized, and/or the extent of the externally exposed surface area (that exposed to the external environment) of the individual component that is anodized. For instance the simplest embodiment is a 100% anodized total surface area of the cup 104, and/or front body portion 4602, whereby every surface has been anodized, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% anodized total surface area. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% anodized total surface area. Another embodiment has at least 50% anodized interior exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% anodized interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% anodized interior exposed surface area. Another embodiment has at least 50% anodized externally exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% anodized externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% anodized externally exposed surface area.
[0408]The disclosed unique construction, relationships, and methods involve innovative discoveries necessary to produce a golf club head comprising one or more of the disclosed aluminum alloy components that meets or exceeds the performance of the traditional titanium golf club head construction. After all, Ti-6Al-4V (cast or forged) is much stiffer and much stronger than any 7000-series aluminum alloy; the stiffness/rigidity difference is challenging since titanium alloy is ˜2× as rigid as a 7075-T6 aluminum alloy; the strength difference is significant with titanium alloy having ˜2.5-3× the yield strength of forged 7000-series aluminum alloys; and a density difference of ˜60% further complicates mass distribution considerations.
[0409]The mechanical properties disclosed including yield strength, Young's modulus, and shear modulus were determined in accordance with ASTM E8/E8M (tensile testing of metallic materials), ASTM E111 (modulus determination), and ASTM E143 (shear modulus testing). Hardness values (HRB/HRC) were measured in accordance with ASTM E18 (Rockwell hardness testing of metallic materials).
[0410]In some embodiments, the ring can comprise any combination of metals, metal alloys (e.g., Ti alloys, steel, boron infused steel, aluminum, copper, beryllium), composite materials (e.g., carbon fiber reinforced polymer, with short or long fibers), hard plastics, resilient elastomers, other polymeric materials, and/or other suitable materials. Any material selection for the ring can also be combined with any of various formation methods, such as any combination of the following: casting, injection molding, sintering, machining, milling, forging, extruding, stamping, and rolling.
[0411]A plastic ring (fiber reinforced polycarbonate ring) may offer both mass savings e.g. about 5 grams compared to an aluminum ring, cost savings as well, give greater design flexibility due to processes used to form the ring e.g. injection molded thermoplastic, and perform similarly to an aluminum ring in abuse testing e.g. slamming the club head into a concrete cart path (extreme abuse) or shaking it in a bag where other metal clubs can repeatedly impact it (normal abuse).
[0412]In some embodiments, the ring can comprise a polymeric material (e.g., plastic) with a non-conductive vacuum metallizing (NCVM) coating. For example, in some embodiments, the ring may include a primer layer having an average thickness of about 5-11 micrometers (μm) or about 8.5 μm, and under coating layer on top of the primer layer having an average thickness of about 5-11 μm or about 8.5 μm, a NCVM layer on top of under coating layer having an average thickness of about 1.1-3.5 μm or about 2.5 μm, a color coating layer on top of the NCVM layer having an average thickness of about 25-35 μm or about 29 μm, and a top coating (UV protection coat) outer layer on top of the color coating layer having an average thickness of about 20-35 μm or about 26 μm. In general, for a NCVM coated part or ring the NCVM layer will be the thinnest and the color coating layer and the top coating layers will be the thickest and generally about 8-15 times thicker than NCVM layer. Generally, all the layers will combine to have a total average thickness of about 60-90 μm or about 75 μm. The described layers and NCVM coating could be applied to other parts other than the ring, such as the crown, sole, forward cup, and removable weights, and it can be applied prior to assembly.
[0413]In some embodiments, the ring can comprise a physical vapor deposition (PVD) coating or film layer. In some embodiments, the ring can include a paint layer, or other outer coloring layer. Conventionally, painting a golf club heads is all done by hand and requires masking various components to prevent unwanted spray on unwanted surfaces. Hand painting, however, can lead to great inconsistency from club to club. Separately forming the ring not only allows for greater access to the rearward portion of the face for milling operations to remove unwanted alpha case and allows for machining in various face patterns, but it also eliminates the need for masking off various components. The ring can be painted in isolation prior to assembly. Or in the case of anodized aluminum, no painting may be necessary, eliminating a step in the process such that the ring can simply be bonded or attached to a cup that may also be fully finished. Similarly if the ring is coated using PVD or NCVM, this coating can be applied to the ring prior to assembly, again eliminating several steps. This also allows for attachment of various color rings that may be selectable by an end user to provide an alignment or aesthetic benefit to the user. Whether the ring is a NCVM coated ring or a PVD coated ring, as mentioned above, it can be colored an array of colors, such as red, green, blue, gray, white, orange, purple, pink, fuchsia, black, clear, yellow, gold, silver, or metallic colors.
[0414]The following properties of the golf club heads disclosed herein proceeds with reference to the golf club head 100. However, unless otherwise noted, the properties described with reference to the golf club head 100 also apply to the golf club head 200, the golf club head 300, and the golf club head 400. The golf club head 100 is made from two of at least one first material, having a density between 0.9 g/cc and 3.5 g/cc, at least one second material, having a density between 3.6 g/cc and 5.5 g/cc, and at least one third material, having a density between 5.6 g/cc and 20.0 g/cc. In a first example, the cup 104 is made of the second material and the ring 106, the crown insert 108, and the sole insert 110 are made of the first material. In this first example, according to one instance, the cup 104 is made of a titanium alloy, the ring 106 is made of an aluminum alloy, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. In this first example, according to another instance, the cup 104 is made of a titanium alloy, the ring 106 is made of plastic, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. According to a second example, the cup 104 is made of the second material, the ring 106 is made of the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this second example, according to one instance, the cup 104 and the ring 106 are made of a titanium alloy and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material.
[0415]In some examples, the at least one first material is a fiber-reinforced polymeric material that includes continuous fibers embedded in a polymeric matrix (e.g., epoxy or resin), which is a thermoset polymer is certain examples. The continuous fibers are considered continuous because each one of the fibers is continuous across a length, width, or diagonal of the part formed by the fiber-reinforced polymeric material. The continuous fibers can be long fibers having a length of at least 3 millimeters, 10 millimeters, or even 50 millimeters. In other embodiments, shorter fibers can be used having a length of between 0.5 and 2.0 millimeters. Incorporation of the fiber reinforcement increases the tensile strength, however it may also reduce elongation to break therefore a careful balance can be struck to maintain sufficient elongation. Therefore, one embodiment includes 35-55% long fiber reinforcement, while in an even further embodiment has 40-50% long fiber reinforcement. The continuous fibers, as well as the fiber-reinforced polymeric material in general, can be the same or similar to that described in Paragraph 295 of U.S. Patent Application Publication No. 2016/0184662, published Jun. 30, 2016, now U.S. Pat. No. 9,468,816, issued Oct. 18, 2016, which is incorporated herein by reference in its entirety. In several examples, the crown insert 108 and the sole insert 110 are made of the fiber-reinforced polymeric material. Accordingly, in some examples, each one of the continuous fibers of the fiber-reinforced polymeric material does not extend from the crown portion 119 to the sole portion 117 of the golf club head 100. Alternatively, or additionally, in certain examples, each one of the continuous fibers of the fiber-reinforced polymeric material does not extend from the crown portion 119 to the forward portion 112 of the golf club head 100. The crown insert 108 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc in one example. The sole insert 110 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc in one example.
[0416]In certain examples, the first material is a fiber-reinforced polymeric material as described in U.S. patent application Ser. No. 17/006,561, filed Aug. 28, 2020. Composite materials that are useful for making club-head components comprise a fiber portion and a resin portion. In general the resin portion serves as a “matrix” in which the fibers are embedded in a defined manner. In a composite for club-heads, the fiber portion is configured as multiple fibrous layers or plies that are impregnated with the resin component. The fibers in each layer have a respective orientation, which is typically different from one layer to the next and precisely controlled. The usual number of layers for a striking face is substantial, e.g., forty or more. However for a sole or crown, the number of layers can be substantially decreased to, e.g., three or more, four or more, five or more, six or more, examples of which will be provided below. During fabrication of the composite material, the layers (each comprising respectively oriented fibers impregnated in uncured or partially cured resin; each such layer being called a “prepreg” layer) are placed superimposed on each other in a “lay-up” manner. After forming the prepreg lay-up, the resin is cured to a rigid condition. If interested, a specific strength may be calculated by dividing the tensile strength by the density of the material. This is also known as the strength-to-weight ratio or strength/weight ratio.
[0417]In tests involving certain club-head configurations, composite portions formed of prepreg plies having a relatively low fiber areal weight (FAW) have been found to provide superior attributes in several areas, such as impact resistance, durability, and overall club performance. FAW is the weight of the fiber portion of a given quantity of prepreg, in units of g/m2. FAW values below 100 g/m2, and more desirably below 70 g/m2, can be particularly effective. A particularly suitable fibrous material for use in making prepreg plies is carbon fiber, as noted. More than one fibrous material can be used. In other embodiments, however, prepreg plies having FAW values below 70 g/m2 and above 100 g/m2 may be used. Generally, cost is the primary prohibitive factor in prepreg plies having FAW values below 70 g/m2.
[0418]In particular embodiments, multiple low-FAW prepreg plies can be stacked and still have a relatively uniform distribution of fiber across the thickness of the stacked plies. In contrast, at comparable resin-content (R/C, in units of percent) levels, stacked plies of prepreg materials having a higher FAW tend to have more significant resin-rich regions, particularly at the interfaces of adjacent plies, than stacked plies of low-FAW materials. Resin-rich regions tend to reduce the efficacy of the fiber reinforcement, particularly since the force resulting from golf-ball impact is generally transverse to the orientation of the fibers of the fiber reinforcement. The prepreg plies used to form the panels desirably comprise carbon fibers impregnated with a suitable resin, such as epoxy.
[0419]
[0420]Embodiments incorporating non-metal strike plates 943 further provide advantages relating to significantly improved geometric control of the face curvature during manufacturing, and thus the confidence to produce a strike plate 943 with the disclosed small roll radius and not worry about significant variations at the extremities of the bell curve. For example, in one embodiment the non-metal strike plate 943 has a roll radius of less than 230 mm, 220 mm, or 210 mm, and due to the stability and manufacturing methods of the non-metallic strike plate 943, the resulting parts exhibit a roll-radius 3-sigma variation of less than 75% of the face height Hss, which in further embodiments is reduced to less than 70%, 65%, 60%, 55%, or 50% of the face height Hss. In one embodiment the roll-radius 3-sigma variation is less than 30 mm, and less than 28 mm or 26 mm in further embodiments. This tight dimensional tolerance permits the engineer to confidently design the strike plate 943 with such a small roll radius without risking excessive curvature deviation across production lots. A smaller variation in roll radius also reduces backspin deviation across the face, thereby improving distance consistency for off-center impacts and enhancing fitting reliability for players with varying impact patterns. By contrast, conventional metal-faced driver heads commonly exhibit a roll-radius standard deviation of approximately 23 mm, with a corresponding 3-sigma variation approaching 75 mm, which introduces substantial uncertainty into the resulting face geometry and limits the designer's ability to reliably implement smaller roll radii. Accordingly, the use of the disclosed non-metallic strike plate 943 provides both superior manufacturing tolerances and improved performance consistency relative to traditional metal driver constructions.
[0421]In some examples, the strike plate 943 can be machined from a composite plaque. In an example, the composite plaque can be substantially rectangular with a length between about 90 mm and about 130 mm or between about 100 mm and about 120 mm, preferably about 110 mm±1.0 mm, and a width between about 50 mm and about 90 mm or between about 6 mm and about 80 mm, preferably about 70 mm±1.0 mm plaque size and dimensions. The strike plate 943 is then machined from the plaque to create a desired face profile. For example, the face profile length 912 can be between about 80 mm and about 120 mm or between about 90 mm and about 110 mm, preferably about 102 mm. The face profile width 911 can be between about 40 mm and about 65 mm or between about 45 mm and about 60 mm, preferably about 53 mm. The height 913 of a preferred impact zone 953 on the strike face, defined by the strike plate 943 and centered on a geometric center of the strike face, can be between about 25 mm and about 50 mm, between about 30 mm and about 40 mm, or between about 17 mm and about 45 mm, such as preferably about 34 mm. The length 914 of the preferred impact zone 953 can be between about 40 mm and about 70 mm, between about 28 mm and about 65 mm, or between about 45 mm and about 65 mm, preferably about 55.5 mm or 56 mm. In certain examples, the preferred impact zone 953 of the strike face defined by the strike plate 943 has an area between 500 mm2 and 1,800 mm2. Alternatively, the strike plate 943 can be molded to provide the desired face dimensions and profile.
[0422]Additional features can be machined or molded into face the strike plate 943 to create the desired face profile. For example, as shown in
[0423]In another example, backside bumps 4230A, 4230B, 4230C, 4230D may be machined or molded into the backside of the strike plate 943. The backside bumps 4230A, 4230B, 4230C, 4230D can be configured to provide for a bond gap. A bond gap is an empty space between the club head body and the strike plate 943 that is filled with adhesive during manufacturing. The backside bumps 4230A, 4230B, 4230C, 4230D protrude to separate the face from the club head body when bonding the strike plate 943 to the club head body during manufacturing. In some examples, too large or too small of a bond gap may lead to durability issues of the club head, the strike plate 943, or both. Further, too large of a bond gap can allow too much adhesive to be used during manufacturing, adding unwanted additional mass to the club head. The backside bumps 4230A, 4230B, 4230C, 4230D can protrude between about 0.1 mm and 0.5 mm, preferably about 0.25 mm. In some embodiments, the backside bumps are configured to provide for a minimum bond gap, such as a minimum bond gap of about 0.25 mm and a maximum bond gap of about 0.45 mm.
[0424]Further, one or more of the edges of the strike plate 943 can be machined or molded with a chamfer. In an example, the strike plate 943 includes a chamfer substantially around the inside perimeter edge of the strike plate 943, such as a chamfer between about 0.5 mm and about 1.1 mm, preferably 0.8 mm.
[0425]
[0426]Additionally, in certain examples, the preferred impact zone 953 is off-center or offset relative to the geometric center of the strike face, and can be thicker toeward of the geometric center of the strike face. In some examples, the thickness of the strike plate 943 within the preferred impact zone 953 is variable (e.g., between about 3.5 mm and about 5.0 mm) and the thickness of the strike plate 943 outside of the preferred impact zone 953 is constant (e.g., between 3.5 mm and 4.2 mm) and less than within preferred impact zone 953. In some examples, the strike plate 943 have a thickness between 3.5 mm and 6.0 mm.
[0427]The strike plate 943 has a toe edge region and a heel edge region outside of the preferred impact zone 953 such that the preferred impact zone is between the toe edge region and the heel edge region. The toe edge region is closer to the toe portion than the heel edge region. The heel edge region is closer to the heel portion than the toe edge region. The toe edge region thickness is less than the maximum thickness. A thickness of the strike plate 943 transitions from the maximum thickness, within the preferred impact zone 953, to a toe edge region thickness, within the toe edge region, between 3.85 mm and 4.5 mm.
[0428]In some embodiments, the strike plate 943 is manufactured from multiple layers of composite materials. Exemplary composite materials and methods for making the same are described in U.S. patent application Ser. No. 13/452,370, filed Apr. 20, 2012 (published as U.S. Pat. App. Pub. No. 2012/0199282), which is incorporated by reference in the entirety. In some embodiments, an inner and outer surface of the composite face can include a scrim layer, such as to reinforce the strike plate 943 with glass fibers making up a scrim weave. Multiple quasi-isotropic panels (Q's) can also be included, with each Q panel using multiple plies of unidirectional composite panels offset from each other. In an exemplary four-ply Q panel, the unidirectional composite panels are oriented at 90°, −45°, 0°, and 45°, which provide for structural stability in each direction. Clusters of unidirectional strips (C's) can also be included, with each C using multiple unidirectional composite strips. In an exemplary four-strip C, four 27 mm strips are oriented at 0°, 125°, 90°, and 55°. C's can be provided to increase thickness of the strike plate 943 in a localized area, such as in the center face at the preferred impact zone. Some Q's and C's can have additional or fewer plies (e.g., three-ply rather than four-ply), such as to fine tune the thickness, mass, localized thickness, and provide for other properties of the strike plate 943, such as to increase or decrease COR of the strike plate 943.
[0429]In some embodiments, the strike face, such as the strike plate 243, of some examples of the golf club head disclosed herein is manufactured from multiple layers of composite materials. Exemplary composite materials and methods for making the same are described in U.S. patent application Ser. No. 13/452,370 (published as U.S. Pat. App. Pub. No. 2012/0199282), which is incorporated by reference. In some embodiments, an inner and outer surface of the composite face can include a scrim layer, such as to reinforce the strike face with glass fibers making up a scrim weave. Multiple quasi-isotropic panels (Q's) can also be included, with each Q panel using multiple plies of unidirectional composite panels offset from each other. In an exemplary four-ply Q panel, the unidirectional composite panels are oriented at 90°, −45°, 0°, and 45°, which provide for structural stability in each direction. Clusters of unidirectional strips (C's) can also be included, with each C using multiple unidirectional composite strips. In an exemplary four-strip C, four 27 mm strips are oriented at 0°, 125°, 90°, and 55°. C's can be provided to increase thickness of the strike face, or other composite features, in a localized area, such as in the center face at the preferred impact zone. Some Q's and C's can have additional or fewer plies (e.g., three-ply rather than four-ply), such as to fine tune the thickness, mass, localized thickness, and provide for other properties of the strike face, such as to increase or decrease COR of the strike face.
[0430]Additional composite materials and methods for making the same are described in U.S. Pat. Nos. 8,163,119 and 10,046,212, which is incorporated by reference. For example, the usual number of layers for a strike plate is substantial, e.g., fifty or more. However, improvements have been made in the art such that the layers may be decreased to between 30 and 50 layers. According to one example, the strike plate, according to any of the various examples disclosed herein, when made of a fiber-reinforced polymeric material, can be made in a manner the same as, or similar to, that described in U.S. patent application Ser. No. 17/321,315, filed May 14, 2021, and U.S. Provisional Patent Application No. 63/312,771, filed Feb. 22, 2022, which are incorporated herein by reference in their entireties.
[0431]Table 3 below provide examples of possible layups of one or more of the composite parts of the golf club head disclosed herein. These layups show possible unidirectional plies unless noted as woven plies. The construction shown is for a quasi-isotropic layup. A single layer ply has a thickness of ranging from about 0.065 mm to about 0.080 mm for a standard FAW of 70 gsm with about 36% to about 40% resin content. The thickness of each individual ply may be altered by adjusting either the FAW or the resin content, and therefore the thickness of the entire layup may be altered by adjusting these parameters.
| TABLE 3 | ||||||||
|---|---|---|---|---|---|---|---|---|
| ply 1 | ply 2 | ply 3 | ply 4 | ply 5 | ply 6 | ply 7 | ply 8 | AW g/m2 |
| 0 | −60 | +60 | 290-360 | |||||
| 0 | −45 | +45 | 90 | 390-480 | ||||
| 0 | +60 | 90 | 60 | 0 | 490-600 | |||
| 0 | +45 | 90 | −45 | 0 | 490-600 | |||
| 90 | +45 | 0 | −45 | 90 | 490-600 | |||
| +45 | 90 | 0 | 90 | −45 | 490-600 | |||
| +45 | 0 | 90 | 0 | −45 | 490-600 | |||
| −60 | −30 | 0 | +30 | 60 | 90 | 590-720 | ||
| 0 | 90 | +45 | −45 | 90 | 0 | 590-720 | ||
| 90 | 0 | +45 | −45 | 0 | 90 | 590-720 | ||
| 0 | 90 | 45 | −45 | −45 | 45 | 0/90 | 680-840 | |
| woven | ||||||||
| 90 | 0 | 45 | −45 | −45 | 45 | 90/0 | 680-840 | |
| woven | ||||||||
| +45 | −45 | 90 | 0 | 0 | 90 | −45/45 | 680-840 | |
| woven | ||||||||
| 0 | 90 | 45 | −45 | −45 | 45 | 90 UD | 680-840 | |
| 0 | 90 | 45 | −45 | 0 | −45 | 45 | 0.90 | 780-960 |
| woven | ||||||||
| 90 | 0 | 45 | −45 | 0 | −45 | 45 | 90.0 | 780-960 |
| woven | ||||||||
The Area Weight (AW) is calculated by multiplying the density times the thickness. For the plies shown above made from composite material the density is about 1.5 g/cm3 and for titanium the density is about 4.5 g/cm3.
[0432]In general, a composite face plate or composite face insert may have a peak thickness that varies between about 3.8 mm and 5.15 mm. In general, the composite face plate is formed from multiple composite plies or layers. The usual number of layers for a composite striking face is substantial, e.g., forty or more, preferably between 30 to 75 plies, more preferably, 50 to 70 plies, even more preferably 55 to 65 plies. In an example, a first composite face insert can have a peak thickness of 4.1 mm and an edge thickness of 3.65 mm, including 12 Q's and 2 C's, resulting in a mass of 24.7 g. In another example, a second composite face insert can have a peak thickness of 4.25 mm and an edge thickness of 3.8 mm, including 12 Q's and 2 C's, resulting in a mass of 25.6 g. The additional thickness and mass is provided by including additional plies in one or more of the Q's or C's, such as by using two 4-ply Q's instead of two 3-ply Q's. In yet another example, a third composite face insert can have a peak thickness of 4.5 mm and an edge thickness of 3.9 mm, including 12 Q's and 3 C's, resulting in a mass of 26.2 g. Additional and different combinations of Q's and C's can be provided for a composite strike plate (e.g., face insert) with a mass between about 20 g and about 30 g, or between about 15 g and about 35 g. In some examples, wherein the strike plate, such as the strike plate 943, has a total mass between 22 grams and 28 grams.
[0433]
[0434]
[0435]
[0436]In some examples, the crown insert, such as the crown insert 108, and the sole insert, such as the sole insert 110, are made of a carbon-fiber reinforced polymeric material. In one example, the crown insert is made of layers of unidirectional tape, woven cloth, and composite plies.
[0437]Referring to
[0438]In some examples, any of the disclosed components of the golf club head 100 may be formed of one or more of the following materials: carbon steel, stainless steel (e.g. 17-4 PH stainless steel), alloy steel, Fe—Mn—Al alloy, nickel-based ferroalloy, cast iron, super alloy steel, aluminum alloy (including but not limited to 3000 series alloys, 5000 series alloys, 6000 series alloys, such as 6061-T6, and 7000 series alloys, such as 7075), magnesium alloy, copper alloy, titanium alloy (including but not limited to 6-4 titanium, 3-2.5, 6-4, SP700, 15-3-3-3, 10-2-3, Ti 9-1-1, ZA 1300, or other alpha/near alpha, alpha-beta, and beta/near beta titanium alloys), or super strong and tough densified wood structure is formed by subjecting a cellulose-based natural wood material to a chemical treatment that partially removes lignin therefrom, such as those disclosed in U.S. Pat. No. 11,554,514, issued Jan. 17, 2023, which is incorporated herein by reference in the entirety, or mixtures thereof.
[0439]In one example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is a 9-1-1 titanium alloy. Titanium alloys comprising aluminum (e.g., 8.5-9.5% Al), vanadium (e.g., 0.9-1.3% V), and molybdenum (e.g., 0.8-1.1% Mo), optionally with other minor alloying elements and impurities, herein collectively referred to a “9-1-1 Ti”, can have less significant alpha case, which renders HF acid etching unnecessary or at least less necessary compared to faces made from conventional 6-4 Ti and other titanium alloys. Further, 9-1-1 Ti can have minimum mechanical properties of 820 MPa yield strength, 958 MPa tensile strength, and 10.2% elongation. These minimum properties can be significantly superior to typical cast titanium alloys, such as 6-4 Ti, which can have minimum mechanical properties of 812 MPa yield strength, 936 MPa tensile strength, and ˜6% elongation. In certain examples, the titanium alloy is 8-1-1 Ti.
[0440]In another example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is an alpha-beta titanium alloy comprising 6.5% to 10% Al by weight, 0.5% to 3.25% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti (one example is sometimes referred to as “1300” or “ZA1300” titanium alloy). The alpha-beta titanium alloy or ZA 1300 titanium alloy has a first ultimate tensile strength of at least 1,000 MPa in some examples and at least 1,100 MPa in other examples. An ultimate tensile strength of the material forming the body 102, other than the strike face 145, can be less than the first ultimate tensile strength by at least 10%. In another representative example, the alloy may comprise 6.75% to 9.75% Al by weight, 0.75% to 3.25% or 2.75% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti. In yet another representative example, the alloy may comprise 7% to 9% Al by weight, 1.75% to 3.25% Mo by weight, 1.25% to 2.75% Cr by weight, 0.5% to 1.5% V by weight, and/or 0.25% to 0.75% Fe by weight, with the balance comprising Ti. In a further representative example, the alloy may comprise 7.5% to 8.5% Al by weight, 2.0% to 3.0% Mo by weight, 1.5% to 2.5% Cr by weight, 0.75% to 1.25% V by weight, and/or 0.375% to 0.625% Fe by weight, with the balance comprising Ti. In another representative example, the alloy may comprise 8% Al by weight, 2.5% Mo by weight, 2% Cr by weight, 1% V by weight, and/or 0.5% Fe by weight, with the balance comprising Ti (such titanium alloys can have the formula Ti-8Al-2.5Mo-2Cr-1V-0.5Fe). As used herein, reference to “Ti-8Al-2.5Mo-2Cr-1V-0.5Fe” refers to a titanium alloy including the referenced elements in any of the proportions given above. Certain examples may also comprise trace quantities of K, Mn, and/or Zr, and/or various impurities.
[0441]Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have minimum mechanical properties of 1150 MPa yield strength, 1180 MPa ultimate tensile strength, and 8% elongation. These minimum properties can be significantly superior to other cast titanium alloys, including 6-4 Ti and 9-1-1 Ti, which can have the minimum mechanical properties noted above. In some examples, Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have a tensile strength of from about 1180 MPa to about 1460 MPa, a yield strength of from about 1150 MPa to about 1415 MPa, an elongation of from about 8% to about 12%, a modulus of elasticity of about 110 GPa, a density of about 4.45 g/cm3, and a hardness of about 43 on the Rockwell C scale (43 HRC). In particular examples, the Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy can have a tensile strength of about 1320 MPa, a yield strength of about 1284 MPa, and an elongation of about 10%. The Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy, particularly when used to cast golf club head bodies, promotes less deflection for the same thickness due to a higher ultimate tensile strength compared to other materials. In some implementations, providing less deflection with the same thickness benefits golfers with higher swing speeds because over time the face of the golf club head will maintain its original shape over time.
[0442]In yet certain examples, the golf club head 100 is made of a non-metal material with a density less than about 2 g/cm3, such as between about 1 g/cm3 to about 2 g/cm3. The non-metal material may include a polymer, such as fiber-reinforced polymeric material. The polymer can be either thermoset or thermoplastic, and can be amorphous, crystalline and/or a semi-crystalline structure. The polymer may also be formed of an engineering plastic such as a crystalline or semi-crystalline engineering plastic or an amorphous engineering plastic. Potential engineering plastic candidates include polyphenylene sulfide ether (PPS), polyethelipide (PEI), polycarbonate (PC), polypropylene (PP), acrylonitrile-butadiene styrene plastics (ABS), polyoxymethylene plastic (POM), nylon 6, nylon 6-6, nylon 12, polymethyl methacrylate (PMMA), polyphenylene oxide (PPO), polybothlene terephthalate (PBT), polysulfone (PSU), polyether sulfone (PES), polyether ether ketone (PEEK) or mixtures thereof. Organic fibers, such as fiberglass, carbon fiber, or metallic fiber, can be added into the engineering plastic, so as to enhance structural strength. The reinforcing fibers can be continuous long fibers or short fibers. One of the advantages of PSU is that it is relatively stiff with relatively low damping which produces a better sounding or more metallic sounding golf club compared to other polymers which may be overdamped. Additionally, PSU requires less post processing in that it does not require a finish or paint to achieve a final finished golf club head.
[0443]One exemplary material from which any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, can be made from is a thermoplastic continuous carbon fiber composite laminate material having long, aligned carbon fibers in a PPS (polyphenylene sulfide) matrix or base. A commercial example of a fiber-reinforced polymer, from which the sole insert 110, the crown insert 108, and/or the strike face can be made, is TEPEX® DYNALITE 207 manufactured by Lanxess®. TEPEX® DYNALITE 207 is a high strength, lightweight material, arranged in sheets, having multiple layers of continuous carbon fiber reinforcement in a PPS thermoplastic matrix or polymer to embed the fibers. The material may have a 54% fiber volume, but can have other fiber volumes (such as a volume of 42% to 57%). According to one example, the material weighs 200 g/m2. Another commercial example of a fiber-reinforced polymer, from which the sole insert 110, crown insert 108, and/or the strike face is made, is TEPEX® DYNALITE 208. This material also has a carbon fiber volume range of 42 to 57%, including a 45% volume in one example, and a weight of 200 g/m2. DYNALITE 208 differs from DYNALITE 207 in that it has a TPU (thermoplastic polyurethane) matrix or base rather than a polyphenylene sulfide (PPS) matrix.
[0444]By way of example, the fibers of each sheet of TEPEX® DYNALITE 207 sheet (or other fiber-reinforced polymer material, such as DYNALITE 208) are oriented in the same direction with the sheets being oriented in different directions relative to each other, and the sheets are placed in a two-piece (male/female) matched die, heated past the melt temperature, and formed to shape when the die is closed. This process may be referred to as thermoforming and is especially well-suited for forming the sole insert 110, the crown insert 108, and/or the strike face. After the sole insert 110, the crown insert 108, and/or the strike face are formed (separately, in some implementations) by the thermoforming process, each is cooled and removed from the matched die. In some implementations, the sole insert 110, the crown insert 108, and/or the strike face has a uniform thickness, which facilitates use of the thermoforming process and ease of manufacture. However, in other implementations, the sole insert 110, the crown insert 108, and/or the strike face may have a variable thickness to strengthen select local areas of the insert by, for example, adding additional plies in select areas to enhance durability, acoustic properties, or other properties of the respective inserts.
[0445]In some examples, any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, can be made by a process other than thermoforming, such as injection molding or thermosetting. In a thermoset process, any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, may be made from “prepreg” plies of woven or unidirectional composite fiber fabric (such as carbon fiber composite fabric) that is preimpregnated with resin and hardener formulations that activate when heated. The prepreg plies are placed in a mold suitable for a thermosetting process, such as a bladder mold or compression mold, and stacked/oriented with the carbon or other fibers oriented in different directions. The plies are heated to activate the chemical reaction and form the crown insert 126 and/or a sole insert. Each insert is cooled and removed from its respective mold.
[0446]The carbon fiber reinforcement material for any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, made by the thermoset manufacturing process, may be a carbon fiber known as “34-700” fiber, available from Grafil, Inc., of Sacramento, California, which has a tensile modulus of 234 Gpa (34 Msi) and a tensile strength of 4500 Mpa (650 Ksi). Another suitable fiber, also available from Grafil, Inc., is a carbon fiber known as “TR50S” fiber which has a tensile modulus of 240 Gpa (35 Msi) and a tensile strength of 4900 Mpa (710 Ksi). Exemplary epoxy resins for the prepreg plies used to form the thermoset crown and sole inserts include Newport 301 and 350 and are available from Newport Adhesives & Composites, Inc., of Irvine, California. In one example, the prepreg sheets have a quasi-isotropic fiber reinforcement of 34-700 fiber having an areal weight between about 20 g/m{circumflex over ( )}2 to about 200 g/m{circumflex over ( )}2 preferably about 70 g/m{circumflex over ( )}2 and impregnated with an epoxy resin (e.g., Newport 301), resulting in a resin content (R/C) of about 40%. For convenience of reference, the plipary composition of a prepreg sheet can be specified in abbreviated form by identifying its fiber areal weight, type of fiber, e.g., 70 FAW 34-700. The abbreviated form can further identify the resin system and resin content, e.g., 70 FAW 34-700/301, R/C 40%.
[0447]In some examples, polymers used in the manufacturing of the golf club head 100 may include without limitation, synthetic and natural rubbers, thermoset polymers such as thermoset polyurethanes or thermoset polyureas, as well as thermoplastic polymers including thermoplastic elastomers such as thermoplastic polyurethanes, thermoplastic polyureas, metallocene catalyzed polymer, unimodalethylene/carboxylic acid copolymers, unimodal ethylene/carboxylic acid/carboxylate terpolymers, bimodal ethylene/carboxylic acid copolymers, bimodal ethylene/carboxylic acid/carboxylate terpolymers, polyamides (PA), polyketones (PK), copolyamides, polyesters, copolyesters, polycarbonates, polyphenylene sulfide (PPS), cyclic olefin copolymers (COC), polyolefins, halogenated polyolefins [e.g. chlorinated polyethylene (CPE)], halogenated polyalkylene compounds, polyalkenamer, polyphenylene oxides, polyphenylene sulfides, diallylphthalate polymers, polyimides, polyvinyl chlorides, polyamide-ionomers, polyurethane ionomers, polyvinyl alcohols, polyarylates, polyacrylates, polyphenylene ethers, impact-modified polyphenylene ethers, polystyrenes, high impact polystyrenes, acrylonitrile-butadiene-styrene copolymers, styrene-acrylonitriles (SAN), acrylonitrile-styrene-acrylonitriles, styrene-maleic anhydride (S/MA) polymers, styrenic block copolymers including styrene-butadiene-styrene (SBS), styrene-ethylene-butylene-styrene, (SEBS) and styrene-ethylene-propylene-styrene (SEPS), styrenic terpolymers, functionalized styrenic block copolymers including hydroxylated, functionalized styrenic copolymers, and terpolymers, cellulosic polymers, liquid crystal polymers (LCP), ethylene-propylene-diene terpolymers (EPDM), ethylene-vinyl acetate copolymers (EVA), ethylene-propylene copolymers, propylene elastomers (such as those described in U.S. Pat. No. 6,525,157, to Kim et al, the entire contents of which is hereby incorporated by reference), ethylene vinyl acetates, polyureas, and polysiloxanes and any and all combinations thereof.
[0448]Of these preferred are polyamides (PA), polyphthalimide (PPA), polyketones (PK), copolyamides, polyesters, copolyesters, polycarbonates, polyphenylene sulfide (PPS), cyclic olefin copolymers (COC), polyphenylene oxides, diallylphthalate polymers, polyarylates, polyacrylates, polyphenylene ethers, and impact-modified polyphenylene ethers. Especially preferred polymers for use in the golf club heads of the present invention are the family of so called high performance engineering thermoplastics which are known for their toughness and stability at high temperatures. These polymers include the polysulfones, the polyethelipides, and the polyamide-imides. Of these, the most preferred are the polysulfones.
[0449]Aromatic polysulfones are a family of polymers produced from the condensation polymerization of 4,4′-dichlorodiphenylsulfone with itself or one or more dihydric phenols. The aromatic polysulfones include the thermoplastics sometimes called polyether sulfones, and the general structure of their repeating unit has a diaryl sulfone structure which may be represented as -arylene-SO2-arylene-. These units may be linked to one another by carbon-to-carbon bonds, carbon-oxygen-carbon bonds, carbon-sulfur-carbon bonds, or via a short alkylene linkage, so as to form a thermally stable thermoplastic polymer. Polymers in this family are completely amorphous, exhibit high glass-transition temperatures, and offer high strength and stiffness properties even at high temperatures, making them useful for demanding engineering applications. The polymers also possess good ductility and toughness and are transparent in their natural state by virtue of their fully amorphous nature. Additional key attributes include resistance to hydrolysis by hot water/steam and excellent resistance to acids and bases. The polysulfones are fully thermoplastic, allowing fabrication by most standard methods such as injection molding, extrusion, and thermoforming. They also enjoy a broad range of high temperature engineering uses.
[0450]Three commercially important polysulfones are a) polysulfone (PSU); b) Polyethersulfone (PES also referred to as PESU); and c) Polyphenylene sulfoner (PPSU).
[0451]Particularly important and preferred aromatic polysulfones are those comprised of repeating units of the structure —C6H4SO2-C6H4-O— where C6H4 represents a m- or p-phenylene structure. The polymer chain can also comprise repeating units such as —C6H4-, C6H4-O—, —C6H4-(lower-alkylene)-C6H4-O—, —C6H4-O—C6H4-O—, —C6H4-S—C6H4-O—, and other thermally stable substantially-aromatic difunctional groups known in the art of engineering thermoplastics. Also included are the so called modified polysulfones. Individual preferred polymers include (a) the polysulfone made by condensation polymerization of bisphenol A and 4,4′-dichlorodiphenyl sulfone in the presence of base, and the abbreviation PSF and sold under the tradenames Udel®, Ultrason® S, Eviva®, RTP PSU, (b) the polysulfone made by condensation polymerization of 4,4′-dihydroxydiphenyl and 4,4′-dichlorodiphenyl sulfone in the presence of base, and having the main repeating structure and the abbreviation PPSF and sold under the tradenames RADEL® resin; and (c) a condensation polymer made from 4,4′-dichlorodiphenyl sulfone in the presence of base and having the principle repeating structure and the abbreviation PPSF and sometimes called a “polyether sulfone” and sold under the tradenames Ultrason® E, LNP™, Veradel® PESU, Sumikaexce, and VICTREX® resin,” and any and all combinations thereof.
[0452]In some examples, one exemplary material from which any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, can be made from is a composite material, such as a carbon fiber reinforced polymeric material, made of a composite including multiple plies or layers of a fibrous material (e.g., graphite, or carbon fiber including turbostratic or graphitic carbon fiber or a hybrid structure with both graphitic and turbostratic parts present). Examples of some of these composite materials for use in the and their fabrication procedures are described in U.S. patent application Ser. No. 10/442,348 (now U.S. Pat. No. 7,267,620), Ser. No. 10/831,496 (now U.S. Pat. No. 7,140,974), Ser. Nos. 11/642,310, 11/825,138, 11/998,436, 11/895,195, 11/823,638, 12/004,386, 12,004,387, 11/960,609, 11/960,610, and 12/156,947, which are incorporated herein by reference in their entirety. The composite material may be manufactured according to the methods described at least in U.S. patent application Ser. No. 11/825,138, the entire contents of which are herein incorporated by reference.
[0453]Alternatively, short or long fiber-reinforced formulations of the previously referenced polymers can be used. Exemplary formulations include a Nylon 6/6 polyamide formulation, which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 285. This material has a Tensile Strength of 35000 psi (241 MPa) as measured by ASTM D 638; a Tensile Elongation of 2.0-3.0% as measured by ASTM D 638; a Tensile Modulus of 3.30×106 psi (22754 MPa) as measured by ASTM D 638; a Flexural Strength of 50000 psi (345 MPa) as measured by ASTM D 790; and a Flexural Modulus of 2.60×106 psi (17927 MPa) as measured by ASTM D 790.
[0454]Other materials also include is a polyphthalamide (PPA) formulation which is 40% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 4087 UP. This material has a Tensile Strength of 360 MPa as measured by ISO 527; a Tensile Elongation of 1.4% as measured by ISO 527; a Tensile Modulus of 41500 MPa as measured by ISO 527; a Flexural Strength of 580 MPa as measured by ISO 178; and a Flexural Modulus of 34500 MPa as measured by ISO 178.
[0455]Yet other materials include is a polyphenylene sulfide (PPS) formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 1385 UP. This material has a Tensile Strength of 255 MPa as measured by ISO 527; a Tensile Elongation of 1.3% as measured by ISO 527; a Tensile Modulus of 28500 MPa as measured by ISO 527; a Flexural Strength of 385 MPa as measured by ISO 178; and a Flexural Modulus of 23,000 MPa as measured by ISO 178.
[0456]Especially preferred materials include a polysulfone (PSU) formulation which is 20% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 983. This material has a Tensile Strength of 124 MPa as measured by ISO 527; a Tensile Elongation of 2% as measured by ISO 527; a Tensile Modulus of 11032 MPa as measured by ISO 527; a Flexural Strength of 186 MPa as measured by ISO 178; and a Flexural Modulus of 9653 MPa as measured by ISO 178.
[0457]Also, preferred materials may include a polysulfone (PSU) formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 985. This material has a Tensile Strength of 138 MPa as measured by ISO 527; a Tensile Elongation of 1.2% as measured by ISO 527; a Tensile Modulus of 20685 MPa as measured by ISO 527; a Flexural Strength of 193 MPa as measured by ISO 178; and a Flexural Modulus of 12411 MPa as measured by ISO 178.
[0458]Further preferred materials include a polysulfone (PSU) formulation which is 40% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 987. This material has a Tensile Strength of 155 MPa as measured by ISO 527; a Tensile Elongation of 1% as measured by ISO 527; a Tensile Modulus of 24132 MPa as measured by ISO 527; a Flexural Strength of 241 MPa as measured by ISO 178; and a Flexural Modulus of 19306 MPa as measured by ISO 178.
[0459]Any one or more of the sole insert 110, the crown insert 108, the cup 103, the ring 106, and/or the strike face, such as the strike plate 243, can have a complex three-dimensional shape and curvature corresponding generally to a desired shape and curvature of the golf club head 100. It will be appreciated that other types of club heads, such as fairway wood-type club heads, hybrid club heads, and iron-type club heads, may be manufactured using one or more of the principles, methods, and materials described herein.
[0460]Referring to
[0461]Conventional processes for bonding together surfaces of a golf club head, including surface preparation via non-laser ablation methods, may not provide a sufficient pattern uniformity and surface energy for producing strong and reliable bonds. For example, chemical ablation and media-blast ablation processes are unable to achieve pattern uniformities and surface energies of bonding surfaces that are achievable by the laser ablation of the present disclosure. The patterns of peaks and valleys on bonding surfaces ablated via a chemical ablation process or a media-blast ablation process are irregular and inconsistent, which leads to lower and non-uniform bonding strength across a bond between the bonding surfaces.
[0462]As shown in
[0463]The depth of the portion of the first-part surface 520 that is sublimated (e.g., removed) is dependent on the material of the first-part surface 520 and the characteristics of the first-part laser beam 508. The characteristics of the first-part laser beam 508 include the intensity (e.g., optical power per unit area) of, the pulse frequency of, and the duration of the impact on the first-part surface 520 by the first-part laser beam 508. After the portion of the first-part surface 520 is removed, the first-part ablated surface 522 is exposed. Accordingly, generally speaking, the first-part laser beam 508 removes a top surface of the first part 502 so that a fresh surface of the first part 502 is exposed. The first-part ablated surface 522 (e.g., fresh surface or exposed surface) is relatively free of contaminants (e.g., oxides, moisture, etc.) present on the first-part surface 520.
[0464]Similarly, as shown in
[0465]In certain examples of the method 550, the first-part laser beam 508 is moved along the first-part surface 520 at a first-part rate to form the first-part ablated surface 522 in the first part 502. Similarly, in some examples, the second-part laser beam 510 is moved along the second-part surface 524 at a second-part rate to form the second-part ablated surface 526 in the second part 504. In this manner, a laser beam with a relatively small footprint can be used to form an ablated surface with a relatively larger surface area. Moreover, in various examples, a laser beam can be split into separate sub-beams, using optics, to move along and form separate portions of an ablated surface. Also, according to some examples, multiple laser beams generated from multiple lasers can be used to form an ablated surface in a single part. The rate at which a laser beam moves along a corresponding part is dependent on the type of material of the part. For example, a given laser beam may need to be moved along a given part at a faster rate, compared to another part, when the material of the given part sublimates faster than the material of the other part. In contrast, a given laser beam may need to be moved along a given part at a slower rate, compared to another part, when the material of the given part sublimates slower than the material of the other part.
[0466]The rate of sublimation, and thus the rate of movement of a laser beam along a part, is dependent on the type of laser generating the laser beam and the characteristics of the generated laser beam. Different types of lasers generate different types of laser beams. For example, a carbon-dioxide laser generates a laser beam that is different than the one generated by a fiber laser. Likewise, an Nd-YAG (neodymium-dopped yttrium aluminum garnet) laser generates a laser beam that is different than the ones generated by a carbon-dioxide laser and fiber laser, respectively. Additionally, in some examples, a laser can be selectively controlled to adjust characteristics of the generated laser. For example, a laser can be selectively controlled to adjust one or both of an intensity or pulse frequency of the generated laser. Generally, the higher the intensity of the laser beam or the higher the pulse frequency of the laser beam, the higher the rate of sublimation.
[0467]After the first part 502 is laser ablated, to form the first-part ablated surface 522, and the second part 504 is laser ablated, to form the second-part ablated surface 526, the first-part ablated surface 522 and the second-part ablated surface 526 are bonded together. Referring to
[0468]In some examples, the type of the first-part laser 506, the rate of movement of the first laser beam 508 (i.e., first-part rate), and/or the characteristics of the first-part laser beam 508 is dependent on the type of material of the first part 502. Similarly, in some examples, the type of the second-part laser 510, the rate of movement of the second-part laser beam 512 (i.e., second-part rate), and/or the characteristics of the second-part laser beam 512 is dependent on the type of material of the second part 504.
[0469]According to certain examples, the first part 502 is made of a first material and the second part is made of a second material, where the first material is different than the second material. In one example, the first part 502 is made of a first type of metallic material and the second part 504 is made of a second type of metallic material. In another example, the first part 502 is made of a first type of non-metallic material and the second part 504 is made of a second type of non-metallic material. In yet a further example, the first part 502 is made of a non-metallic material and the second part 504 is made of a metallic material. In the above examples, at least one of the type of the first-part laser 506, the rate of movement of the first-part laser beam 508, or the characteristics of the first-part laser beam 508 is different than the type of the second-part laser 510, the rate of movement of the second-part laser beam 512, or the characteristics of the second-part laser beam 512, respectively. According to some examples, the type of the first-part laser 506 is different than that of the second-part laser 510 (e.g., such that the first-part laser 506 is different than and separate from the second-part laser 510). In some examples, the first-part rate is different than the second-part rate. In one example, the intensity of the first-part laser beam 508 is different than the second-part laser beam 512. Additionally, or alternatively, according to certain examples, the pulse frequency of the first-part laser beam 508 is different than the pulse frequency of the second-part laser beam 512.
[0470]According to some examples, the first material is a fiber-reinforced polymeric material and the second material is a metallic material. In one example, the fiber-reinforced polymeric material is at least one of a glass-fiber-reinforced polymeric material or a carbon-fiber-reinforced polymeric material, such as one of those described above, and the metallic material is a titanium alloy, such as a cast titanium material. In these examples, at least one of: the first-part laser 506 is a carbon dioxide laser and the second-part laser 510 is a fiber laser; the first-part rate is slower than the second-part rate; the intensity of the first-part laser beam 508 is less than the intensity of the second-part laser beam 512; or the pulse frequency of the first-part laser beam 508 is less than the pulse frequency of the second-part laser beam 512. When the first-part rate is slower than the second-part rate, in some examples, the first-part rate is between 600 mm/s and 800 mm/s (e.g., 700 mm/s), and the second-part rate is between 600 mm/s and 800 mm/s (e.g., 700 mm/s). When the intensity of the first-part laser beam 508 is less than the intensity of the second-part laser beam 512, in certain examples, the intensity of the first-part laser beam 508 is between 40 watts and 60 watts, and the intensity of the second-part laser beam 512 is between 40 watts and 60 watts. When the pulse frequency of the first-part laser beam 508 is less than the pulse frequency of the second-part laser beam 512, in some examples, the pulse frequency of the first-part laser beam 508 is between 40 kHz and 60 kHz, and the pulse frequency of the second-part laser beam 512 is between 40 kHz and 60 kHz.
[0471]When either the first material of the first part 502 or the second material of the second part 504 is a fiber-reinforced polymeric material, which includes a plurality of reinforcement fibers embedded in a resin or epoxy matrix, the corresponding first-part surface 520 or the second-part surface 524 is defined entirely by the resin or epoxy matrix of the fiber-reinforced polymeric material. Accordingly, the first-part laser beam 508 or the second-part laser beam 512 impacts and ablates only the resin or epoxy matrix, without ablating the reinforcement fibers embedded therein. Moreover, in some examples, the first part 502 or the second part 504 is made of plies of a carbon-fiber-reinforced polymeric material sandwiched between opposing outer plies of a glass-fiber-reinforced polymeric material. In such examples, the corresponding laser beam impacts and ablates only the resin or epoxy matrix of the glass-fiber-reinforced polymeric material.
[0472]As presented previously, due the ability to precisely control the energy, pulse frequency, and directionality of a laser, laser ablation of a surface can result in a fresh (e.g., relatively uncontaminated) surface having a high uniformity of peaks and valleys, and a high surface energy. Generally, each pulse of the laser beam sublimates and removes a localized portion of the surface being ablated. The removed portion of the surface defines a valley (e.g., dimple or depression) that has a shape that corresponds with a cross-sectional shape of the laser beam and a depth that corresponds with the intensity and frequency of the laser beam. Because the laser beam is moved relative to the surface being ablated, each pulse of the laser beam contacts a different portion of the surface, which results in disparate and spaced apart valleys corresponding with the removed portions. Because the portions of the surface between the removed portions are not removed, the unremoved portions of the surface define peaks between diagonal ones of the valleys. In this manner, as the laser beam is moved relative to the surface, a pattern of peaks and valleys in the surface is formed.
[0473]Referring to
[0474]An ablation pattern 540 includes a plurality of peaks 542 spaced apart by a plurality of valleys 544. Generally, the laser beam is moved and pulsed such that the valleys are located relative to each other to form a desired pattern. The pattern of valleys can be symmetrical or non-symmetrical. Moreover, the spacing between valleys can be uniform or non-uniform. In one example, such as shown in
[0475]In some examples, each one of the valleys 544 is separated from an adjacent one of the valleys 544, across one of the peaks 542 and along a length L (or width) of the part, by a valley-to-valley distance Dvv. The valley-to-valley distance Dvv is defined as the distance from a center point of one of the valleys 544 and the center point of an adjacent one of the valleys 544. Moreover, each one of the valleys 544 has a valley depth dv measured from a hypothetical boundary 546 that is generally co-planar with the surface prior to being laser ablated. Referring to
[0476]In some examples, the major dimension D1 of at least one of the valleys 544 is between 40 micrometers and 80 micrometers, and the minor dimension D2 is equal to the major dimension D1 or may vary by as much as 10% or 20% or by 10-20 micrometers. Additionally, or alternatively, the valley-to-valley distance Dvv between two valleys 544 can range from 80%-200% (preferably at least 120%) of the major dimension D1 of any one of the two valleys 544. As defined herein, in relation to the valleys 544, a first valley is adjacent a second valley when the second valley is the nearest neighbor to the first valley. Moreover, in some examples, such as those with uniform spacing between valleys, a given valley can be considered to be adjacent to multiple valleys. The center point of a valley 544 is defined as the location of greatest depth of the valley 544, which will typically be half of the major dimension inwards from an outer perimeter of the valley 544. The outer perimeter (e.g., perimeter) of a valley 544 is defined as the transition region where a change in the valley depth dv of the valley 544, versus an unablated surface, is no more than 5 micrometers, preferably between 0 to 2 micrometers versus an unablated surface.
[0477]According to one example, the uniformity of an ablation pattern of peaks and valleys, as used herein, can be defined in terms of the variation of the size of the valleys of the ablation pattern. As previously mentioned, the substantially non-controllable ablation pattern left behind by some ablation process, such as media-blast ablation processes, include valleys of widely disparate sizes, shapes, and spacing. The ability to precisely control the energy, pulse frequency, and directionality of the laser results in an ablation pattern where all the valleys of the pattern have a uniform size. The uniformity of the sizes of the valleys of the ablation pattern formed by the laser beam can be expressed by the percent difference in the size of one valley of the ablation pattern relative to any other one (e.g., all other ones) of the valleys of the ablation pattern. The percent difference, as pertaining to the size of the valleys, is equal to the ratio (expressed as a percentage) of the size of one valley in the pattern and the size of any other one of the valleys in the pattern. The lower the percent difference in the size of the valleys of the ablation pattern, the higher the uniformity of the ablation pattern. In some examples, the percent difference of the size of one valley of a given pattern and the size of any other one of the valleys of the given pattern is no more than 20%. In other words, the size of one valley is within 20% of the size of any other one, or all other ones, of the valleys. In other examples, the percent difference of the size of one valley of a given pattern and the size of any other one of the valleys of the given pattern is no more than 10%.
[0478]The size of a valley can be expressed as a cross-sectional area, the major dimension D1, the minor dimension D2, the depth dv, or other characteristic of the size of the valley. In certain examples, the major dimension D1 or the minor dimension D2 of one valley is within 20% of the corresponding major dimension D1 or the minor dimension D2 of any other one, or all other ones, of the valleys. According to one example, the major dimension D1 of one valley is within 20% of the major dimension D1 of any other one, or all other ones, of the valleys, and the minor dimension D2 of the one valley is within 20% of the minor dimension D2 of any other one, or all other ones, of the valleys. In certain examples, the major dimension D1 or the minor dimension D2 of one valley is within 10% of the corresponding major dimension D1 or the minor dimension D2 of any other one, or all other ones, of the valleys. According to one example, the major dimension D1 of one valley is within 10% of the major dimension D1 of any other one, or all other ones, of the valleys, and the minor dimension D2 of the one valley is within 10% of the minor dimension D2 of any other one, or all other ones, of the valleys. Although the above examples reference the major dimension D1 and the minor dimension D2 of the valleys, other characteristics of the size of the valleys, such as cross-sectional area and depth, can be interchanged with the major dimension D1 and the minor dimension D2.
[0479]Additionally, or alternatively, in some examples, the uniformity of an ablation pattern of peaks and valleys, as used herein, can be defined in terms of the variation of the distance between adjacent valleys of the ablation pattern. The ability to precisely control the energy, pulse frequency, and directionality of the laser results in an ablation pattern where all the valleys of the pattern are uniformly spaced apart from each other. The uniformity of the distance between the valleys of the ablation pattern formed by the laser beam can be expressed by the percent difference in the distance between two adjacent valleys of the ablation pattern relative to the distance between any other two adjacent valleys (e.g., all adjacent valleys) of the ablation pattern. The percent difference, as pertaining to the distances between valleys, is equal to the ratio (expressed as a percentage) of the distance between two adjacent valleys in the pattern and the distance between any other two adjacent valleys in the pattern. The lower the percent difference in the distances between the valleys of the ablation pattern, the higher the uniformity of the ablation pattern. In some examples, the percent difference of the distances between two adjacent valleys of a given pattern and the difference between any other two adjacent valleys of the given pattern is no more than 20%. In other words, the distance between two adjacent valleys is within 20% of the distance between any other two adjacent valleys. In other examples, the percent difference of the distances between two adjacent valleys of a given pattern and the difference between any other two adjacent valleys of the given pattern is no more than 10%.
[0480]Corresponding with the uniformity of the peaks and valleys of the ablation pattern on the ablated surfaces of the parts disclosed herein, laser ablating a surface of a part of the golf club head also promotes a higher surface energy compared to surfaces treated using other types of ablation processes. As presented above, a higher surface energy of surfaces to be bonded enables a stronger and more reliable bond between the surfaces. The surface energy of a surface is inversely proportional to the water contact angle of the surface. In other words, the lower the water contact angle of the surface, the higher the surface energy of that surface. The water contact angle is defined as the angle (through the water) a drop of water, on a surface, makes with the surface. The lower the water contact angle, the higher the wettability of the surface, which promotes the adhesiveness of the adhesive and the ability of the adhesive to bond to the surface. Accordingly, the lower the water contact angle, the better the bond, and the higher the strength of the bond. In some examples, the water contact angle can be measured by using a goniometer or other measuring device. According to Table 4 below, the water contact angle for various laser ablated surfaces of several examples of a golf club head, prior to forming a bonded joint, are shown.
| TABLE 4 | ||||
|---|---|---|---|---|
| Crown-Hosel | Crown-Toe | Sole-Hosel | Sole-Toe | |
| Example 1 | 14° | 6° | 10° | 5° |
| Example 2 | 16° | 12° | 10° | 6° |
| Example 3 | 14° | 13° | 10° | 10° |
| Example 4 | 11° | 13° | 10° | 2° |
| Example 5 | 16° | 13° | 10° | 12° |
| Example 6 | 14° | 21° | 10° | 6° |
| Example 7 | 14° | 14° | 10° | 6° |
| Example 8 | 15° | 15° | 16° | 15° |
| Example 9 | 18° | 18° | 9° | 10° |
| Example 10 | 18° | 17° | 8° | 2° |
In another embodiment of the above examples, each value is ±25% of the indicated value, which is narrowed in additional embodiments to ±20%, ±15%, ±10%, or ±5% of the indicated value
[0481]In Table 4, the crown-hosel surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the crown portion 119 than the sole portion 117, and closer to the hosel 120 than the toe portion 114; the crown-toe surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the crown portion 119 than the sole portion 117, and closer to the toe portion 114 than the hosel 120; the sole-hosel surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the sole portion 117 than the crown portion 119, and closer to the hosel 120 than the toe portion 114; and the sole-toe surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the sole portion 117 than the crown portion 119, and closer to the toe portion 114 than the hosel 120. Accordingly, with reference to Table 4, in some examples, the second-part ablated surface 526, or any laser ablated surface of the golf club head 100, has a water contact angle between 2° and 25°, or between 5° and 18°. According to yet certain examples, the water contact angle of an ablated surface of the golf club head 100 is less than 50°, less than 45°, less than 40°, less than 35°, less than 30°, less than 25°, or less than 20°. In some examples, the water contact angle of an ablated surface of the golf club head 100 is greater than zero degrees and less than 30° or greater than zero degrees and less than 25°. In certain examples, the water contact angle of an ablated surface of the golf club head 100 is between 1° and 18°.
[0482]Referring to
[0483]When the first part 502 is the strike plate 143 of the golf club head 100, the first-part surface 520 includes the interior surface 166 or rear surface of the strike plate 143, which is opposite the strike face 145 of the strike plate 143. Accordingly, as shown in
[0484]When the second part 504 is the body 102, the second-part surface 524 includes the plate-opening recessed ledge 147 of the body 102. Accordingly, as shown in
[0485]In view of the foregoing, according to some examples, such as with the golf club head 300 of
[0486]Referring to
[0487]When the first part 502 is the crown insert 108, the first-part surface 520 includes an interior surface 108A of the crown insert 108. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the interior surface 108A of the crown insert 108 within and along a designated first-part bond area 548, at least partially on the interior surface 108A of the crown insert 108, to form a crown-insert ablated surface 108B. The first-part ablated surface 522 includes, at least partially, the crown-insert ablated surface 108B. Accordingly, only a portion (e.g., outer peripheral portion) of the entire interior surface of the crown insert 108 is laser ablated, with the remaining portion of the interior surface of the crown insert 108 being non-ablated. In some examples, the bond area on the interior surface 108A of the crown insert 108 will range from 2,000 mm2 to 2,500 mm2, such as at least 2,248 mm2. Moreover, in certain examples, a total surface area of the interior surface 108A of the crown insert 108 is between 7,000 mm2 and 12,000 mm2 or between 9,000 mm2 and 11,000 mm2 (e.g., a minimum surface area between 7,000 mm2 and 9,000 mm2), such as between 9,379 mm2 and 10,366 mm2 (e.g., around 9,873 mm2). In some examples, a percentage of the total surface area of the interior surface 108A occupied by the bond area on the interior surface 108A of the crown insert 108 is no more than 25%, 30%, 35%, or 40% and no less than 10%, 15%, 20%, or 25%. According to certain examples, the percentage of the total surface area of the interior surface 108A occupied by the bond area on the interior surface 108A of the crown insert 108 is between 20% and 25%, such as 22%, between 20% and 27%, or between 22% and 25%.
[0488]In some examples, the bond area on the interior surface 110A of the sole insert 110 will range from 1,800 mm2 to 2,200 mm2, such as at least 2,076 mm2. Moreover, in certain examples, a total surface area of the interior surface 110A of the sole insert 110 is between 7,000 mm2 and 12,000 mm2 or between 9,000 mm2 and 11,000 mm2 (e.g., a minimum surface area between 7,000 mm2 and 9,000 mm2), such as between 8,182 mm2 and 9,043 mm2 (e.g., around 8,613 mm2). In some examples, a percentage of the total surface area of the interior surface 110A occupied by the bond area on the interior surface 110A of the sole insert 110 is no more than 25%, 30%, 35%, or 40% and no less than 10%, 15%, 20%, or 25%. According to certain examples, the percentage of the total surface area of the interior surface 110A occupied by the bond area on the interior surface 110A of the sole insert 110 is between 20% and 27%, between 22% and 25%, or between 21% and 26%, such as 24%.
[0489]In some examples, the bond area on the interior surface of the strike plate 143 will range from 1,770 mm2 to 2,170 mm2, such as at least 1,976 mm2. Moreover, in certain examples, a total surface area of the interior surface of the strike plate 143 is less than 7,000 mm2, such as between 1,500 mm2 and 7,000 mm2, between 3,200 mm2 and 4,700 mm2, or between 3,572 mm2 and 3,949 mm2 (e.g., around 3,761 mm2). In some examples, a percentage of the total surface area of the interior surface of the strike plate 143 occupied by the bond area on the interior surface of the strike plate 143 is no more than 55%, 60%, 65%, or 70% and no less than 30%, 35%, 40%, or 45%. According to certain examples, the percentage of the total surface area of the interior surface of the strike plate 143 occupied by the bond area on the interior surface of the strike plate 143 is between 47% and 58%, such as 52%.
[0490]In some examples, the first-part surface 520 also includes a peripheral edge surface of the crown insert 108 and the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact (e.g., an entirety of) the peripheral edge surface of the crown insert 108 such that a crown-insert-edge ablated surface 108C is formed. Accordingly, the first-part ablated surface 522 can further include the crown-insert-edge ablated surface 108C and the designated first-part bond area 548 can further include the peripheral edge surface of the crown insert 108. The crown-insert ablated surface 108B and the crown-insert-edge ablated surface 108C can have the same ablation pattern in certain examples. In some examples, an orientation of the crown insert 108 relative to the first-part laser 506 is adjusted when laser ablating the peripheral edge surface of the crown insert 108, compared to when laser ablating the interior surface 108A, because of the angle of the peripheral edge surface relative to the interior surface 108A.
[0491]When the first part 502 is the crown insert 108, the second-part surface 524 includes the crown-opening recessed ledge 168. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the crown-opening recessed ledge 168 within and along a designated second-part bond area, at least partially on the crown-opening recessed ledge 168, to form a top-ledge ablated surface 141A. The second-part ablated surface 526 includes, at least partially, the top-ledge ablated surface 141A. In some examples, the second-part surface 524 also includes a top recessed-ledge sidewall, circumferentially surrounding and defining a depth of the crown-opening recessed ledge 168, and the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact (e.g., an entirety of) the top recessed-ledge sidewall such that a top-sidewall ablated surface 141B is formed. Accordingly, the second-part ablated surface 526 can further include the top-sidewall ablated surface 141B and a designated second-part bond area can further include the top recessed-ledge sidewall. The top-ledge ablated surface 141A and the top-sidewall ablated surface 141B can have the same ablation pattern in certain examples. In some examples, an orientation of the body 102 relative to the second-part laser 510 is adjusted when laser ablating the top recessed-ledge sidewall, compared to when laser ablating the crown-opening recessed ledge 168, because of the angle of the top recessed-ledge sidewall relative to the crown-opening recessed ledge 168.
[0492]In view of the foregoing, according to some examples, the second-part ablated surface 526 is defined by the ablated surfaces of two sub-components (e.g., the cup 104 and the ring 106) made of different materials. Therefore, when the second-part ablated surface 526 is laser ablated, the different materials defining the second-part ablated surface 526 can be laser ablated in a single, continuous step.
[0493]When the first part 502 is the sole insert 110, the first-part surface 520 includes an interior surface 110A of the sole insert 110. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the interior surface 110A of the sole insert 110 within and along a designated first-part bond area 548, at least partially on the interior surface 110A of the crown insert 110, to form a sole-insert ablated surface 110B. The first-part ablated surface 522 includes, at least partially, the sole-insert ablated surface 110B. Accordingly, only a portion (e.g., outer peripheral portion) of the entire interior surface of the sole insert 110 is laser ablated, with the remaining portion of the interior surface of the sole insert 110 being non-ablated. In some examples, the first-part surface 520 also includes a peripheral edge surface of the sole insert 110 and the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact (e.g., an entirety of) the peripheral edge surface of the sole insert 110 such that a sole-insert-edge ablated surface 110C is formed. Accordingly, the first-part ablated surface 522 can further include the sole-insert-edge ablated surface 110C and the designated first-part bond area 548 can further include the peripheral edge surface of the sole insert 110. The sole-insert ablated surface 110B and the sole-insert-edge ablated surface 110C can have the same ablation pattern in certain examples. In some examples, an orientation of the sole insert 110 relative to the first-part laser 506 is adjusted when laser ablating the peripheral edge surface of the sole insert 110, compared to when laser ablating the interior surface 110A, because of the angle of the peripheral edge surface relative to the interior surface 110A.
[0494]Furthermore, when the first part 502 is the sole insert 110, the second-part surface 524 includes the sole-opening recessed ledge 170. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the sole-opening recessed ledge 170 within and along a designated second-part bond area, at least partially on the sole-opening recessed ledge 170, to form a bottom-ledge ablated surface 142A. The second-part ablated surface 526 includes, at least partially, the bottom-ledge ablated surface 142A. In some examples, the second-part surface 524 also includes a bottom recessed-ledge sidewall, circumferentially surrounding and defining a depth of the sole-opening recessed ledge 170, and the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact (e.g., an entirety of) the bottom recessed-ledge sidewall such that a bottom-sidewall ablated surface 142B is formed. Accordingly, the second-part ablated surface 526 can further include the bottom-sidewall ablated surface 142B and the designated second-part bond area can further include the bottom recessed-ledge sidewall. The bottom-ledge ablated surface 142A and the bottom-sidewall ablated surface 142B can have the same ablation pattern in certain examples. In some examples, an orientation of the body 102 relative to the second-part laser 510 is adjusted when laser ablating the bottom recessed-ledge sidewall, compared to when laser ablating the sole-opening recessed ledge 170, because of the angle of the bottom recessed-ledge sidewall relative to the sole-opening recessed ledge 170.
[0495]As disclosed above, in some examples, an orientation of a part being laser ablated can be adjusted relative to the laser that is ablating the part. In one example, as shown by directional arrows, with dashed lines, in
[0496]According to another example, as shown by directional arrows, with solid lines, in
[0497]Although in some examples, the methods disclosed herein may be performed manually, in other examples, the methods are automated. As used herein, automated means operated at least partially by automatic equipment, such as computer-numerically-controlled (CNC) machines. The process of controlling the laser, including the directionality and/or characteristics of the laser beam, and/or controlling the orientation/position of the part relative to the laser beam is automated in some examples. For example, an electronic controller can control the laser and part-adjustment components (e.g., motors, cylinders, gears, rails, etc.) that hold and adjust the orientation/position of the part.
[0498]Because the golf club head 100 has both a crown insert 108 and a sole insert 110 attached to the body 102, in some examples, the method 550 can be performed to make a golf club head that has more than one first part 502 coupled to the second part 504. In other words, in at least one example, the golf club head 100 includes at least two first parts 502 coupled to the second part 504. Moreover, because the golf club head 100 also includes a strike plate 148 attached to the body 102, in certain examples, the method 550 can be performed to make a golf club head that has at least three first parts 502 coupled to the second part 504.
[0499]As described above, the body 102 of the golf club head 100 includes multiple pieces that are attached together to form a multi-piece construction. For example, referring to
[0500]When the first part 502 is the ring 106 and the second part 504 is the cup 104, the first-part surface 520 includes the toe cup-engagement surface 152A and the heel cup-engagement surface 152B. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the toe cup-engagement surface 152A and the heel cup-engagement surface 152B within and along a designated first-part bond area, at least partially on the toe cup-engagement surface 152A and the heel cup-engagement surface 152B, to form a toe cup-engagement ablated surface 148C and a heel cup-engagement surface 148D, respectively. The first-part ablated surface 522 includes, at least partially, the toe cup-engagement ablated surface 148C and the heel cup-engagement surface 148D. The toe cup-engagement ablated surface 148C and the heel cup-engagement surface 148D can have the same ablation pattern in certain examples.
[0501]Correspondingly, when the first part 502 is the ring 106 and the second part 504 is the cup 104, the second-part surface 524 includes the toe ring-engagement surface 150A and the heel ring-engagement surface 150B. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the toe ring-engagement surface 150A and the heel ring-engagement surface 150B within and along a designated second-part bond area, at least partially on the toe ring-engagement surface 150A and the heel ring-engagement surface 150B, to form a toe ring-engagement ablated surface 148A and a heel ring-engagement surface 148B, respectively. The first-part ablated surface 522 includes, at least partially, the toe ring-engagement ablated surface 148A and the heel ring-engagement surface 148B. The toe ring-engagement ablated surface 148A and the heel ring-engagement surface 148B can have the same ablation pattern in certain examples.
[0502]After the ring 106 is bonded to the cup 104, the ring 106 and the cup 104 can collectively define a second part 504 to which a first part 502 is bonded according to the method 550. In other words, the second part 504 can have a multi-piece construction. In fact, with reference to
[0503]As used herein, dashed leader lines are used to indicate features in a prior state. For example, a surface referenced by a dashed leader line indicates that surface prior to being modified into a surface referenced by a solid leader line. This methodology is helpful in understanding the correlation between a surface before and after being ablated.
[0504]In some examples, the step of laser ablating the first-part surface 520 or the step of laser ablating the second-part surface 524 is performed to remove alpha case from a corresponding one of the first part 502 or the second part 504. In such examples, the corresponding one of the first part 502 or the second part 504 is made of a titanium alloy that is prone to developing a layer of alpha case on the first-part surface 520 or the second-part surface 524, respectively, during manufacturing (e.g., casting) of the corresponding part (see, e.g., U.S. Pat. No. 10,780,327, issued Sep. 22, 2020, which is incorporated herein by reference). The corresponding one of the first-part surface 520 or the second-part surface 524 is ablated to a depth sufficient to remove the layer of alpha case from the corresponding part. Using the laser ablation method disclosed herein enables the alpha case to be removed with more precision, efficiency, and lower waste materials that conventional methods, such as chemical etching, computer numerically-controlled (CNC) machine, or abrasion techniques.
[0505]Referring to
[0506]In certain examples, the second part 504 in the method 560 is made of a titanium alloy, such as a cast alloy, and the first part 502 in the method 560 is made of a fiber-reinforced polymeric material. For example, the first part 502 can be the strike plate 143, the second part 504 can be the body 102, and the second-part ablated surface 526 can define the plate-opening recessed ledge 147 of the body 102. However, unlike the strike plate 143 shown in
[0507]According to some examples, the method 560 is used to make a golf club head similar to the golf club head 100, except the strike plate 143, the crown insert 108, and/or the sole insert 110 does not have a laser-ablated surface. Instead, in some examples, only the body 102, which can be made of a cast titanium alloy, includes laser-ablated surfaces. According to one example, the body 102 includes the top-ledge ablated surface 141A, the bottom-ledge ablated surface 141B, and the front-ledge ablated surface 179A, but the crown insert 108 does not include the crown-insert ablated surface 108B, the sole insert 110 does not include the sole-insert ablated surface 110B, and the strike plate 143 does not include the strike-plate-interior ablated surface 179C.
[0508]Each bonded joint of the golf club head 100 is defined by two bonded surfaces (e.g., faying surfaces). Because a bonded joint has two equal and opposite bonded surfaces, a surface area of each bonded joint (i.e., bond area of each bonded joint) is defined as the surface area of just one of the two bonded surfaces. In other words, as defined herein, the bond area of each bonded joint does not include the surface area of both bonded surfaces of the bonded joint. Accordingly, as used herein, the bond area of a bonded joint, defined between two surfaces of the golf club head disclosed herein, is the surface area of the portion of any one (but just one) of the two surfaces of the bonded joint that is covered by or in direct contact with an adhesive between the two surfaces. In view of this definition, the bond area is equal to the surface area of one of two surfaces of the adhesive (e.g., the bonding tape 174) defining the bonded joint. Accordingly, as used herein, the maximum surface area of a side of the bonding tape 174, bonded to a part to form a bonded joint with the part, is equal to the bond area of the bonded joint, as described in detail below.
[0509]In some examples, at least one of the two bonded surfaces of at least one bonded joint of the golf club head 100 is a laser ablated surface. Accordingly, the bond area of a bonded joint defined by a laser ablated surface can be the surface area of the laser ablated surface. Therefore, unless otherwise noted, a surface area of an ablated surface is equal to the bond area of the bonded joint defined by the laser ablated surface. Moreover, the bond area of a bonded joint defined by a non-ablated surface (e.g., the first-part surface 520 of
[0510]As defined herein, the surface area of a laser ablated surface is the area of the portion of the surface covered by the pattern of peaks and valleys formed by the laser beam. Accordingly, the surface area of a laser ablated surface can be calculated as a length times a width of the portion of the surface that includes the pattern of peaks and valleys, or calculated by the combined surface area of the peaks and valleys of the pattern of peaks and valleys. Moreover, because in some examples, the bonded surfaces of a bonded joint are contoured, to provide a more convenient way of calculating the area of the bonded surfaces, as defined herein, the surface area of a surface is a projected surface area, which is the surface area of the surface projected onto a hypothetical plane substantially facing the surface.
[0511]Generally, a total bond area of the golf club head 100 is higher than conventional golf club heads. Moreover, a high percentage, such as 50%-100%, of the total bond area of the golf club head 100 is defined by laser ablated surfaces bonded together using the bonding tape 174. According to one example, the second-part ablated surface 526 of the golf club head 100 has a surface area between 800 mm2 and 2,880 mm2. In this, or other examples, the second-part ablated surface 526 of the golf club head 100 has a surface area of at least 1,560 mm2, of at least 1,770 mm2, of at least 2,062 mm2, or of at least 2,600 mm2. As defined previously, the first-part surface 520 or the first-part ablated surface 522 of the golf club head 100 can have corresponding surface areas because they would define the side of a bonded joint opposite the second-part ablated surface 526. Referring to Table 5 below, areas of some features and the bond area (in mm2) of bonded surfaces of bonded joints of several examples of the golf club heads disclosed herein, which can be the same as or different than the examples of Table 4, is shown.
| TABLE 5 | |||
|---|---|---|---|
| Example | Example | Example | |
| 1 | 2 | 3 | |
| Plate Opening Area | 2266 | 1674 | 1330-2720 |
| Front-Ledge Ablated Surface Area | 1010 | — | 800-1220 |
| Front-Sidewall Ablated Surface Area | 806 | — | 640-970 |
| Strike Face Ablated Surface Area | 1073 | 1073 | 850-1290 |
| Lower Cup Piece Ablated Surface | — | 599 | 470-720 |
| Area | |||
| Lower Cup Piece Ledge Ablated | — | 267 | 210-330 |
| Surface Area | |||
| Lower Cup Piece Sidewall Ablated | — | 222 | 170-270 |
| Surface Area | |||
| Ring-Engagement Ablated Surface | 80 | — | 60-100 |
| Area | |||
| Cup-Engagement Ablated Surface | 112 | — | 80-140 |
| Area | |||
| Cup Top-Ledge Ablated Surface Area | 1424 | — | 1130-2000 |
| Cup Bottom-Ledge Ablated Surface | 1000 | — | 800-1200 |
| Area | |||
| Ring Top-Ledge Ablated Surface | 935 | — | 740-1130 |
| Area | |||
| Ring Bottom-Ledge Ablated Surface | 1420 | — | 1130-1710 |
| Area | |||
[0512]In some examples, the forward sole-opening recessed ledge 170A (e.g., the cup bottom-ledge ablated surface area of Table 5) defines a bond area of about 1,054 mm2, the forward crown-opening recessed ledge 168A (e.g., the cup top-ledge ablated surface area of Table 5) defines a bond area of about 1,910 mm2, the toe ring-engagement surface 150A and the heel ring-engagement surface 150B (e.g., the ring-engagement ablated surface area of Table 5) or the toe cup-engagement surface 152A and the heel cup-engagement surface 152B (e.g., the cup-engagement ablated surface area of Table 5) are about 98 mm2, the plate-opening recessed ledge 147 and the sidewall 146 (e.g., the front-ledge ablated surface area and the front-sidewall ablated surface area) define a bond area of about 2,240 mm2, a total bond area defined by the cup 104 is 5,300 mm2. According to the same or alternative examples, the rearward crown-opening recessed ledge 168B (e.g., the ring top-ledge ablated surface area of Table 5) defines a bond area of about 928 mm2, the rearward sole-opening recessed ledge 170B (e.g., the ring bottom-ledge ablated surface area of Table 5) defines a bond area of about 1,222 mm2, and a total bond area defined by the ring 106 is 2,250 mm2.
[0513]In view of the foregoing, in some examples, the golf club head 100 includes a single component or piece (e.g., the ring 106) that is bonded to three other components or pieces of the golf club head 100 where a total bonded area between these four components or pieces of the golf club head 100 is between 1,950 mm2 and 2,500, mm2, or more preferably between 2,100 mm2 and 2,400 mm2. According to some examples, the golf club head 100 includes a single component or piece (e.g., the cup 104) that is bonded to three other components or pieces of the golf club head 100 where a total bonded area between these four components or pieces of the golf club head 100 is between 2,250 mm2 and 3,400, mm2, or more preferably between 2,900 mm2 and 3,200 mm2. According to yet some examples, the golf club head 100 includes a single component or piece (e.g., the cup 104) that is bonded to four other components or pieces of the golf club head 100 where a total bonded area between these five components or pieces of the golf club head 100 is between 4,750 mm2 and 6,200, mm2, or more preferably between 4,900 mm2 and 5,500 mm2. In certain examples, the golf club head includes a single component or piece (e.g., the upper cup piece 304A) that is bonded to five other components or pieces of the golf club head 100 where a total bonded area between these six components or pieces of the golf club head 100 is between 5,500 mm2 and 7,000, mm2, or more preferably between 5,700 mm2 and 6,300 mm2.
[0514]The golf club heads of the present disclosure have a high bond area, between multiple pieces of the golf club heads, relative to a volume of the golf club heads. In other words, for a given size of a golf club head, the amount of bonded area is significantly higher than for conventional golf club heads. According to some examples, the volume of a golf club head, such as the golf club head 100, disclosed herein is between 450 cc and 600 cc, and more preferably between 450 cc and 470 cc. Moreover, in certain examples, a bond-volume ratio, or a ratio of a combined bond area of the plurality of bonded joints of the golf club head to a volume of the golf club head is at least 3.75 mm2/cc and at most 15.5 mm2/cc (e.g., at least 9.1 mm2/cc and at most 14.0 mm2/cc). In some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 7.9 mm2/cc and at most 13.7 mm2/cc (e.g., at least 8.1 mm2/cc and at most 12.2 mm2/cc). In yet some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 3.75 mm2/cc and at most 7.5 mm2/cc (e.g., at least 4.8 mm2/cc and at most 7.1 mm2/cc).
[0515]According to some alternative examples, a bond-volume ratio, or a ratio of a combined bond area of the plurality of bonded joints of the golf club head to a volume of the golf club head is at least 10 mm2/cc and at most 18.8 mm2/cc (e.g., at least 10 mm2/cc and at most 15.5 mm2/cc or at least 11.6 mm2/cc and at most 17.7 mm2/cc). In some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 10.5 mm2/cc and at most 15.3 mm2/cc, at least 11.6 mm2/cc and at most 18.8 mm2/cc, or at least 12.1 mm2/cc and at most 17.5 mm2/cc.
[0516]The golf club head disclosed herein is made of multiple pieces adhesively bonded together. Accordingly, in some examples, the golf club head disclosed herein includes multiple pieces coupled together via the bonding tape 174 such that no portions or pieces of the golf club head are welded together.
[0517]The bond area of a bonded joint is defined by a width (WBA) and a length (LBA) of the bonded joint (see, e.g.,
[0518]The bonding tape 174 has a tape width (WT) and a tape length (LT), measured in the same manner as disclosed and illustrated with respect to the width (WBA) and the length (LBA) of the bonded joint (see, e.g.,
[0519]According to some examples, the bond area of, or the bonding tape 174 forming, at least one bonded joint of the golf club head 100 has a length LBA, which can be a continuous or segmented length, of between 174 mm and 405 mm, such as at least 250 mm. For example, the combined bond area defined by the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B has a length LBA of at least 268 mm, of at least 300 mm, at least 316 mm, at least 353 mm, or at least 370 mm. As another example, the combined bond area defined by the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B has a length LBA of at least 281 mm, of at least 314 mm, at least 331 mm, at least 350 mm, or at least 367 mm. As another example, the combined bond area defined by the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B has a length LBA of no more than 650 mm, and in further embodiments no more than 600 mm, 550 mm, 500 mm, or 450 mm. According to yet another example, the bond area defined by the plate-opening recessed ledge 147 has a length LBA of at least 174 mm, of at least 194 mm, at least 205 mm, at least 250 mm, or at least 262 mm. According to yet another example, the bond area defined by the plate-opening recessed ledge 147 has a length LBA of no more than 500 mm, and in further embodiments no more than 450 mm, 400 mm, or 350 mm. According to some examples, a combined length of the plurality of bonded joints is at least 723 mm and at most 1,094 mm, such as between 852 mm and 953 mm.
[0520]Unless otherwise noted, the bonding tape 174 has a length and a width the same as, or substantially equal to, the bond length or the bond width of the bonded joint. For example, in some instances, the width WT of the bonding tape 174 is between, and inclusive or, 1 mm and 20 mm, and in another embodiment a maximum bonding tape width WT is at least 2 mm, 3 mm, 4 mm, or 5 mm. In another embodiment the maximum bonding tape width WT is no more than 18 mm, 16 mm, 14 mm, 12 mm, or 10 mm. Reference to a maximum bonding tape width WT does infer that the width varies, and a constant bonding tape width WT has a maximum bonding tape width WT and a minimum bonding tape width WT that is equal to the maximum bonding tape width WT. In one embodiment the bonding tape width WT varies and the maximum bonding tape width WT is at least 25% greater than the minimum bonding tape width WT. In further embodiments the maximum bonding tape width WT is at least 35%, 45%, 55%, 65%, 75%, 85%, 95%, or 105% greater than the minimum bonding tape width WT. Additional embodiments cap the relationship such that the maximum bonding tape width WT is no more than 400%, 375%, 350%, 325%, or 300% of the minimum bonding tape width WT.
[0521]Additionally, for a given surface of a bonded joint (e.g., a surface of a ledge), the bonding tape 174 can adhere to a certain percentage of the total surface area of that given surface. In some examples, the percentage is less than 100% or less than 99%, is between, and inclusive of, 75% and 99% or between, and inclusive of 85% and 99%. The total surface area of a bonded surface can be equal to the total surface area covered by the part bonded to the bonded surface.
[0522]The quantity, size, and location of the bonding tape 174, as well as the number of components joined using the bonding tape 174, as well as their rigidity, all impact the performance, durability, and long-term CT creep of the golf club head. A single-side bonding tape area is the surface area associated with a single side of the bonding tape that attaches to a single component of the golf club head. For example, in
[0523]A face center horizontal plane (FCHP) is a horizontal plane extending through center face 205 and perpendicular to the face center vertical plane (FCVP). In one embodiment considering the total single-side bonding tape area for all components of the golf club head, at least 52.5% the total single-side bonding tape area is located above the FCHP, while in further embodiments the percentage is increased to 55%, 57.5%, 60%, 62.5%, or 65%. In another series of embodiments no more than 85% the total single-side bonding tape area is located above the FCHP, and in additional embodiments the percentage is reduced to 80%, 75%, or 70%.
[0524]As previously noted, the face center vertical plane (FCVP) can be used to delineate the toe portion 114 from the heel portion 116. In one embodiment considering the total single-side bonding tape area for all components of the golf club head, at least 52.5% the total single-side bonding tape area is located in the heel portion, while in further embodiments the percentage is increased to 55%, 57.5%, 60%, 62.5%, or 65%. In another embodiment no more than 85% the total single-side bonding tape area is located in the heel portion, while in further embodiments the percentage is reduced to 80%, 75%, 70%, or 65%.
[0525]In some examples, a length-area ratio, equal to a ratio of the length LBA to the bond area of a bonded joint of, or the length to the surface area of the bonding tape 174 forming, the bond defined by the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B is between 0.13 and 0.16, such as around 0.15. In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B is between 0.13 and 0.16, such as around 0.15.
[0526]In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B is between 0.13 and 0.16, such as around 0.15.
[0527]In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between plate-opening recessed ledge 147 is between 0.10 and 0.13, such as around 0.11.
[0528]As previously disclosed, at least one bonded joint of the golf club heads disclosed herein is formed by the bonding tape 174. More specifically, the bonding tape 174 is situated between two parts and adhesively bonds together the two parts. The shape of the bonding tape 174 corresponds with the shape of the bonded surfaces (e.g., ablated surfaces) of the two parts that are bonded together. In some examples, the shape of the bonding tape 174 is substantially identical to the shape of at least one of the bonded surfaces of the two parts bonded together. Moreover, when the shape of the bonding tape 174 is substantially identical to the shape of the at least one of the bonded surfaces, the size of the bonding tape 174 can be identical to or smaller than the size of the at least one of the bonded surfaces. The bonding tape 174 is not flowable in a precured state (i.e., before the bonding tape 174 is cured). In other words, in a precured state, the bonding tape 174 has a fixed shape (e.g., without pressure, does not flow or conform to the outline of a container). In some examples, as shown in
[0529]Referring to
[0530]The bonding tape 174 of the bonding tape package 254 has a thickness t1. Additionally, the first release layer 256A has a thickness t2 and the second release layer 256B has a thickness t3. In some examples, the thickness t1 of the bonding tape 174 is greater than the thickness t2 of the first release layer 256A and the thickness t3 of the second release layer 256B. In one example, the thickness t2 of the first release layer 256A is different than the thickness t2 of the second release layer 256B. According to one example, the thickness t1 of the bonding tape 174 is between, and inclusive of, 90 μm and 550 μm (e.g., 100 μm or 150 μm), between, and inclusive of, 250 μm and 330 μm, or between, and inclusive of, 300 μm and 390 μm, the thickness t2 of the first release layer 256A is about 100 μm, and the thickness t2 of the second release layer 256B is about 75 μm.
[0531]The bonding tape 174 is made of an adhesive material. According to some examples, the adhesive material of the bonding tape 174 is a thermo-activated adhesive. In other words, the adhesion strength of the bonding tape 174 is maximized after the bonding tape 174 is cured (i.e., heated to a predetermined temperature for a predetermined period of time). The predetermined temperature is associated with a curing temperature and curing period of the adhesive material. In some examples, the bonding tape 174 is made of a thermosetting material, such as a thermosetting acrylic material. According to certain examples, the curing temperature (and associated curing period) of the bonding tape 174 is between, and inclusive of, 90° C. (120 minutes) and 120° C. (20 minutes), or between, and inclusive of, 100° C. (60 minutes) and 115° C. (35 minutes), such as 110° C. (40 minutes). In some other examples, the curing temperature (associated curing period) of the bonding tape 174 is at least 100° C. or at least 120° C. (between, and inclusive of, 60 minutes and 180 minutes), such as between, and inclusive of, 120° C. and 230° C. or between, and inclusive of, 140° C. and 190° C. . . . During curing, the thermosetting material undergoes an irreversible chemical change by producing cross-linked polymer chains. Moreover, after curing, a temperature necessary to reflow the bonding tape 174 is at least 160° C., at least 180° C., at least 200° C., or at least 220° C.
[0532]In some examples, the adhesive material of the bonding tape 174 can be left in a pre-cured state, at room temperature, for up to 24 hours without compromising the adhesion properties of the bonding tape 174. Accordingly, the use of the bonding tape 174 enables flexibility in the handling and storage of the bonding tape 174, including parts bonded by the bonding tape 174, and flexibility in the timing of the manufacturing steps of the golf club head. For example, because the bonding tape 174 can be exposed in a pre-cured state at room temperature for periods of time longer than some conventional adhesives, some steps, such as the temporary adhesion of the bonding tape 174 to a part, can be performed well before the bonding tape 174 is actually cured. Additionally, in some examples, the unique properties of the bonding tape 174 allow the bonding tape 174 to be applied to parts at one facility and cured at another facility. Being able to prep parts with bonding tape 174 well in advance of curing the bonding tape 174 can promote speed and efficiency in assembling a golf club head, which can broaden the locations in which the golf club head manufacturing can be finalized (e.g., on-site at a retailer).
[0533]After the bonding tape 174 is cured, the shear strength of the bonding tape 174, which is a measure of the ability of the bonding tape 174 to resist separation of parts bonded by the bonding tape 174, is at least 10 Mpa (e.g., between, and inclusive of, 11 MPa and 21 MPa), at least 11 MPa, at least 12 MPa, at least 13 MPa, at least 26 MPa, at least 30 MPa, or at least 35 MPa. To promote adhesion between the bonding tape 174 and parts forming the bond, pressure should be applied to the parts such that, when the bonding tape 174 is being cured, opposing compression forces from the parts are acting on the bonding tape 174. In other words, while the bonding tape 174 is being cured, the parts forming the bond should be compressed against the bonding tape 174. Ideally, the pressure applied to the parts should be uniform to promote a uniform adhesion of the bonding tape 174 along the parts, and thus a uniform adhesion strength along the bond. However, uniformly compressing one part toward another part, particularly when the parts are contoured or have complex shapes, can be difficult. Described herein are examples of systems, apparatuses, and methods that promote uniform compression of bonded parts, while the bonding tape 174 between the bonded parts is being cured, in an accurate, a reliable, a clean, and an efficient manner. Moreover, as described in more detail, the use of the bonding tape 174, as opposed to a flowable adhesive, enables the uniform compression of bonded parts using the systems, apparatuses, and methods described herein.
[0534]Referring to
[0535]The recess 262 has a shape corresponding with the shape of the bonding tape package 254, cut from the sheet 250. In this manner, the bonding tape package 254 can be seated in the recess 262, as shown in
[0536]With the bonding tape package 254 seated in the recess 262, activation of the vacuum device 268 reduces the pressure in the conduits 264. Because the bonding tape package 254 covers the openings of the conduits 264 in the recess 262, the drop in pressure in the conduits 264 urges the bonding tape package 254 against the bottom of the recess 262, via a suction force, which helps to retain the bonding tape package 254 in the recess 262. When the bonding tape package 254 is urged against the bottom of the recess 262, which is shown in
[0537]After the first release layer 256A is removed, a surface of the bonding tape 174, facing away from the recess, is exposed. While retaining the bonding tape package 254 in the recess 262, via the suction force, a part can be pressed against the exposed surface of the bonding tape 174, as shown in
[0538]The tape-retention fixture 260, including the conduits 264 and the recess 262, can be configured to accommodate one of many parts of a golf club head. For a golf club head that has multiple bonded joints joining together multiple sets of parts, additional tape-retention fixtures 260 can be employed and configured to accommodate other parts of the golf club head. In the illustrated example of
[0539]However, in other examples, with reference to
[0540]In yet other examples, with reference to
[0541]According to some examples, with reference to
[0542]Although in the illustrated examples above, the bonding tape 174 is used to bond together multiple parts of a driver-type golf club head, in other examples, bonding tape can be used to bond together multiple parts of other types of golf club heads in the same or a similar manner as described above. According to one example, as shown in
[0543]The golf club head 1110 further includes a crown insert 1108 that is attached to the body 1102 over the crown opening 1162 so as to cover the crown opening 1162. The crown insert 1108 is adhered to the body 1102 over the crown opening 1162 by a crown-opening strip 1174 of bonding tape 1174. The crown-opening strip 1174 can be a single continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the crown-opening strip 1174 is a single continuous strip in the shape of an outer periphery of the crown insert 1108. When attached, the crown-opening strip 1174 is interposed between the crown insert 1108 and the body 1102 to adhere the crown insert 1108 to the body 1102. In some examples, the crown insert 1108 is made of a non-metal material, such as a fiber-reinforced polymeric material as described above.
[0544]The golf club head 1110 also includes a strike plate 1143 that is attached to the body 1102 over the plate opening 1149 so as to cover the plate opening 1149. In some examples, the strike plate 1143 includes a wrap-around portion that effectively wraps around a strike face 1145, thus forming part of the crown portion, a toe portion, a heel portion, and the sole portion 1117 of the golf club head 1100. The strike plate 1143 is adhered to the body 1102 over the plate opening 1149 by a plate-opening strip 1176 of bonding tape 1174. The plate-opening strip 1176 can be a single continuous or non-continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the plate-opening strip 1176 is a single, non-continuous strip in the shape of an outer periphery of the strike plate 1143. When attached, the plate-opening strip 1176 is interposed between the strike plate 1143 and the body 1102 to adhere the strike plate 1143 to the body 1102.
[0545]According to certain examples, the strike plate 1145 is made of a non-metal material, such as a fiber-reinforced polymeric material as described above, and the body 1102 is made of a metallic material. In some examples, the strike plate 1145 is made of a first metallic material and the body 1102 is made of a second metallic material. In one example, the strike plate 1145 is made of a titanium alloy and the body 1102 is made of a steel alloy. According to another example, the strike plate 1145 is made of a steel alloy and the body 1102 is made of a titanium alloy. Typically, when a strike plate and a body are made of a metallic material, the metallic materials are welded together and when one of the metallic materials is heat treated, the other of the metallic materials experiences a less than ideal heat treatment (such as a second heat treatment, an overtreatment, or an undertreatment). However, the bonding tape 1174 eliminates the need for a weldment, and thus the body 1102 and the strike plate 1145 can be heat treated separately, under different individualized heat treatment conditions conducive to the particular types of metallic materials of the body 1102 and the strike plate 1145. Although the metal-to-metal adhesive bond facilitated by the bonding tape 1174 is shown associated with a fairway-metal type golf club head, in other examples, the bonding tape 1174 can facilitate a metal-to-metal adhesive bond between a strike plate and a body of other types of golf club heads, such as driver-type golf club heads, iron-type golf club heads (e.g., having an interior volume of at least 5 cubic centimeters (such as between, and inclusive of, 5 cc and 20 cc), hybrid-type golf club heads, and the like. Accordingly, the golf club heads of the present disclosure have an interior volume of at least 5 cc, and up to 600 cc.
[0546]In certain examples, the golf club head 1100 also includes a sole slot 1191 and a slot cover 1190 attached to the sole portion 1117 over the sole slot 1191, thus covering the sole slot 1191. The slot cover 1190 is adhered to the body 1102 over the sole slot 1191 by a slot strip 1179 of bonding tape 1174. The slot strip 1179 can be a single continuous or non-continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the slot strip 1179 is a single, continuous strip in the shape of an outer periphery of the sole slot 1191. When attached, the slot strip 1179 is interposed between the slot cover 1190 and the body 1102 to adhere the slot strip 1179 to the body 1102. In some examples, a portion of the strike plate 1143 defines a portion of the sole slot 1191, and the slot cover 1190 is also adhered to the portion of the strike plate 1143 that defines the sole slot 1191 via the slot strip 1179. The slot cover 1190 is made of a polymeric material (e.g., thermoplastic polyurethane) in some examples. In certain examples, the slot cover 1190 is flat.
[0547]According to another example, as shown in
[0548]In some examples, the body 1202 is made of a metallic material (e.g., steel) and the rear badge 1292 is made of a non-metallic material (e.g., a polymer). In alternative examples, both the body 1202 and the rear badge 1292 are made of a metallic material.
[0549]Referring to
[0550]The club head include a body 4602 that includes a hosel portion and provides a primary structural support for the club head, and various other components are coupled to the body, which may include the face plate 4610 and the crown 4620, and in some embodiments a sole plate 4640, one or more weights, and/or other features. In some embodiments, the body includes a front body portion (labeled as 4602) and a rear ring portion attached together (e.g., welded, bonded, or mechanically attached) at the heel and toe ends, or integrally formed. Whether attached together or integrally formed, the front body portion 4602 and the rear ring portion compose a frame that serves as the supporting structure for the attachment of other components, which may include the crown 4620, the face plate 4610, and/or the sole plate 4640. Further, as disclosed later in detail, the face plate 4610 may be attached to, or integrally formed with the frame and/or front body portion 4602 and therefore the use of the term plate is not to imply a separate component, although it may be a separate component as disclosed in more detail later. Similarly, the sole plate 4640 may be attached to, or integrally formed with the frame, front body portion 4602, and/or rear ring portion, and therefore the use of the term plate is not to imply a separate component, although it may be as disclosed in more detail later.
[0551]While many of the disclosed embodiments relate to interfaces associated with a crown 4620 bonded to the frame and wrapping toward the face plate 4610, all of the disclosed relationships apply equally to one, or more, sole panels 4640 wrapping toward the face plate 4610, skirt panels wrapping toward the face plate 4610 at the heel and/or toe, and/or the rear ring portion 4630 wrapping toward the face plate 4610. For instance,
[0552]After at least two parts of the golf club head 100 are temporarily bonded together by the bonding tape 174, when in an uncured state, the at least two parts of the golf club head 100 are permanently bonded together, by converting the bonding tape 174 into a cured state, via the application of heat and pressure. Referring to
[0553]It is noted that when the vacuum bag 274 is used to apply a uniform pressure to the golf club head 100, the parts of the golf club head 100 being bonded together are in a fully-formed state (i.e., parts that have been formed into a permanent form or shape in preparation for final assembly). For example, for parts that are made of a fiber-reinforced polymeric material, the fiber-reinforced material has been previously shaped and cured into a final shape. Accordingly, the collapsed vacuum bag 274 is used solely to apply pressure to the bonding tape 174 and, with the parts of the golf club head 100 in a fully-formed state, does not shape or contribute to the formation of the individual parts.
[0554]As shown in
[0555]Referring back to
[0556]As shown in
[0557]When the vacuum bag 274 is collapsed against and applies pressure onto the golf club head 100, according to the pressure differential created by the vacuum device 269, the golf club head 100 is heated to at least the curing temperature of the bonding tape 174. As stated above, the concurrent application of the pressure and heat cures the bonding tape 174 between parts to permanently bond the parts together. Referring to
[0558]In alternative examples, rather than collapse the vacuum bag 274 by reducing the pressure within the vacuum bag 274, the pressure outside the vacuum bag 274 can be increased to create the necessary pressure differential to collapse the vacuum bag 274 onto the golf club head 100. For example, in some examples, the oven 276 is fluidically coupled to a vacuum device, which is selectively operable to increase the pressure within the enclosed cavity 227 when a vacuum bag 274, sealed to enclose the golf club head 100 within the vacuum bag 274, is positioned within the enclosed cavity 227. In this manner, the oven 276, acting as an autoclave, can concurrently apply heat and create the pressure differential necessary to cure the bonding tape 174.
[0559]Because of the unique characteristics of the bonding tape 174, compared to flowable adhesives, the bonding tape 174 can be cured, via pressure and heat, with greater control of the deformation of the bonding tape 174 during pressurization and heating of the bonding tape 174, particularly the VP bonding tape 174. Accordingly, the pressure necessary to cure the bonding tape 174 can be applied via the vacuum bag 274. In contrast, with conventional flowable adhesives, the application of pressure by a vacuum bag would cause the adhesives to flow out of the bonded joint and smear against the interior of the vacuum bag and the part. Such a result would create unnecessary delays, expense, and labor associated with removing excess adhesives from the part. Moreover, bleeding of the adhesives onto the vacuum bag would prevent the vacuum bag from being reusable for pressurizing other parts. Additional advantages associated with the use of the bonding tape 174 include a reduction in the complexity of the bonding process and the necessary training required to implement the bonding process, which translates into lower training costs.
[0560]In some examples, for golf club heads with multiple parts bonded together via multiple bonded joints, such as the golf club head 100, all the bonded joints are formed concurrently by concurrently pressurizing and heating the bonding tape 174 forming the bonded joints. In other words, the bonding tape 174 of all the bonded joints of the golf club head 100 can be cured (e.g., pressurized and heated) in a single pressurization and heating step using one vacuum bag. For example, the strike plate 143, the crown insert 108, and/or the sole insert 110 can be bonded to the body 102 by curing the bonding tape 174 between them at the same time. However, in other examples, at least one bonded joint of the golf club head 100 can be formed in a first pressurizing and heating step, using a first vacuum bag, and at least another bonded joint of the golf club head 100 can be formed subsequently in a second pressurizing and heating step, using the first vacuum bag or a second vacuum bag. For example, the crown insert 108 and the sole insert 110 can be bonded to the body, by curing the bonding tape 174 between them at a first time, and the strike plate 143 can be bonded to the body 102, by curing the bonding tape 174 between them at a second time, different (e.g., later or earlier) than the first time. By staggering the curing of the bonding tape 174 in this manner, inspection of one or more bonded joints, from an inside of the golf club head 100, can be performed before the inside of the golf club head 100 is enclosed. Further, in one embodiment the first pressurizing and heating step takes place with a first step attribute, while the second pressurizing and heating step takes place with a second step attribute, and the first step attribute is different than the second step attribute. Such step attributes may be temperature, pressure, and/or cure period.
[0561]Unlike conventional, flowable adhesives, the deformation of bonding tape 174 is more predictable and controllable, particularly with the later disclosed VP bonding tape 174. Accordingly, the size and positioning of the bonding tape 174, between the parts to be bonded, can be selected to accommodate the deformation of the bonding tape 174 and ensure the bonding tape 174 is properly distributed in the bonded joint without excessive bleeding (e.g., squeeze out) from the bonded joint during pressurization and heating. Referring to
[0562]In the example of
[0563]In an embodiment the offset OS, associated with the crown insert 108 and/or the sole insert 110, varies from a minimum offset OSmin to a maximum offset OSmax. A 10 mm heel offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 10 mm heelward; and similarly a 10 mm toe offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 10 mm toeward. A 15 mm heel offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 15 mm heelward; and similarly a 15 mm toe offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 15 mm toeward. A 20 mm heel offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 20 mm heelward; and similarly a 20 mm toe offset plane is a plane parallel to the face center vertical plane (FCVP) that has been offset 20 mm toeward. In one embodiment the location of the maximum offset OSmax is heelward of the 10 mm heel offset plane, or heelward of the 15 mm heel offset plane, or heelward of the 20 mm heel offset plane. In another embodiment the location of the maximum offset OSmax is toeward of the 10 mm toe offset plane, or toeward of the 15 mm toe offset plane, or toeward of the 20 mm toe offset plane. In another embodiment the location of the minimum offset OSmin is between the 20 mm toe offset plane and the 20 mm heel offset plane, while in another embodiment it is between the 15 mm toe offset plane and the 15 mm heel offset plane, and in yet a further embodiment it is between the 10 mm toe offset plane and the 10 mm heel offset plane.
[0564]Referring to
[0565]The gap filler 197 is made from any of various materials capable of keeping its shape (e.g., not flowing or bleeding) when the bonding tape 174 is heating and pressurized during curing of the bonding tape 174. Accordingly, the material of the gap filler 197 is different than that of the bonding tape 174. In some example, the material of the gap filler 197 is also different than that of the first part and the second part. In one example, the gap filler 197 is made of a flowable material that is curable to become non-flowable, and remain relatively non-flowable when the bonding tape 174 is cured. According to some examples, the gap filler 197 is made of an adhesive material, such as an epoxy-based structural adhesive.
[0566]According to some examples, the gap filler 197 is injected into the gap between the second part and the outer peripheries of the bonding tape 174 and the first part, after the first part is temporarily adhered to the second part via the bonding tape 174 and before the bonding tape 174 is cured. The gap filler 197 is then cured. The curing conditions of the gap filler 197 are different than those of the bonding tape 174, such that curing of the gap filler 197 does not cure the bonding tape 174. In some examples, the gap filler 197 is cured at approximately room temperature for a predetermined period, such as at least 2 hours. After the gap filler 197 is cured, the bonding tape 174 is then pressurized and heated, as presented above, to cure the bonding tape 174 and form the bonded joint between the first part and the second part. In one embodiment the gap filler 197 is attached to the bonding tape 174 such that it may be used to aid in locating the bonding tape 174 as well as crown insert 108. For instance, in
[0567]According to some examples, the golf club heads of the present disclosure are configured to be swung at a swing speed such that each collision with a golf ball imparts a force onto the strike face of the golf club heads in the range of 10,000 g to 20,000 g, where g is equal to the force per unit mass due to gravity. The bonding tape of the golf club heads, as described herein, is configured to withstand (e.g., maintain an adequate adhesive bond between bonded parts of the golf club head to maintain proper performance characteristics of the golf club head after) repeated impacts with a golf ball at swing speeds of at least 70 miles per hour (mph) (e.g., between, and inclusive of, 70 mph and 100 mph).
[0568]Now, with the basics of the bonding tape 174 disclosed, more detail is disclosed with respect to embodiments illustrated in
[0569]One skilled in the art will appreciate that modern golf club heads often incorporate aggressive shaping such as bulbous crowns, along with the associated peak crown height (PCH) magnitude and location, and volume minimizing sole features having weight projections, such as the previously disclosed inertia generating feature 177, to aid in achieving the desired mass properties of the golf club head. Accordingly, the joints between the various components of the golf club head, and thus the bonding tape 174, often do not exist in a convenient flat x-y plane (a horizontal plane containing the x-axis and γ-axis, with no change in the z direction). In fact, the bonding tape 174 orientation, twist, and curvature creates manufacturing challenges, which ultimately impact performance and durability of the golf club head if not overcome. The present golf club head, golf club, and methods of manufacture overcome the challenges to result in an easier to manufacture club head, and thus less costly, but also one presenting improved durability and performance.
[0570]For instance, an exterior perimeter (EP) and an interior perimeter (IP) of the bonding tape 174, as seen in
[0571]As seen in
[0572]For instance, with reference to
[0573]However, the roll angle may be determined for any location along the exterior perimeter (EP) of the bonding tape 174 by taking a first EP point at the location under consideration, offsetting the first EP point 3 mm along the exterior perimeter (EP) in a first direction to identify a second EP point, offsetting the first EP point 3 mm along the exterior perimeter (EP) in a second direction, opposite the first direction, to identify a third EP point, creating an EP line segment from the second EP point to the third EP point, extending a perpendicular EP line segment from a midpoint of the EP line segment and oriented perpendicular to the EP line segment, and rotating the perpendicular EP line segment about the EP line segment until the perpendicular EP line segment contacts the interior perimeter (IP) of the bonding tape 174 and thereby establishing an IP analysis point, and the midpoint of the EP line segment may be referred to as an EP analysis point. The orientation relative to the ground plane 181 of the perpendicular EP line segment contacting the IP analysis point establishes the roll angle of the bonding tape 174 at the first EP point; and a magnitude of the length of the perpendicular EP line segment at the first EP point establishes a bonding tape width at the first EP point. The midpoint of the EP line segment, aka the EP analysis point, has an EPAP z-axis coordinate 999, as seen in
[0574]Additionally, a pitch angle may be determined for any location along the exterior perimeter (EP) of the bonding tape 174 using the procedure identified with respect to the roll angle. The first step is identifying a first EP point at the location under consideration, offsetting the first EP point 3 mm along the exterior perimeter (EP) in a first direction to identify a second EP point, offsetting the first EP point 3 mm along the exterior perimeter (EP) in a second direction, opposite the first direction, to identify a third EP point, creating an EP line segment from the second EP point to the third EP point, extending a perpendicular EP line segment from a midpoint of the EP line segment, and oriented perpendicular to the EP line segment, and rotating the perpendicular EP line segment about the EP line segment until the perpendicular EP line segment contacts the interior perimeter (IP) of the bonding tape 174 and establishing an IP analysis point, which is also referred to as a first IP point. Then, offset the first IP point 3 mm along the interior perimeter (IP) in the first direction to identify a second IP point, offsetting the first IP point 3 mm along the interior perimeter (IP) in the second direction, opposite the first direction, to identify a third IP point, creating an IP line segment from the second IP point to the third IP point. The angle of the EP line segment from the ground plane is an EP line segment pitch, and the angle of the IP line segment from the ground plane is an IP line segment pitch. Then, the average of the EP line segment pitch and the IP line segment pitch is the pitch angle of the bonding tape 174 at the first EP point. The first direction is the direction of travel of the hypothetical vehicle previously disclosed, the EP line segment pitch is positive if the second EP point is at a higher elevation than the third EP point, the EP line segment pitch is negative if the third EP point is at a higher elevation than the second EP point, the IP line segment pitch is positive if the second IP point is at a higher elevation than the third IP point, the IP line segment pitch is negative if the third IP point is at a higher elevation than the second IP point. The length of the perpendicular EP line segment from the exterior perimeter (EP) to the interior perimeter (IP) defines a bonding tape width WT at any point.
[0575]In the example of
[0576]The roll angle and the pitch angle of the crown-insert strip 178 of the bonding tape 174 are easy to comprehend with respect to the embodiment of
[0577]A bonding tape roll angle inflection of the crown-insert strip 178 of the bonding tape 174 is the number of times that the sign of the roll angle changes while traversing the length of the crown-insert strip 178. In one embodiment the bonding tape roll angle inflection of the crown-insert strip 178 is no more than 4, while in additional embodiments it is no more than 3 or 2.
[0578]In one embodiment the crown insert 108 curves downward adjacent the face, as disclosed in U.S. Ser. No. 19/318,710 filed on Sep. 4, 2025, and so does the crown-insert strip 178 of the bonding tape 174, thus at such a location the EPAP z-axis coordinate is less than the IPAP z-axis coordinate the roll angle is negative. Thus, in one embodiment a portion of the exterior perimeter (EP) of the bonding tape 174, which may be the exterior perimeter (EP) of the crown-insert strip 178 of the bonding tape 174, is located forward of the shaft axis vertical plane (SAVP) and has a negative roll angle, which in further embodiments is true throughout a portion of the exterior perimeter (EP) having a length of at least 50%, 65%, 80%, 95%, or 105% of the face width Wss. In one embodiment at least 50% of the bonding tape 174, which may be the exterior perimeter (EP) of the crown-insert strip 178 of the bonding tape 174, located forward of the center of gravity 50 has a negative roll angle, while in further embodiment the percentage is increased to at least 60%, 70%, 80%, 90%, or 100%. In another embodiment at least 50% of the bonding tape 174, which may be the exterior perimeter (EP) of the crown-insert strip 178 of the bonding tape 174, located rearward of the center of gravity 50 has a negative roll angle, while in further embodiment the percentage is increased to at least 60%, 70%, 80%, 90%, or 100%.
[0579]As seen in
[0580]In one embodiment a first portion of the sole-insert strip 180 located forward of a vertical plane containing the CG x-axis 90, has a pitch angle of at least 60 degrees, and a second portion of the sole-insert strip 180 located forward of the vertical plane containing the CG x-axis 90 has a pitch angle of less than −60 degrees. In another embodiment the first portion of the sole-insert strip 180 located forward of the vertical plane containing the CG x-axis 90 has a pitch angle of at least 70 or 80 degrees, and the second portion of the sole-insert strip 180 located forward of the vertical plane containing the CG x-axis 90 has a pitch angle of less than −70 or −80 degrees.
[0581]In another embodiment a first portion of the sole-insert strip 180 located rearward of the vertical plane containing the CG x-axis 90 has a pitch angle of at least 60 degrees, and a second portion of the sole-insert strip 180 located rearward of the vertical plane containing the CG x-axis 90 has a pitch angle of less than −60 degrees. In another embodiment the first portion of the sole-insert strip 180 located rearward of the vertical plane containing the CG x-axis 90 has a pitch angle of at least 70 or 80 degrees, and the second portion of the sole-insert strip 180 located rearward of the vertical plane containing the CG x-axis 90 has a pitch angle of less than −70 or −80 degrees.
[0582]In one embodiment a first portion of the sole-insert strip 180, located toeward of the face center vertical plane (FCVP), is located above a horizontal plane containing the CG y-axis, as seen in
[0583]The EPAP z-axis coordinate 999, as seen in
[0584]One skilled the art will appreciate the unique impact load and stress distribution, and associated envelope deformation, associated with a multi-component golf club head such as that illustrated in
[0585]Further embodiments consider only the portion of the golf club head behind the shaft axis vertical plane (SAVP) to eliminate consideration of whether the face is integrally formed or a separate strike face 145 attached via welding, bonding, or via bonding tape 174. In one such embodiment at least 35%, 45%, 55%, or 65% of a post-SAVP external surface area of the golf club head is created by attached components joined to different components by the bonding tape 174. The post-SAVP external surface area is the exposed external surface area of the golf club head that is located rearward of the SAVP. The attached components may include the crown insert 108, the sole insert 110, the ring 106, and/or aft-body component 5000.
[0586]In one embodiment the cup 104 and ring 106 will be considered together as a body 102, whether the cup 104 and ring 106 are a single component or multiple components joined together. In this embodiment the attached components are the crown insert 108 and the sole insert 110; and the each attached component has a post-SAVP external surface area, meaning the crown insert 108 has a post-SAVP crown insert external surface area and the sole insert 110 has a post-SAVP sole insert external surface area. In this embodiment a total post-SA VP attached external surface area is a sum of the post-SAVP crown insert external surface area and the post-SAVP sole insert external surface area. In this embodiment the total post-SAVP attached external surface area is at least 35%, 45%, 55%, or 65% of a post-SAVP external surface area of the golf club head. In a further embodiment the total post-SA VP attached external surface area is less than 99%, 95%, 90%, or 85% of the post-SAVP external surface area of the golf club head.
[0587]In one embodiment the cup 104 and ring 106 will again be considered together as a body 102, whether the cup 104 and ring 106 are a single component or multiple components joined together. In this embodiment the attached component is the crown insert 108 or the sole insert 110; and the attached component has a post-SAVP external surface area, meaning the crown insert 108 has a post-SAVP crown insert external surface area and the sole insert 110 has a post-SAVP sole insert external surface area. In this embodiment the post-SAVP crown insert external surface area or the post-SAVP sole insert external surface area is at least 16%, 20%, 24%, or 28% of a post-SAVP external surface area of the golf club head. In a further embodiment the post-SAVP crown insert external surface area or the post-SAVP sole insert external surface area is less than 75%, 70%, 65%, or 60% of the post-SAVP external surface area of the golf club head.
[0588]In another embodiment the ring 106 will be considered as one of the attached components. Thus, in this embodiment the attached components are the ring, the crown insert 108, and the sole insert 110; and the each attached component has a post-SA VP external surface area, meaning the ring 106 has a post-SAVP ring external surface area, the crown insert 108 has a post-SA VP crown insert external surface area, and the sole insert 110 has a post-SAVP sole insert external surface area. In this embodiment a total post-SA VP attached external surface area is a sum of the post-SAVP ringsert external surface area, the post-SA VP crown insert external surface area, and the post-SAVP sole insert external surface area. In this embodiment the total post-SAVP attached external surface area is at least 35%, 45%, 55%, or 65% of a post-SAVP external surface area of the golf club head. In a further embodiment the total post-SAVP attached external surface area is less than 99%, 95%, 90%, or 85% of the post-SAVP external surface area of the golf club head. In a further embodiment the aft-body component 5000 is the attached component.
[0589]In one embodiment a second portion of the sole-insert strip 180, located heelward of the face center vertical plane (FCVP), is located above the horizontal plane containing the CG y-axis 95. The rear elevation view of
[0590]Further, consistent with the default procedure but stated another way, in this sole-insert strip example the roll angle is positive when the left wheels would have smaller z-axis coordinates than the right wheels, while traversing the sole-insert strip 180 in a clockwise direction from the hosel area from the forward heel region to the toe region, rearward from the forward toe region to the rearward toe region, from the rearward toe region to the rearward heel region, the forward from the rearward heel region to the forward heel region near the hosel and closing the loop, however as previously noted the bonding tape 174 need not create a continuous loop, although it does in some embodiments. Thus, continuing with this example, the roll angle is negative when left wheels would have larger (higher) z-axis coordinates than the right wheels. Again, the z-axis coordinates discussed are at the contact point between the hypothetical wheels and the sole-insert strip 180, for this example, and thus are also the z-axis coordinates for the contact point between the sole-insert strip 180 and the interior surface 110A of the sole insert 110.
[0591]The same procedure and rationale is applied to the crown-insert strip 178 of the bonding tape 174, again with the hypothetical vehicle traveling on the surface of the crown-insert strip 178 that faces the external environment in the same clockwise route. In the embodiment of
[0592]The infinity crown embodiment of U.S. Ser. No. 19/318,710 filed on Sep. 4, 2025, is a case where the roll angle would be significantly more negative than the roll angle of
[0593]Thus, the EP-IP Z-coordinate differential is positive when the exterior perimeter Z-coordinate 999, or EPAP z-axis coordinate, is less than the interior perimeter Z-coordinate 998, or IPAP z-axis coordinate, meaning when the roll angle is negative. In one embodiment an absolute value of the EP-IP Z-coordinate differential is at least X1 mm through a length of at least Y1 mm, where the Y1 length is measured along the external perimeter (EP) of the bonding tape 174. In one embodiment the value of X1 is 2, while in further embodiments it is 3, 4, or 5. In another embodiment the value of Y1 is 15, while in further embodiments it is 20, 25, or 30. In one embodiment an absolute value of the EP-IP Z-coordinate differential is no more than X2 mm, and in one embodiment X2 is 20, while in further embodiments it is 18, 16, 14, 12, or 10. In another embodiment the length is no more than Y2 mm, where Y2 length is measured along the external perimeter (EP) of the bonding tape 174. In one embodiment the value of Y2 is 1000, and is 800, 600, or 400 in additional embodiments.
[0594]In another embodiment an EP-IP Z-coordinate differential is at least X1 mm through a length of at least Y1 mm, where the Y1 length is measured along the external perimeter (EP) of the bonding tape 174. In one embodiment the value of X1 is 2, while in further embodiments it is 3, 4, or 5. In another embodiment the value of Y1 is 15, while in further embodiments it is 20, 25, or 30. In one embodiment the EP-IP Z-coordinate differential is no more than X2 mm, and in one embodiment X2 is 20, while in further embodiments it is 18, 16, 14, 12, or 10.
[0595]In another embodiment an EP-IP Z-coordinate differential is no more than X1 mm through a length of at least Y1 mm, where the Y1 length is measured along the external perimeter (EP) of the bonding tape 174. In one embodiment the value of X1 is −2, while in further embodiments it is −3, −4, or −5. In another embodiment the value of Y1 is 15, while in further embodiments it is 20, 25, or 30. In one embodiment the EP-IP Z-coordinate differential is at least X2 mm, and in one embodiment X2 is −20, while in further embodiments it is −18, −16, −14, −12, or −10.
[0596]The Y1 length may be a sum of individual segments meeting the disclosed X1 magnitude, however in one embodiment the Y1 length is a continuous length occurring on a single piece of bonding tape 174, which may be the crown-insert strip 178, the sole-insert strip 180, and the bonding tape 174 in general whether specifically associated with a sole insert 110, a crown insert 108, a strike plate 143, or an aft-body component 5000, as seen in
[0597]Now referring to
[0598]Just as the embodiment of
[0599]Further, as previously disclosed, an aft-body component embodiment may incorporate one or more aft-body components 5000 joined to the body portion 4602 to create the golf club head, as seen in
[0600]As easily appreciated with reference to
[0601]One embodiment includes a crown-insert strip 178 that has a roll angle that varies by at least 10 degrees around the perimeter of the crown-insert strip 178, while in further embodiments the roll angle varies by at least 15, 20, 25, 30, or 35 degrees. In another series of embodiments the roll angle of the crown-insert strip 178 varies by no more than 180 degrees, and in further embodiments no more than 165, 150, 135, or 120 degrees. In one embodiment the roll angle of the crown-insert strip 178 is negative throughout at least 60% of the perimeter, while in further embodiments it is negative throughout at least 70%, 80%, 90%, or 100%. However, in one embodiment the roll angle of the crown-insert strip 178 is positive at some point along the perimeter. The roll angle of the crown-insert strip 178 is negative throughout the forward portion 112, in one embodiment. In another embodiment the crown-insert strip 178 is present both at an elevation above the elevations of the center of gravity CG of the golf club head, as well as at an elevation below the elevations of center of gravity CG; in a further embodiment this occurs at a location in the rearward portion 118.
[0602]Now referring generally to the non-face bonding tape 174, and not limiting it to a crown-insert strip 178 or a sole-insert strip 180, the non-face bonding tape 174 has a roll angle that varies by at least 35 degrees at any two points of the non-face bonding tape 174, while in further embodiments the roll angle varies by at least 45, 55, 65, 75, or 85 degrees. In another series of embodiments the roll angle of the non-face bonding tape 174 varies by no more than 180 degrees, and in further embodiments no more than 165, 150, 135, or 120 degrees. The roll angle of the non-face bonding tape 174 is positive at some locations and negative at other locations.
[0603]Any of the disclosed roll angle variation options may be on separate sections of any of the disclosed bonding tape strips attaching one of the disclosed components, however in one embodiment the roll angle variations occur on a single continuous section, even though the particular strip may be composed of multiple sections.
[0604]At this point it should be clear that the disclosed multi-piece golf club head adds complexities in the manufacturing process and presents challenges due to the wide variety of joints, as well as the location and orientation of those joints, and the bonding tape 174 present in the joints. Nonetheless, the present embodiments overcome the complexities to produce a high performance golf club head having good durability and reduces assembly costs compared to a similar club head utilizing a liquid adhesive. This is in part by controlling the deformation of the bonding tape 174 during the pressurization and heating of the bonding tape 174 during the curing stage, which of course impacts the performance, sound, durability, and long-term CT creep of the golf club head, as does the orientation of the golf club head during the curing stage, and more specifically the orientation of the bonding tape 174 during the manufacturing process. Therefore, given the complex joint geometry and necessary changes in location and orientation to achieve the desired construction, mass properties, performance, sound, and durability, utilization of bonding tape 174, and controlling the deformation, positively impacts these goals.
[0605]The bonding tape 174 has a tape thickness, and a bonding tape width WT. One skilled in the art will appreciate an initial joint fit-up of a configuration involving the sole insert 108 and the sole-insert strip 180 of
[0606]In one such embodiment a roll angle differential is used. When evaluating any of the strips of bonding tape 174 there will be a maximum roll angle and a minimum roll angle; and a roll angle differential is equal to the maximum roll angle minus the minimum roll angle. For example if the maximum roll angle is 80 degrees and the minimum roll angle is −15 degrees, the roll angle differential is 95 degrees; thereby indicating that the strip of bonding tape 174 under consideration has significant twisting as it is traversed, and will require significant control of the deformation of the bonding tape 174 during the final curing process. Here the absolute value of the roll angle differential will be used for the reasons previously discussed.
[0607]The previously disclosed EP-IP Z-coordinate differential has a maximum absolute value EP-IP Z-coordinate differential and a minimum absolute value EP-IP Z-coordinate differential as the length of a strip of the bonding tape 174 is traversed, whether associated with the crown insert, referred to as the crown-insert strip, the sole insert, referred to as the sole-insert strip 180, a strike plate 143, referred to as a strike plate strip, or an aft-body component 5000, referred to as an aft-body strip. The absolute value of the EP-IP Z-coordinate differential is used in this embodiment so that differentials are considered whether the roll angle is positive or negative. In one embodiment the maximum post-cure region width 2186 is greater than 7.5% of the maximum absolute value EP-IP Z-coordinate differential, and in additional embodiments is at least 10%, 12.5%, 15%, or 17.5%. These relationships provide the needed control of the deformation of the bonding tape 174 based upon extreme variations in the orientation of the joints and bonding tape 174.
[0608]While the post-cure bonding tape width WT may be constant throughout the length of the exterior perimeter (EP), in one embodiment it varies from a maximum post-cure bonding tape width WT to a minimum post-cure bonding tape width WT, where the maximum post-cure bonding tape width WT is at least 10% greater than the minimum post-cure bonding tape width WT. In further embodiments the maximum post-cure bonding tape width WT is at least 20%, 30%, 40%, 50%, 60%, 70%, or 80% greater than the minimum post-cure bonding tape width WT. Another embodiment caps the relationship such that the maximum post-cure bonding tape width WT is no more than 350%, 325%, 300%, 275%, 250%, or 225% of the minimum post-cure bonding tape width WT. The minimum post-cure bonding tape width WT is at least 200% of the post-cure tape thickness in one embodiment, and the percentage increases in additional embodiments to 250%, 300%, or 350%. The maximum post-cure bonding tape width WT is at least 400% of the post-cure tape thickness in one embodiment, and the percentage increases in additional embodiments to 500%, 600%, or 700%. In another embodiment the maximum post-cure bonding tape width WT and/or the minimum post-cure bonding tape width WT is no more than 100 times the post-cure tape thickness, which is reduced in additional embodiments to 90, 80, 70, or 60. The post-cure tape thickness is no more than 0.4 mm in one embodiment, and in additional embodiments no more than 0.35 mm, 0.30 mm, or 0.25 mm. In another series of embodiments the post-cure tape thickness 2178 is at least 0.10 mm, 0.15 mm, or 0.20 mm. These post-cure bonding tape width WT relationships and embodiments apply to the post-cure bonding tape 174 associated with a strike plate 143, referred to as a strike plate strip, the bonding tape 174 associated with an aft-body component 5000, referred to as an aft-body strip, the crown insert, referred to as the crown-insert strip, and/or the sole insert, referred to as the sole-insert strip 180.
[0609]While the pre-cure bonding tape width WT may be constant throughout the length of the exterior perimeter (EP), in one embodiment it varies from a maximum pre-cure bonding tape width WT to a minimum pre-cure bonding tape width WT, where the maximum pre-cure bonding tape width WT is at least 10% greater than the minimum pre-cure bonding tape width WT. In further embodiments the maximum pre-cure bonding tape width WT is at least 20%, 30%, 40%, 50%, 60%, 70%, or 80% greater than the minimum pre-cure bonding tape width WT. Another embodiment caps the relationship such that the maximum pre-cure bonding tape width WT is no more than 350%, 325%, 300%, 275%, 250%, or 225% of the minimum pre-cure bonding tape width WT. The minimum pre-cure bonding tape width WT is at least 200% of the pre-cure tape thickness in one embodiment, and the percentage increases in additional embodiments to 250%, 300%, or 350%. The maximum pre-cure bonding tape width WT is at least 400% of the pre-cure tape thickness in one embodiment, and the percentage increases in additional embodiments to 500%, 600%, or 700%. In another embodiment the maximum pre-cure bonding tape width WT and/or the minimum pre-cure bonding tape width WT is no more than 100 times the pre-cure tape thickness, which is reduced in additional embodiments to 90, 80, 70, or 60. The pre-cure tape thickness 2178 is no more than 0.9 mm in one embodiment, and in additional embodiments no more than 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.45 mm, 0.40 mm, or 0.35 mm. In another series of embodiments the pre-cure tape thickness 2178 is at least 0.15 mm, 0.20 mm, or 0.25 mm. The loads associated with strike face strip are unique and the pre-cure tape thickness is no more than 1.0 mm in one embodiment, and in additional embodiments no more than 0.90 mm. 0.80 mm, 0.75 mm, 0.70 mm, or 0.65 mm. In another series of embodiments the pre-cure tape thickness 2178 associated with strike face strip is at least 0.25 mm, 0.35 mm, or 0.45 mm. In one embodiment the pre-cure region width is ±90% of the pre-cure tape thickness, and is ±80%, ±70%, ±60%, or ±50% in additional embodiments. These pre-cure bonding tape width WT relationships and embodiments apply to the pre-cure bonding tape 174 associated with a strike plate 143, referred to as a strike plate strip, the bonding tape 174 associated with an aft-body component 5000, referred to as an aft-body strip, the crown insert, referred to as the crown-insert strip, and/or the sole insert, referred to as the sole-insert strip 180.
[0610]Differences in the materials being joined may drive the variation of the pre-cure bonding tape width WT. For instance, the crown-insert strip 178 may have a cup interface max pre-cure bonding tape width WT at locations where the crown-insert strip 178 is joining the cup 104 with the crown insert 108, and the crown-insert strip 178 may have a ring interface max pre-cure bonding tape width WT at locations where the crown-insert strip 178 is joining the ring 106 with the crown insert 108. In embodiments where the cup material is different than the ring material, the cup interface max pre-cure bonding tape width WT is different than the ring interface max pre-cure bonding tape width WT. The different materials of the cup 104 and the ring 106 have different characteristics such as adhesion, surface energy, and/or wettability, and therefore the cup interface max pre-cure bonding tape width WT is different than the ring interface max pre-cure bonding tape width WT. Adhesive bonding depends on the surface energy of the substrate and the adhesive's ability to wet that surface. Materials like metals or glass have high surface energy, allowing good wetting and strong adhesive forces even with narrow tape. In contrast, low-surface-energy materials such as polyethylene, polypropylene, or PTFE resist wetting, leading to weaker adhesion. To compensate, using a wider tape increases the total contact area, which enhances the overall adhesive bond strength even when the adhesive-to-surface attraction is limited. Because low-surface-energy materials provide poor wetting, the adhesive forms weaker intermolecular bonds. A wider tape increases the effective contact area, improving overall adhesion despite the substrate's poor surface energy.
[0611]In some embodiments, adhesive bonding between a metallic frame (cup 104 or ring 106) and a non-metallic panel (crown insert 108 or sole insert 110) depends upon the surface energy of each substrate and the ability of the adhesive to wet those surfaces. High-energy materials, such as aluminum alloy, generally permit uniform wetting and promote strong intermolecular attraction, thereby achieving adequate bond strength even when a relatively narrow bonding tape is employed. Titanium alloys, exhibit a lower surface energy due to the composition of their native oxide layer, and may therefore require enhanced surface preparation and/or an increased bond area to achieve comparable adhesion. Non-metallic materials, such as polymeric or fiber-reinforced composite inserts, typically possess substantially lower surface energies, which inhibit adhesive wetting and limit the formation of strong adhesive-to-substrate bonds. In such cases, the overall joint strength is often governed by the lowest-energy surface within the assembly. To compensate for this limitation, the width or total area of the bonding tape may be increased so that the applied load is distributed over a larger contact surface, thereby improving the effective adhesion even where local bonding forces are weak. For example, an aluminum-to-insert joint may achieve sufficient mechanical strength with an aluminum interface max pre-cure bonding tape width WT, whereas a titanium-to-insert joint may require a titanium interface max pre-cure bonding tape width WT of 1.2-2.5 times the bonding area to provide equivalent performance, and a polymer-to-polymer interface max pre-cure bonding tape width WT may require between two and five times the bonding area to achieve comparable structural strength.
[0612]Crown insert 108 has a crown insert mass, and the crown-insert strip 178 has a crown-strip mass of less than 7.5% of the crown insert mass, while in further embodiments the percentage is reduced to 6.5%, 5.5%, or 4.5%. The crown-strip mass is at least 2% of the crown insert mass in an embodiment, and at least 2.5%, 3%, or 3.5% in additional embodiments. Sole insert 110 has a sole insert mass, and the sole-insert strip 180 has a sole-strip mass of less than 7.5% of the sole insert mass, while in further embodiments the percentage is reduced to 6.5%, 5.5%, or 4.5%. The sole-strip mass is at least 2% of the sole insert mass in an embodiment, and at least 2.5%, 3%, or 3.5% in additional embodiments.
[0613]In one embodiment the bonding tape 174 has a bonding tape density of 1.65 g/cc or less, and in further embodiments it is reduced to 1.55, 1.45, 1.35, or 1.25 g/cc. This is significantly less dense than multi-part, toughened epoxy structural adhesives. Another series of embodiments establishes a floor for the bonding tape density of at least 0.85, 0.95, 1.05, or 1.15 g/cc.
[0614]In one embodiment the crown insert mass and/or the sole insert mass is less than 20 grams, while in further embodiments is less than 19, 18, 17, 16, 15, or 14 grams. In one embodiment the sole insert mass and/or the sole insert mass is less than 20 grams, while in further embodiments is less than 19, 18, 17, 16, 15, or 14 grams.
[0615]The bonding tape 174 is made of an adhesive material. According to some examples, the adhesive material of the bonding tape 174 is a thermo-activated adhesive. In other words, the adhesion strength of the bonding tape 174 is maximized after the bonding tape 174 is cured (i.e., heated to a predetermined temperature for a predetermined period of time). The predetermined temperature is associated with a curing temperature and curing period of the adhesive material. In some examples, the bonding tape 174 is made of a thermosetting material, such as a thermosetting acrylic material. According to certain examples, the curing temperature (and associated curing period) of the bonding tape 174 is between, and inclusive of, 90° C. and 120° C., or between, and inclusive of, 100° C. and 115° C., such as 110° C. In some other examples, the curing temperature of the bonding tape 174 is at least 90° C. for at least 20, 40, 60, 80, or 100 minutes, while in another embodiment it is at least 100° C. for at least 30, 50, 70, 90, or 110 minutes, and in a further embodiment is at least 110° C. for at least 35 minutes. In another embodiment the curing temperature is no more than 150° C. and the curing period is no more than 150 minutes. During curing, the thermosetting material undergoes an irreversible chemical change by producing cross-linked polymer chains. Moreover, after curing, a temperature necessary to reflow the bonding tape 174 is at least 160° C., at least 180° C., at least 200° C., or at least 220° C.
[0616]After the bonding tape 174 is cured, the shear strength of the bonding tape 174, which is a measure of the ability of the bonding tape 174 to resist separation of parts bonded by the bonding tape 174, is at least 10 MPa, at least 14 MPa, at least 18 MPa, at least 22 MPa, at least 26 MPa, at least 30 MPa, or at least 35 MPa. To promote adhesion between the bonding tape 174 and parts forming the bond, pressure should be applied to the parts such that, when the bonding tape 174 is being cured, opposing compression forces from the parts are acting on the bonding tape 174. In other words, while the bonding tape 174 is being cured, the parts forming the bond should be compressed against the bonding tape 174. Ideally, the pressure applied to the parts should be uniform to promote a uniform adhesion of the bonding tape 174 along the parts, and thus a uniform adhesion strength along the bond. However, uniformly compressing one part toward another part, particularly when the parts are contoured or have complex shapes, can be difficult. An embodiment of the present method includes the step of uniformly compressing the bonded parts, while the bonding tape 174 between the bonded parts is being cured, in an accurate, reliable, clean, and efficient manner. The golf club head is subjected to an external pressure sufficient to press the bonding tape against the mating surface of the club head, thereby promoting uniform adhesion across the interface. In some examples, the applied pressure is sufficient to conform the bonding tape to the mating surfaces of the golf club head, and may correspond to a pressure level within a range of about 30 cmHg to 70 cmHg, about 40 cmHg to 60 cmHg, or about 50 cmHg. The pressure may be generated by any suitable device or system configured to exert substantially uniform force on the golf club head, such as a vacuum system, pneumatic system, or mechanical press. A goal of the disclosed method is to cure all strips of bonding tape 174 at the same time.
[0617]As previously noted, the quantity, size, and location of the bonding tape 174, as well as the number of components joined using the bonding tape 174, as well as their rigidity, all impact the performance, durability, and long-term CT creep of the golf club head. Numerous relationships have been disclosed that produced desirable performance, durability, and long-term CT creep of the golf club head. The bonding tape 174 offers great opportunities to improve manufacturing efficiencies.
[0618]A single-side bonding tape area is the surface area associated with a single side of the bonding tape that attaches to a single component of the golf club head. For example, in
[0619]A face center horizontal plane (FCHP) is a horizontal plane extending through center face 205 and perpendicular to the face center vertical plane (FCVP). In one embodiment considering the total single-side bonding tape area for all components of the golf club head, at least 52.5% the total single-side bonding tape area is located above the FCHP, while in further embodiments the percentage is increased to 55%, 57.5%, 60%, 62.5%, or 65%. In another series of embodiments no more than 85% the total single-side bonding tape area is located above the FCHP, and in additional embodiments the percentage is reduced to 80%, 75%, or 70%.
[0620]As previously noted, the face center vertical plane (FCVP) can be used to delineate the toe portion 114 from the heel portion 116. Further, a vertical mid-depth plane, abbreviated VMDP, is a vertical plane parallel to the SAVP and passing through a midpoint of the club head depths Dch can be used to delineate a forward portion 112 from a rearward portion 118. An origin x-axis vertical plane, abbreviated OXAVP, is a vertical plane parallel to the SAVP and containing the origin x-axis. In one embodiment considering the total single-side bonding tape area for all components of the golf club head, at least 52.5% the total single-side bonding tape area is located in the heel portion, while in further embodiments the percentage is increased to 55%, 57.5%, 60%, 62.5%, or 65%. In another embodiment no more than 85% the total single-side bonding tape area is located in the heel portion, while in further embodiments the percentage is reduced to 80%, 75%, 70%, or 65%.
Forged Aluminum Alloy Components
[0621]U.S. patent application Ser. No. 18/957,619, filed Nov. 22, 2024, is incorporated by reference herein. Additionally, in addition to the various features described herein, any of the golf club heads, and/or methods of creating the golf club heads or components thereof, disclosed herein may also incorporate additional features, and/or the methods may be used to create the golf club heads or components thereof, which can include any of the those disclosed in U.S. patent application Ser. No. 18/807,487, filed Aug. 16, 2024, 18/102,001, filed Jan. 26, 2023, 18/077,794, filed Dec. 8, 2022, 17/963,491, filed Oct. 11, 2022, 18/397,351, filed Dec. 27, 2023, 18/898,332, filed Sep. 26, 2024, 18/540,571, filed Dec. 14, 2023, 18/662,372, filed May 13, 2024, 18/468,273, filed Sep. 15, 2023, 18/743,971, filed Jun. 14, 2024, 18/657,023, filed May 7, 2024, 18/595,140, filed Mar. 4, 2024, 18/355,384, filed Jul. 19, 2023, 18/791,808, filed Aug. 1, 2024, 18/764,001, filed Jul. 3, 2024, 18/939,302, filed Nov. 6, 2024, 17/164,033, filed Feb. 1, 2021, 18/830,380, filed Sep. 10, 2024, 18/892,181, filed Sep. 20, 2024, 17/100,273, filed Nov. 20, 2020, 18/197,594, filed May 15, 2023, 18/604,909, filed Mar. 14, 2024, 18/212,861, filed Jun. 22, 2023, 18/436,878, filed Feb. 8, 2024, 18/534,985, filed Dec. 11, 2023, 17/974,279, filed Oct. 26, 2022, 17/504,327, filed Oct. 18, 2021, 18/822,842, filed Sep. 3, 2024, 18/761,819, filed Jul. 2, 2024, 17/010,395, filed Sep. 2, 2020, 17/878,661, filed Aug. 1, 2022, 18/478,155, filed Sep. 29, 2023, 18/436,841, filed Feb. 8, 2024, 18/504,887, filed Nov. 8, 2023, 17/515,112, filed Oct. 29, 2021, 18/913,535, filed Oct. 11, 2024, 18/124,325, filed Mar. 21, 2023, 17/570,613, filed Jan. 7, 2022, 18/612,969, filed Mar. 21, 2024, 18/468,304, filed Sep. 15, 2023, 18/376,179, filed Oct. 3, 2023, 18/531,430, filed Dec. 6, 2023, 2024-154117, filed Sep. 6, 2024, JP2020100117A, filed Jun. 9, 2020, 17/107,447, filed Nov. 30, 2020, 18/815,207, filed Aug. 26, 2024, 18/792,777, filed Aug. 2, 2024, 18/807,320, filed Aug. 16, 2024, 18/784,461, filed Jul. 25, 2024, 17/526,855, filed Nov. 15, 2021, 18/379,512, filed Oct. 12, 2023, 17/105,109, filed Nov. 25, 2020, 18/110,636, filed Feb. 16, 2023, 18/502,408, filed Nov. 6, 2023, 18/211,751, filed Jun. 20, 2023, 18/135,502, filed Apr. 17, 2023, 18/135,463, filed Apr. 17, 2023, 18/808,923, filed Aug. 19, 2024, 18/825,926, filed Sep. 5, 2024, 18/370,314, filed Sep. 19, 2023, 18/332,099, filed Jun. 9, 2023, 17/975,150, filed Oct. 27, 2022, 18/653,254, filed May 2, 2024, 18/515,737, filed Nov. 21, 2023, 18/936,651, filed Nov. 4, 2024, 18/889,078, filed Sep. 18, 2024, Ser. No. 18/943,215, filed Nov. 11, 2024, Ser. No. 18/911,709, filed Oct. 10, 2024, Ser. No. 18/888,500, filed Sep. 18, 2024, Ser. No. 18/827,140, filed Sep. 6, 2024, Ser. No. 18/817,539, filed Aug. 28, 2024, Ser. No. 18/814,646, filed Aug. 26, 2024, Ser. No. 18/808,224, filed Aug. 19, 2024, Ser. No. 18/800,504, filed Aug. 12, 2024, Ser. No. 18/796,753, filed Aug. 7, 2024, Ser. No. 18/777,649, filed Jul. 19, 2024, Ser. No. 18/736,758, filed Jun. 7, 2024, Ser. No. 18/736,646, filed Jun. 7, 2024, Ser. No. 18/647,379, filed Apr. 26, 2024, Ser. No. 18/544,301, filed Dec. 18, 2023, Ser. No. 18/534,512, filed Dec. 8, 2023, Ser. No. 18/519,327, filed Nov. 27, 2023, Ser. No. 18/518,013, filed Nov. 22, 2023, Ser. No. 18/444,811, filed Feb. 19, 2024, Ser. No. 18/414,128, filed Jan. 16, 2024, Ser. No. 18/406,312, filed Jan. 8, 2024, Ser. No. 18/375,888, filed Oct. 2, 2023, Ser. No. 18/226,294, filed Jul. 26, 2023, Ser. No. 18/207,276, filed Jun. 8, 2023, Ser. No. 18/082,735, filed Dec. 16, 2022, Ser. No. 18/082,271, filed Dec. 15, 2022, Ser. No. 17/734,185, filed May 2, 2022, Ser. No. 17/668,902, filed Feb. 10, 2022, and Ser. No. 17/068,355, filed Oct. 12, 2020, all of which are herein incorporated by reference in their entirety.
[0622]This section will first disclose the methods used to produce a trimmed final forged workpiece 22100, and the attributes of the trimmed final forged workpiece 22100, which is any of the front body portion embodiments, or any of the cup embodiments, disclosed in U.S. patent application Ser. No. 18/957,619, filed Nov. 22, 2024, and incorporated by reference herein, and will be generally referred to as a front body portion 4602 within this disclosure when a face insert is attached to the front body portion 4602 to cover an opening in the front body portion 4602. However, the disclosure equally applies to the cup embodiments, which are generally referred to as a cup face when the front body portion 4602 has a face portion that is integrally formed with at least one, two, three, or four of the following other aspects of a front body portion 4602, namely: a portion of a crown portion 119 and/or a crown opening 162, a portion of sole portion 117 and/or a sole opening 164, a portion of a toe portion 114, a portion of a heel portion 116, a toe-side joint 112A, a heel-side joint 112B, a front body portion ledge 4680, a sole component attachment ledge wall 4690, a crown recessed surface 4682, a forward crown-opening recessed ledge 168A, a hosel portion 4604, a lower opening 195, a slot 171, a threaded port 175, and/or a front body portion mass pad 186.
[0623]First, a transverse forging method will be disclosed with respect to
[0624]Use of the term “transverse” simply means that a forging force is applied to the initial workpiece 20000 in a direction other than a direction parallel to an origin y-axis of a golf club head, which is illustrated in
[0625]The axis illustrated in
[0626]While as noted above, generally the use of the term “transverse” simply means that the forging force is applied to the initial workpiece 20000 in a direction other than a direction parallel to an origin y-axis, and thus the forging force has a WP x-axis component and/or WP z-axis component. In one embodiment the forging force has a WP z-axis component, while in another embodiment the forging force has both a WP z-axis component and a WP y-axis component, and in yet another embodiment the forging force has a WP z-axis component, a WP y-axis component, and a WP x-axis component. Similarly, in another embodiment the forging force has a WP x-axis component, while in another embodiment the forging force has both a WP x-axis component and a WP y-axis component, and in yet another embodiment the forging force has a WP x-axis component, a WP y-axis component, and a WP z-axis component. In still another embodiment the WP z-axis forging force component is at least 60% of the forging force, while in further embodiments the percentage is increased to at least 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99%, or even 100%. In a further embodiment the WP x-axis forging force component is no more than 50% of the forging force, while in further embodiments the percentage is decreased to no more than 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 1%, or is 0%. Similarly, in a further embodiment the WP y-axis forging force component is no more than 50% of the forging force, while in further embodiments the percentage is decreased to no more than 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 1%, or is 0%.
[0627]In a simple embodiment the initial workpiece 20000 has a shape of a rectangular prism, also known as a rectangular cuboid, a cube, or a square prism, although none of the surfaces (WP top surface 20100, WP bottom surface 20200, WP forward surface 20300, WP rearward surface 20400, WP toe surface 20500, and/or WP heel surface 20600) need be planar. Nonetheless, in one embodiment at least one of the WP forward surface 20300 and the WP rearward surface 20400 of the initial workpiece 20000 is a substantially flat planar surface, while in another embodiment both the WP forward surface 20300 and the WP rearward surface 20400 of the initial workpiece 20000 are substantially flat planar surfaces. In another embodiment at least one of the substantially flat planar surfaces is substantially parallel with the orientation of a primary forging force component, which is simply the greatest forging force component of the WP x-axis component, the WP y-axis component, and the WP z-axis component. For instance, in a simple exemplary embodiment the WP z-axis forging force component is at least 60% of the forging force (or any of the previously disclosed percentages) and at least one of the substantially flat planar surfaces is substantially parallel with the WP z-axis forging force component, while in a further embodiment this is true for both the WP forward surface 20300 and the WP rearward surface 20400 of the initial workpiece 20000. In one embodiment the WP height 20020 is parallel to the primary forging force component, which is simply the greatest forging force component. For instance, in a simple exemplary embodiment the WP z-axis forging force component is at least 60% of the forging force (or any of the previously disclosed percentages) and WP height 20020 is substantially parallel with the WP z-axis forging force component.
[0628]The initial workpiece 20000 has a WP perimeter 20005 when viewed along the WP y-axis, as illustrated in
[0629]The initial workpiece 20000 has a WP bottom perimeter 20007 when viewed along the WP z-axis, as illustrated in
[0630]The initial workpiece 20000 has a WP toe perimeter 20008 when viewed along the WP x-axis, as illustrated in
[0631]Similarly, the initial workpiece 20000 has a WP heel perimeter 20009 when viewed along the WP x-axis, as illustrated in
[0632]The size and shape of the initial workpiece 20000 play a significant role in the efficiency of the manufacturing process and the quality of the final part, and this includes unique relationships among the WP height 20020, the WP depth 20030, and the WP width 20010, all illustrated in
[0633]In another embodiment the WP depth 20030 is no more than 50% of the WP height 20020; while in further embodiments the percentage is reduced to no more than 47.5%, 45%, 42.5%, 40%, or 37.5%. In another embodiment the WP depth 20030 is at least 20% of the WP height 20020; while in additional embodiments the percentage is increased to at least 22.5%, 25%, 27.5%, 30%, or 32.5%. Referring now to FIGS. 312 and 313 of U.S. patent application Ser. No. 18/957,619, filed Nov. 22, 2024, is incorporated by reference herein, a finished club head has a maximum club head height Hch defined as the maximum above ground z-axis coordinate of the outer surface of the crown. Similarly, a maximum club head width Wch can be defined as the distance between the maximum extents of the heel and toe portions of the body measured along an axis parallel to the x-axis when the club head is at normal address position, where per the USGA the heel measurement point is deemed to be 0.875 inches (22.23 mm) above the horizontal ground plane. A maximum club head depth Dch, or length, defined as the distance between the forwardmost and rearwardmost points on the surface of the body measured along an axis parallel to the y-axis when the club head is at normal address position. Generally, the height and width of the club head should be measured according to the USGA “Procedure for Measuring the Clubhead Size of Wood Clubs”, TPX3003, Rev. 2.1, 9 Apr. 2019. The heel portion of the club head is broadly defined as the portion of the club head from a vertical plane passing through the origin y-axis toward the hosel, while the toe portion is that portion of the on the opposite side of the vertical plane passing through the origin y-axis.
[0634]In one embodiment the WP width 20010 is at least 90% of the maximum club head width Wch; and in further embodiments the percentage is increased to at least 95%, 100%, 105%, 110%, or 115%. In another embodiment the WP width 20010 is no more than 165% of the maximum club head width Wch; and in further embodiments the percentage is reduced to no more than 155%, 145%, 135%, or 125%.
[0635]The WP depth 20030 may vary or may remain constant throughout the initial workpiece 20000, and in embodiments having a variable WP depth 20030, the WP depth 20030 referenced in this disclosure is a maximum WP depth 20030 present in the initial workpiece 20000.
[0636]Now it is necessary to disclose aspects of the finished golf club head in order to further disclose aspects of the present method and initial workpiece 20000. Thus, the forward portion 112 of the golf club head 100 may also be referred to as the front body portion and/or the cup, cup portion, and cup face. Each figure of U.S. patent application Ser. No. 18/957,619, filed Nov. 22, 2024, and incorporated by reference herein, is referred to herein by incrementing the figure number by 200. For example, FIG. 15 of U.S. patent application Ser. No. 18/957,619, now referred to as
[0637]While the terms heel ring-engagement surface 150B and toe ring-engagement surface 150A include the term “ring,” one skilled in the art will recognize that they exist whether or not the particular embodiment has a distinct and/or separate ring component; and may simply be referred to as a finished front body portion rearward toe extension 21800 and a finished front body portion rearward heel extension 21900, illustrated in
[0638]The finished front body portion rearward toe extension 21800 is located at a toe extension setback distance 21810 behind the leading edge 1170, as seen in
[0639]The toe of the golf club head is characterized by a toe curvature 3000, seen in
[0640]Referring again to
[0641]In one embodiment the initial workpiece 20000 has a WP volume of no more than 275 cc, and in additional embodiments no more than 260, 245, 230, 215, or 200 cc. In another embodiment the WP volume is at least 120 cc, which is increased in additional embodiments to 130, 140, 150, 160, 170, or 180 cc. Similarly, in one embodiment the initial workpiece 20000 has a WP mass of at least 300 grams, and in further embodiments at least 325, 350, 375, 400, 425, 450, or 475 grams. However, additional embodiments cap the WP mass to no more than 775 grams, and in further embodiments is no more than 725, 675, 625, or 575 grams.
[0642]However, in another embodiment, illustrated in
[0643]Such WP through opening 20050 embodiments significantly reduce the WP volume and WP mass of the initial workpiece 20000. For instance in one embodiment the initial workpiece 20000 has a WP volume of no more than 115 cc, and in additional embodiments no more than 105, 95, or 85 cc. In another embodiment the WP volume is at least 40 cc, which is increased in additional embodiments to 50, 60, 70, or 80 cc. Similarly, in one embodiment the initial workpiece 20000 has a WP mass of at least 135 grams, and in further embodiments at least 145, 155, 165, 175, 185, 195, or 205 grams. However, additional embodiments cap the WP mass to no more than 325 grams, and in further embodiments is no more than 300, 275, or 250 grams.
[0644]In one embodiment the initial workpiece 20000, and its variations and embodiments, comprises an extruded aluminum alloy, such as embodiments illustrated in FGS. 119A-131, or a billet of aluminum alloy, which may be formed by extrusion, continuous casting, and/or hot rolling, while further embodiments the initial workpiece 20000 may be formed by metal injection molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM. Metal additive manufacturing (metal AM) includes, but is not limited to, powder bed additive manufacturing, metal binder jetting manufacturing, sheet lamination manufacturing, direct energy deposition manufacturing, and bound powder extrusion. One such embodiment utilizes powder bed fusion (PBF) methods employing the use of either a laser or electron beam to melt and fuse the metal powder into a solid. This technique includes the following metal additive manufacturing methods: electron beam melting (EBM), direct metal laser sintering (DMLS), selective heat sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS). One such metal binder jetting manufacturing embodiment utilizes metal powders that are jetted onto a build platform to print objects using either a continuous or drop on demand (DOD) approach, followed by application of a liquid binder combine the powder layer by layer, building the desired object, followed by post-processing steps of sintering and/or infiltration to be strengthened. One such sheet lamination process includes the joining of sheets, or strips, of material together layer by layer through bonding, ultrasonic welding or ultrasonic additive manufacturing, or brazing to build an object. Sheet lamination methods are low-temperature processes and can bond different materials together. In a direct energy deposition manufacturing embodiment a focused energy source, such as a laser or electron beam, is directed at the building material to melt it while it is simultaneously being deposited layer by layer, and/or may incorporate use of a heated nozzle to deposit melted material onto the specified surface where it solidifies, which may include powder DED such as laser metal deposition (LMD) and/or laser engineering net shaping (LENS), as well as wire DED techniques such as electron beam additive manufacturing (EBAM).
[0645]In some embodiments the initial workpiece 20000 is formed of heat-treatable aluminum alloy, specifically one of: the 2xxx series aluminum alloy, namely an aluminum-copper alloy known for high strength, but lower corrosion resistance; the 4xxx series aluminum alloys, primarily aluminum-silicon (Al—Si) alloys known for excellent wear resistance, corrosion resistance, and thermal properties, as well as their ability to be used in applications requiring good machinability and high-temperature stability; the 6xxx series aluminum alloy, namely aluminum-magnesium-silicon alloys known for good strength, corrosion resistance, and weldability; or the 7xxx series aluminum alloy, namely an aluminum-zinc alloy with exceptional strength. In one embodiment the 2xxx series aluminum alloy is one of the following 2xxx aluminum alloys: 2024, 2124, 2219, 2618, 2011, 2014, 2036, or 2045; while in a further embodiment the 2219 aluminum alloy forms the initial workpiece 20000 when it is joined by welding to other components of the finished golf club head. In one embodiment a heat-treatable 4xxx series aluminum alloy is one of the following 4xxx aluminum alloys: 4032, 4045, or 4643. In one embodiment the 6xxx series aluminum alloy is one of the following 6xxx aluminum alloys: 6061, 6063, 6082, 6463, 6060, 6106, 6351, 6066, 6181, 6262, or 6065. In one embodiment the 7xxx series aluminum alloy is one of the following 7xxx aluminum alloys: 7075, 7050, 7475, 7150, 7178, 7474, 7055, 7477, 7079. In other embodiments that do not require later heat treatment, the initial workpiece 20000 may be formed of the 1xxx series aluminum alloys, the 3xxx aluminum alloys, the non-heat-treatable 4xxx series aluminum alloys, or the 5xxx series aluminum alloys. In one embodiment the 1xxx series aluminum alloy is one of the following 1xxx aluminum alloys: 1050, 1060, 1100, 1145, or 1350. In one embodiment the 3xxx series aluminum alloy is one of the following 3xxx aluminum alloys: 3003, 3103, 3105, 3004, 3104, 3005, or 3030. In one embodiment the non-heat-treatable 4xxx series aluminum alloy is one of the following 4xxx aluminum alloys: 4045, 4035, 4015, 4047, or 4030. In one embodiment the 5xxx series aluminum alloy is one of the following 5xxx aluminum alloys: 5005, 5050, 5052, 5083, 5086, 5154, 5454, 5456, 5754, or 5657. These disclosed methods of forming the initial workpiece 20000, and materials of the initial workpiece 20000, are not limited to the transverse forging disclosure, and are also applicable to the later disclosed longitudinal forging disclosure.
[0646]In one transverse forging method embodiment, upon creation of the initial workpiece 20000 having the desired shape and attributes, the initial workpiece 20000 is heated to a temperature of at least 650° F., as illustrated in
[0647]In one embodiment, the rough forging step produces an intermediary forged workpiece 21000, such as seen
[0648]Then, in an embodiment the intermediary forged workpiece 21000 is heated to a temperature of at least 650° F., as illustrated in
[0649]The final forged workpiece 22000 is then trimmed to a trimmed final forged workpiece 22100, as seen in
[0650]In one embodiment the initial workpiece 20000 has an initial workpiece hardness of less than 10 HRB prior to any of the forging steps occurring, while in further embodiments the initial workpiece hardness is less than 7.5 HRB or 5.0 HRB. Achieving specific controlled jumps in hardness with each forging step plays a significant roll in the durability of the finished golf club head. Thus, in one embodiment a first forging step produces a post-first-forge hardness of the workpiece of at least 35 HRB, and in some embodiments at least 37.5, 40, or 42.5 HRB. However, the post-first-forge hardness of the workpiece is controlled so as to not exceed 50 HRB, and in further embodiments it does not exceed 47.5 or 45 HRB. One skilled in the art will appreciate the number of variables associated with the forging step, including die design and construction, that go into achieving such a controlled post-first-forge hardness of the workpiece. Further, in another embodiment a second forging step produces a post-second-forge hardness of the workpiece that is within 15 HRB of the post-first-forge hardness, which is reduced in additional embodiments such that the post-second-forge hardness of the workpiece is within 12.5, 10, or 7.5 HRB of the post-first-forge hardness. Even further, in another embodiment a third forging step produces a post-third-forge hardness of the workpiece that is within 15 HRB of the post-first-forge hardness, which is reduced in additional embodiments such that the post-third-forge hardness of the workpiece is within 12.5, 10, or 7.5 HRB of the post-first-forge hardness. In one embodiment the post-third-forge hardness is less than 60 HRB, while in further embodiments it is less than 55 or 50 HRB. In one embodiment the post-first-forge hardness of the workpiece is 37.5-50 HRB, the post-second-forge hardness of the workpiece is 40-52.5 HRB, and the post-third-forge hardness of the workpiece is 40-50 HRB.
[0651]One embodiment then introduces a heat treatment step which results in a post-first-HT hardness that is no more than 30 HRB greater than the post-third-forge hardness, which is reduced in further embodiments to no more than 25 HRB or 20 HRB greater than the post-third-forge hardness. In some embodiments the post-first-HT hardness is less than 80, 75, or 70 HRB. A heat treatment step results in a post-second-HT hardness that is no more than 35 HRB greater than the post-first-HT hardness, which is reduced in further embodiments to no more than 30 HRB or 25 HRB greater than the post-first-HT hardness. In some embodiments the post-second-HT hardness is less than 105, 100, 95, or 90 HRB. Another series of embodiments establishes a floor such that the post-second-HT hardness is at least 75, 80, or 85 HRB.
[0652]Some embodiments then include an anodization step resulting in the forged component having a post-anodization component hardness that is within 15 HRB of the post-second-HT hardness, which in further embodiments is reduced to 12.5, 10, 7.5, or 5 HRB.
[0653]In one embodiment the WP depth 20030 is α % less than at least β of the following: the WP rearward toe extension setback distance 20810, the WP rearward heel extension setback distance 20910, the toe extension setback distance 21810, the heel extension setback distance 21910, the first distance D1 of U.S. patent application Ser. No. 18/957,619, the second distance D2 of U.S. patent application Ser. No. 18/957,619, the heel joint distance of U.S. patent application Ser. No. 18/957,619, or the toe joint distance of U.S. patent application Ser. No. 18/957,619. In one embodiment α % is 1%, while in further embodiments it is 2.5%, 5%, 7.5%, 10%, 12.5%, 15%, 17.5%, 20%, 22.5%, or 25%. Further, in one embodiment the value of β is 1, while in further embodiments it is 2, 3, 4, 5, or 6. In another embodiment the WP depth 20030 is at least 35%, 45%, 55%, or 65% of one or more of the following: the WP rearward toe extension setback distance 20810, the WP rearward heel extension setback distance 20910, the toe extension setback distance 21810, the heel extension setback distance 21910, the first distance D1 of U.S. patent application Ser. No. 18/957,619, the second distance D2 of U.S. patent application Ser. No. 18/957,619, the heel joint distance of U.S. patent application Ser. No. 18/957,619, or the toe joint distance of U.S. patent application Ser. No. 18/957,619.
[0654]The trimmed final forged workpiece 22100, as seen in
[0655]
[0656]In one longitudinal forging method embodiment, the initial workpiece 20000 is heated to a temperature of at least 650° F. In a further embodiment the initial workpiece 20000 is heated to a temperature of no more than 950° F. Next, the initial workpiece 20000 is positioned in a lower die such that an upper die is forced toward a lower die at an angle within 25 degrees of the origin y-axis. The upper die is brought into contact with the initial workpiece 20000 during a rough forging step and produces an intermediary forged workpiece 21000. In one embodiment, the rough forging step produces an intermediary forged workpiece 21000, where an intermediary WP depth 20030 has increased to at least 150% of the initial WP depth 20030, which in this example is the cross-sectional dimension. In further embodiments the intermediary WP depth 20030 is at least 175%, 200%, 225%, or 250% of the initial WP depth 20030. However, in another embodiment the intermediary WP depth 20030 is no more than 650% of the initial WP depth 20030, and in further embodiments the percentage is reduced to no more than 600%, 550%, 500%, or 450%. In some embodiments at least a portion of the flash produced is trimmed from the intermediary forged workpiece 21000 prior to the next step. One skilled in the art will recognize that the use of terminology such as “vertically downward” is merely for convenience and consistency with the figures, and the actual direction may be any direction provided the disclosed relationship(s) of the forging direction to the axis are met; and likewise for the terms upper and lower with respect to the dies, as this does not imply any special relationships.
[0657]Then, in an embodiment the intermediary forged workpiece 21000 is heated to a temperature of at least 650° F. In a further embodiment the intermediary forged workpiece 21000 is heated to a temperature of no more than 950° F. Next, the intermediary forged workpiece 21000 is again positioned in a lower die. In this embodiment an upper die is forced toward a lower die an angle within 25 degrees of the origin y-axis. The upper die is brought into contact with the intermediary forged workpiece 21000 during a secondary forging step and produces a second intermediary forged workpiece. In some embodiments at least a portion of the flash produced is trimmed from the intermediary forged workpiece 21000 prior to the next step.
[0658]Then, in an embodiment the second intermediary forged workpiece is heated to a temperature of at least 650° F. In a further embodiment the second intermediary forged workpiece is heated to a temperature of no more than 950° F. Next, the second intermediary forged workpiece is again positioned in a lower die. In this embodiment an upper die is forced toward a lower die an angle within 25 degrees of the origin y-axis. The upper die is brought into contact with the second intermediary forged workpiece during a final forging step and produces a final forged workpiece 22000.
[0659]The final forged workpiece 22000 is then trimmed to a trimmed final forged workpiece 22100. Like the transverse forging embodiments of
[0660]In one embodiment the WP depth 20030 is α % less than at least β of the following: the WP rearward toe extension setback distance 20810, the WP rearward heel extension setback distance 20910, the toe extension setback distance 21810, the heel extension setback distance 21910, the first distance D1 of U.S. patent application Ser. No. 18/957,619, the second distance D2 of U.S. patent application Ser. No. 18/957,619, the heel joint distance of U.S. patent application Ser. No. 18/957,619, or the toe joint distance of U.S. patent application Ser. No. 18/957,619. In one embodiment α % is 1%, while in further embodiments it is 2.5%, 5%, 7.5%, 10%, 12.5%, 15%, 17.5%, 20%, 22.5%, or 25%. Further, in one embodiment the value of β is 1, while in further embodiments it is 2, 3, 4, 5, or 6. In another embodiment the WP depth 20030 is at least 35%, 45%, 55%, or 65% of one or more of the following: the WP rearward toe extension setback distance 20810, the WP rearward heel extension setback distance 20910, the toe extension setback distance 21810, the heel extension setback distance 21910, the first distance D1 of U.S. patent application Ser. No. 18/957,619, the second distance D2 of U.S. patent application Ser. No. 18/957,619, the heel joint distance of U.S. patent application Ser. No. 18/957,619, or the toe joint distance of U.S. patent application Ser. No. 18/957,619.
[0661]In some embodiments the trimmed final forged workpiece 22100, as seen in
[0662]The most common levels of heat treatment for aluminum alloys include T4 (solution heat-treated and naturally aged), T5 (artificially aged after being cooled from a high-temperature shaping process), and T6 (solution heat-treated and artificially aged). Each level offers specific benefits tailored to various applications. T4 treatment provides moderate strength and good ductility, making it suitable for applications requiring formability, such as automotive body panels and structural components. T5 treatment enhances hardness and yield strength without requiring a full solution heat treatment, commonly used in extrusion products for construction, transportation, and consumer goods. T6 treatment delivers maximum strength and hardness by combining solution heat treatment and artificial aging, ideal for aerospace, automotive, and industrial applications where high performance and durability are critical. One embodiment to either the transverse or longitudinal forging embodiments includes at least one of a T4 heat treatment, a T5 heat treatment, and a T6 heat treatment; while a further embodiment includes at least two of a T4 heat treatment, a T5 heat treatment, and a T6 heat treatment.
[0663]In some embodiments the trimmed final forged workpiece 22100 are not subjected to milling/machining until after heat treatment, whereas the reverse order is the common methodology because milling and other machining processes can introduce residual stresses and potentially alter the properties of the alloy due to localized heating or deformation. Heat treating afterward milling and other machining processes helps relieve internal stresses from machining; optimize mechanical properties (e.g., hardness, strength); and refine the microstructure for better performance. In these embodiments the heat treatment(s) are performed before milling to put the material into a specific condition (e.g., softer or more ductile) to facilitate machining without causing excessive tool wear or deformation.
[0664]Milling thin aluminum alloy parts can be challenging due to the material's properties and the specific issues associated with thin workpieces. For instance, aluminum is relatively soft and has a high thermal conductivity, which can cause it to deform or warp under the heat generated during milling. Additionally it is prone to chip welding and galling, where chips adhere to the cutting tool, affecting surface finish and tool life. Further, thin aluminum pieces lack structural rigidity, making them prone to flexing, vibration, and chatter during machining. Additionally, the cutting forces exerted during milling can cause tool deflection, leading to inaccuracies or poor surface finishes. Finally, thin parts have less mass to dissipate heat, increasing the risk of thermal distortion and dimensional instability. Milling thin aluminum alloy parts is indeed more difficult than milling thicker or more rigid materials due to challenges like vibration, thermal distortion, and deflection.
[0665]There are many techniques to overcome the challenges associated with milling aluminum alloy. One such technique is associated with workholding techniques, namely the use vacuum chucks, adhesive fixtures, or custom jigs to secure the thin workpiece uniformly and minimize distortion, often in conjunction with sacrificial backing plates. Another technique is precisely controlled and carefully designed cutting parameters, such as the use of lighter cuts with higher spindle speeds and lower feed rates to minimize cutting forces. Finally, toolpath design and control reduce engagement with the material, such as adaptive or trochoidal milling, to distribute forces evenly. Conventional thinking promotes the avoidance of abrupt changes in direction to minimize stress on the part, however embodiments of the present designs and methods buck this conventional thinking and achieve unexpected results.
[0666]
[0667]Thus the trimmed final forged workpiece 22100 is externally fixtured while a CNC milling machine removes material from the WP forward surface 20300 to create the connection point. Then at least one fixturing device is connected to the connection point so that multiple milling operations may be carried out. In one embodiment the connection point is designed to accommodate engagement with at least one internal milling fixture device and at least one external milling fixture device. For example, an internal milling fixture device would engage the external surface of the WP forward surface 20300 so that the internal surfaces of the trimmed final forged workpiece 22100 are presented to the milling tool. Conversely, an external milling fixture device would engage the internal surface of the WP forward surface 20300 so that the external surfaces of the trimmed final forged workpiece 22100 are presented to the milling tool.
[0668]Forging of the cup 304 and/or front body portion 4602 components, which often have very thin areas and relatively thick areas, induces residual stresses due to plastic deformation and temperature gradients during the cooling process. Subsequent milling removes material and relieves some of the residual stresses. However, subsequent milling may also introduce new residual stresses, particularly if the machining process generates significant heat, and depending on the material and final thickness of the area being milled. Further, titanium alloy has poor thermal conductivity and higher strength compared to aluminum alloy, which can make it more prone to machining issues. For instance, during milling of titanium alloys the heat generated tends to remain more localized, which can lead to localized thermal stresses. Further, titanium alloys have a tendency to work-harden during machining, which can also contribute to the development of new residual stresses. The cup 304, and/or front body portion 4602, is exposed to severe stress upon impact with a golf ball, and controlling residual improves durability and facilitates improved performance. Any of the disclosure relating to the cup 304, and its variations and embodiments, applies equally to the later disclosed front body portion 4602, and its variations and embodiments, and likewise any disclosure relating to the front body portion 4602, and its variations and embodiments, applies equally to the cup 304, and its variations and embodiments. Further, the milling may be further defined by the extent of the total surface area that is milled, the extent of the interior exposed surface area (that exposed to the interior of the club head) that is milled, and/or the extent of the externally exposed surface area (that exposed to the external environment) that is milled. For instance the simplest embodiment is a 100% milled total surface area of the cup 304, and/or front body portion 4602, whereby every surface has been milled, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% milled total surface area. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% milled total surface area. Another embodiment has at least 50% milled interior exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled interior exposed surface area. Another embodiment has at least 50% milled externally exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled externally exposed surface area.
[0669]In one embodiment at least one milling step is carried out using an internal milling fixture device engaging the connection point to remove material from the internal surfaces, and at least one milling step is carried out using an external milling fixture device attached to the connection point to remove material from the external surfaces, before a significant portion of the WP forward surface 20300 is entirely removed, as seen in the steps of CNC4, CNC5, and CNC6 of
[0670]
[0671]In another embodiment majority of the internal surfaces of the crown-opening recessed ledge 168 and/or the front, or forward, ledge 4680 is milled with an internal crown toolpath, an internal crown tool diameter, an internal crown stepover distance, and an internal crown scallop height, as seen in
[0672]The grid illustrated in
[0673]For instance, in one embodiment majority of the external crown toolpath located within a designated Cell A is within 25 degrees of majority of the internal crown toolpath located within the same Cell A. In another embodiment this relationship is true for a designated Cell B, which is adjacent to Cell A. In another embodiment this relationship is true for at least 3, 4, 5, or 6 adjacent cells. In one embodiment the Cell A, and any of the disclosed adjacent cells, is located rearward of the SAVP, while in a further embodiment the Cell A, and any of the adjacent cells, is located forward of the SAVP. In another embodiment the Cell A is located between the 1H plane and the 1T plane. In another embodiment these relationships are present in a cell located toeward of the 4T plane in one embodiment, toeward of the 5T plane in another embodiment, heelward of the 4H plane in one embodiment, and heelward of the 5H plane in another embodiment.
[0674]In another embodiment the external crown stepover distance is at least γ % less than the internal crown stepover distance within Cell A. In another embodiment the external crown stepover distance is within 8% of the internal crown stepover distance within Cell A. In another embodiment either of these relationships are true for a designated Cell B, which is adjacent to Cell A. In another embodiment either of these relationships are true for at least 3, 4, 5, or 6 adjacent cells. In one embodiment the Cell A is located rearward of the SAVP, while in a further embodiment the Cell A is located forward of the SAVP, while in a further embodiment any of the relationships are true in a plurality of cells forward of the SAVP and a plurality of cells rearward of the SAVP. In another embodiment the Cell A is located between the 1H plane and the 1T plane. In one embodiment the γ % is 5%, while in additional embodiments it is 10%, 15%, 20%, 25%, or 30%. However, in another embodiment the 8% is 70%, while in additional embodiments it is 60%, 50%, or 40%. In one particular embodiment the external crown stepover distance is less than 1.0 mm, while the internal crown stepover distance is greater than 1.0 mm.
[0675]In another embodiment the external crown scallop height within a designated Cell A is less than the internal crown scallop height located within the same Cell A. In another embodiment this relationship is true for a designated Cell B, which is adjacent to Cell A. In another embodiment this relationship is true for at least 3, 4, 5, or 6 adjacent cells. In one embodiment the Cell A is located rearward of the SAVP, while in a further embodiment the Cell A is located forward of the SAVP. In another embodiment the Cell A is located between the 1H plane and the 1T plane.
[0676]The external crown toolpath is within 25 degrees of the origin x-axis in one embodiment, which is reduced to 20, 15, or 10 degrees in additional embodiments, for any one or more of the cells illustrated in
[0677]Similarly, the grid illustrated in
[0678]For instance, in one embodiment majority of the external sole toolpath located within a designated Cell SA is angled by at least 30 degrees from the majority of the internal sole toolpath, best illustrated in
[0679]In one embodiment the Cell SA is located rearward of the SAVP, while in a further embodiment the Cell SA is located forward of the SAVP. In another embodiment the Cell SA is located between the 4H plane and the 1H plane, and in another embodiment between the 4H plane and the 2H plane, while in still a further embodiment between the 4H plane and the 3H plane. Similarly, in another embodiment the Cell SA is located between the 4T plane and the 1T plane, and in another embodiment between the 4T plane and the 2T plane, while in still a further embodiment between the 4T plane and the 3T plane. In another embodiment these relationships are present in a cell located toeward of the 4T plane in one embodiment, toeward of the 5T plane in another embodiment, heelward of the 4H plane in one embodiment, and heelward of the 5H plane in another embodiment.
[0680]In another embodiment the external sole stepover distance is at least γ % less than the internal sole stepover distance within Cell SA. In another embodiment the external sole stepover distance is within 8% of the internal sole stepover distance within Cell SA. In another embodiment either of these relationships are true for a designated Cell SB, which is adjacent to Cell SA. In another embodiment either of these relationships are true for at least 3, 4, 5, or 6 adjacent cells. In one embodiment the Cell SA is located rearward of the SAVP, while in a further embodiment the Cell SA is located forward of the SAVP, while in a further embodiment any of the relationships are true in a plurality of cells forward of the SAVP and a plurality of cells rearward of the SAVP. In another embodiment the Cell SA is located between the 1H plane and the 1T plane. In one embodiment the γ % is 5%, while in additional embodiments it is 10%, 15%, 20%, 25%, or 30%. However, in another embodiment the 8% is 70%, while in additional embodiments it is 60%, 50%, or 40%. In one particular embodiment the external sole stepover distance is less than 1.0 mm, while the internal sole stepover distance is greater than 1.0 mm.
[0681]In another embodiment the external sole scallop height within a designated Cell SA is less than the internal sole scallop height located within the same Cell SA. In another embodiment this relationship is true for a designated Cell SB, which is adjacent to Cell SA. In another embodiment this relationship is true for at least 3, 4, 5, or 6 adjacent cells. In one embodiment the Cell SA is located rearward of the SAVP, while in a further embodiment the Cell SA is located forward of the SAVP. In another embodiment the Cell SA is located between the 1H plane and the 1T plane.
[0682]The external sole toolpath is within 25 degrees of the origin x-axis in one embodiment, which is reduced to 20, 15, or 10 degrees in additional embodiments, for any of the cells illustrated in
[0683]
[0684]The front body portion ledge 4680 has a front body portion ledge thickness 4680T, as seen in
[0685]
[0686]
[0687]Further, the milling process may be controlled to produce a plurality of measurement regions, such as those labeled C01, C02, and C03 in
[0688]A finished front body portion 4602 has a finished front body mass of no more than 100 grams, which in further embodiments is no more than 95, 90, 85, 80, or 75 grams.
Mass Properties
[0689]The disclosed multi-piece construction, the diversity of materials, which in some embodiments includes a forged aluminum alloy component, and/or the bonding tape 174 has resulted in more discretionary mass to achieve desirable mass properties, such as that disclosed in Tables 6-14. The Tables below provide several mass properties of exemplary embodiments of the golf club head, with the club head oriented with a face angle of 0 degrees. As with all tables disclosed herein, when a range is disclosed the upper boundary and/or the lower boundary are enabled to stand on their own without association with the opposite boundary. For example, a Zup range in a table may include 16-30 mm, 18-28 mm, 20-27 mm, 20-25 mm, and 21-23 mm, however the disclosure enables embodiments of Zup at least 16, 18, 20, and 21, as well as embodiments of Zup no greater than 30, 28, 27, 25, and 23. Further, any of the disclosed lower bounds may be combined with any of the disclosed upper bounds. Further, any discreet value within the disclosed ranges is fully enabled and may be claimed either as a value or as a boundary to a range. These principles apply to each variable disclosed, and the contents of each table.
| TABLE 6 | |||||
|---|---|---|---|---|---|
| Example 1 | Example 1A | Example 1B | Example 1C | Example 1D | |
| CGX | −5 to 5 mm | −4 to 4 mm | −4 to 3 mm | −4 to 2.5 mm | −4 to 1.5 mm |
| CGY | 33-50 mm | 35-47 mm | 37-47 mm | 39-47 mm | 41-47 mm |
| CGZ | −10 to 0 mm | −8 to −1 mm | −7.5 to −1.5 | −7 to −2.5 mm | −7 to −3 mm |
| mm | |||||
| ZUP | 18-30 mm | 20-28 mm | 21-27 mm | 22-27 mm | 23-27 mm |
| DELTA1 | 20-40 mm | 23-36 mm | 24-35 mm | 25-34 mm | 26-33 mm |
| DELTA2 | 34-42 mm | 35-41 mm | 35.5-40 mm | 35.5-40 mm | 35.5-40 mm |
| MASS | 180-210 g | 195-208 g | 197-206 g | 197-205 g | 198-203 g |
| IXX | 300-450 | 320-445 | 340-440 | 360-435 | 380-430 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 265-350 | 270-340 | 275-330 | 280-320 | 285-315 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 480-700 | 500-675 | 520-625 | 540-600 | 560-600 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-70 mm | 45-65 mm | 45-60 mm | 45-55 mm | 43-54 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 37-43 mm | 38-42 mm | 38-42 mm | 38-42 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 4 mm | −2 to 4 mm | −1 to 4 mm |
| BODY LIE | 53-60 degrees | 54-59 degrees | 55-58 degrees | 55-58 degrees | 55-58 degrees |
| (CASTING) | |||||
| ASM LIE (FCT IN | 51.25-58.25 | 52-57 degrees | 53-56.5 | 53-56.5 | 53-56.5 |
| STD) | degrees | degrees | degrees | degrees | |
| LOFT | 6-12 degrees | 7-12 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-500 cm3 | 400-490 cm3 | 410-480 cm3 | 420-470 cm3 | 420-465 cm3 |
| TABLE 7 | |||||
|---|---|---|---|---|---|
| Example 2 | Example 2A | Example 2B | Example 2C | Example 2D | |
| MASS | 180-200 g | 182.5-197.5 | 185-197.5 g | 187.5-197.5 g | 190-197 g |
| CGX | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2.5 to 2.5 | −1.5 to 1.5 |
| mm | mm | ||||
| CGY | 33-50 mm | 36-49 mm | 39-48 mm | 42-48 mm | 44-48 mm |
| CGZ | −10 to 0 mm | −8 to −1 mm | −7.5 to −1.5 | −7 to −1.5 mm | −6 to −1.5 mm |
| mm | |||||
| ZUP | 18-30 mm | 20-28 mm | 21-27 mm | 22-27 mm | 23-27 mm |
| DELTA1 | 20-40 mm | 23-36 mm | 24-35 mm | 25-34 mm | 26-34 mm |
| DELTA2 | 34-42 mm | 35-40 mm | 35.5-39 mm | 35.5-38 mm | 35.5-38 mm |
| IXX | 300-440 | 310-435 | 320-430 | 340-430 | 360-430 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 265-350 | 270-340 | 275-330 | 280-320 | 280-315 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 480-700 | 500-675 | 520-625 | 540-600 | 560-600 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-70 mm | 45-70 mm | 45-70 mm | 45-70 mm | 45-70 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 37-43 mm | 38-41 mm | 38-41 mm | 38-41 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 4 mm | −2 to 4 mm | −1 to 4 mm |
| BODY LIE | 53-60 degrees | 54-59 degrees | 55-58 degrees | 55-58 degrees | 55-58 degrees |
| (CASTING) | |||||
| ASM LIE (FCT IN | 51.25-58.25 | 52-57 degrees | 53-56.5 | 53-56.5 | 53-56.5 |
| STD) | degrees | degrees | degrees | degrees | |
| LOFT | 6-12 degrees | 7-12 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-500 cm3 | 400-490 cm3 | 410-480 cm3 | 420-470 cm3 | 420-465 cm3 |
| TABLE 8 | |||||
|---|---|---|---|---|---|
| Example 3 | Example 3A | Example 3B | Example 3C | Example 3D | |
| MASS | 200-210 g | 201-209 g | 202-208 g | 202-207 g | 202-207 g |
| CGX | −5 to 5 mm | −4 to 4 mm | −4 to 3 mm | −4 to 2.5 mm | −4 to 1.5 mm |
| CGY | 38-50 mm | 39-47 mm | 40-47 mm | 41-47 mm | 42-46 mm |
| CGZ | −10 to 0 mm | −9 to −1 mm | −8 to −1.5 mm | −7 to -2 mm | −7 to −2.5 mm |
| ZUP | 18-30 mm | 20-28 mm | 21-27 mm | 22-27 mm | 23-27 mm |
| DELTA1 | 24-40 mm | 26-36 mm | 28-35 mm | 29-34 mm | 30-33 mm |
| DELTA2 | 34-42 mm | 35-40 mm | 35.5-40 mm | 35.5-40 mm | 35.5-40 mm |
| IXX | 340-450 | 350-445 | 360-440 | 370-435 | 380-430 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 265-350 | 270-340 | 280-330 | 285-320 | 285-315 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 530-700 | 540-675 | 550-625 | 560-600 | 570-600 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-70 mm | 45-70 mm | 45-70 mm | 45-70 mm | 45-70 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 37-43 mm | 38-41 mm | 38-40 mm | 38-40 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 4 mm | −2 to 4 mm | −1 to 3.5 mm |
| BODY LIE | 53-60 degrees | 54-59 degrees | 55-58 degrees | 55-58 degrees | 55-58 degrees |
| (CASTING) | |||||
| ASM LIE (FCT IN | 51.25-58.25 | 52-57 degrees | 53-56.5 | 53-56.5 | 53-56.5 |
| STD) | degrees | degrees | degrees | degrees | |
| LOFT | 6-12 degrees | 7-12 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-500 cm3 | 400-490 cm3 | 410-480 cm3 | 420-470 cm3 | 420-465 cm3 |
| TABLE 9 | |||||
|---|---|---|---|---|---|
| Example 4 | Example 4A | Example 4B | Example 4C | Example 4D | |
| CGX | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2.5 to 2.5 | −1.5 to 1.5 |
| mm | mm | ||||
| CGY | 31-42 mm | 32-41 mm | 33-40 mm | 34-39 mm | 35-38 mm |
| CGZ | −13 to 0 mm | −13 to −2 mm | −12 to −3 mm | −11 to −4 mm | −10 to −5 mm |
| ZUP | 16-30 mm | 18-28 mm | 20-27 mm | 20-25 mm | 21-23 mm |
| DELTA1 | 21-32 mm | 22-31 mm | 23-30 mm | 24-29 mm | 25-28 mm |
| DELTA2 | 30-40 mm | 32-40 mm | 33-39 mm | 34-39 mm | 35-39 mm |
| MASS | 180-210 g | 195-209 g | 197-208 g | 197-207 g | 197-205 g |
| IXX | 310-440 | 320-430 | 330-420 | 340-410 | 350-400 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 230-325 | 240-315 | 240-305 | 250-295 | 260-285 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 470-595 | 480-570 | 490-560 | 500-550 | 510-540 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 42-62 mm | 44-60 mm | 46-58 mm | 47-54 mm | 48-52 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 36-44 mm | 37-43 mm | 38-42 mm | 39-41 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2 to 2 mm | −1.5 to 1.5 |
| mm | |||||
| BODY LIE | 52-63 degrees | 53-62 degrees | 54-62 degrees | 55-61 degrees | 56-60 degrees |
| (CASTING) | |||||
| ASM LIE (FCT IN | 49-59.5 | 50-59 degrees | 51-58 degrees | 52-57 degrees | 53-56 degrees |
| STD) | degrees | ||||
| LOFT | 6-14 degrees | 7-13 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-550 cm3 | 400-520 cm3 | 410-490 cm3 | 420-480 cm3 | 420-470 cm3 |
| TABLE 10 | |||||
|---|---|---|---|---|---|
| Example 5 | Example 5A | Example 5B | Example 5C | Example 5D | |
| CGX | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2.5 to 2.5 | −1.5 to 1.5 |
| mm | mm | ||||
| CGY | 32-43 mm | 33-42 mm | 34-41 mm | 35-41 mm | 36-40 mm |
| CGZ | −10 to 0 mm | −9 to −1 mm | −8 to −2 mm | −7 to −3 mm | −6 to −4 mm |
| ZUP | 20-30 mm | 21-28.5 mm | 21.5-28 mm | 22-27.5 mm | 23-27 mm |
| DELTA1 | 21-31 mm | 22-30 mm | 23-29 mm | 24-28 mm | 23-27 mm |
| DELTA2 | 30-40 mm | 31-39 mm | 32-38 mm | 33-37 mm | 34-36 mm |
| MASS | 180-210 g | 195-209 g | 197-208 g | 198-207 g | 199-205 g |
| IXX | 320-430 | 330-420 | 340-410 | 350-400 | 360-390 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 245-310 | 250-300 | 255-295 | 260-290 | 265-285 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 470-595 | 480-565 | 490-555 | 500-545 | 510-535 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-62 mm | 47-59 mm | 49-57 mm | 50-56 mm | 51-55 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 36-44 mm | 37-43 mm | 38-42 mm | 39-41 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | -2 to 2 mm | −1.5 to 1.5 |
| mm | |||||
| BODY LIE | 51-63 degrees | 52-61 degrees | 52-60 degrees | 53-59 degrees | 54-58 degrees |
| (CASTING) | |||||
| ASM LIE | 49-59.5 | 50-59 degrees | 51-58 degrees | 52-57 degrees | 53-56 degrees |
| (FCT IN STD) | degrees | ||||
| LOFT | 6-14 degrees | 7-13 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-550 cm3 | 400-520 cm3 | 410-490 cm3 | 420-480 cm3 | 430-465 cm3 |
| TABLE 11 | |||||
|---|---|---|---|---|---|
| Example 6 | Example 6A | Example 6B | Example 6C | Example 6D | |
| CGX | −5 to 5 mm | −4.5 to 4 mm | −4 to 3 mm | −3.5 to 2.5 | −3 to 1.5 mm |
| mm | |||||
| CGY | 25-40 mm | 27-39 mm | 28-38 mm | 28-37 mm | 28-36 mm |
| CGZ | −13 to −1 mm | −12 to −2 mm | −11 to −3 mm | −10 to −4 mm | −9 to −5 mm |
| ZUP | 16-30 mm | 18-28 mm | 20-27 mm | 20-25 mm | 21-23 mm |
| DELTA1 | 24-35 mm | 25-34 mm | 26-33 mm | 27-32 mm | 26-31 mm |
| DELTA2 | 31-42 mm | 32-41 mm | 33-40 mm | 34-39 mm | 35-38 mm |
| MASS | 180-210 g | 195-207 g | 196-206 g | 197-204 g | 198-204 g |
| IXX | 310-400 | 300-390 | 310-380 | 320-370 | 330-360 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 245-310 | 250-300 | 255-295 | 260-290 | 265-285 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 420-550 | 430-540 | 440-530 | 450-520 | 460-510 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-62 mm | 47-59 mm | 49-57 mm | 50-56 mm | 51-55 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 36-44 mm | 37-43 mm | 38-42 mm | 39-41 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2 to 2 mm | −1.5 to 1.5 |
| mm | |||||
| BODY LIE | 51-63 degrees | 52-61 degrees | 52-60 degrees | 53-59 degrees | 54-58 degrees |
| (CASTING) | |||||
| ASM LIE | 49-59.5 | 50-59 degrees | 51-58 degrees | 52-57 degrees | 53-56 degrees |
| (FCT IN STD) | degrees | ||||
| LOFT | 6-14 degrees | 7-13 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-550 cm3 | 400-520 cm3 | 410-490 cm3 | 420-480 cm3 | 430-470 cm3 |
| TABLE 12 | |||||
|---|---|---|---|---|---|
| Example 7 | Example 7A | Example 7B | Example 7C | Example 7D | |
| CGX | −5 to 5 mm | −4.5 to 4 mm | −4 to 3 mm | −3.5 to 2.5 | −3 to 1.5 mm |
| mm | |||||
| CGY | 25-42 mm | 26-41 mm | 27-40 mm | 28-38 mm | 28-36 mm |
| CGZ | −11 to 0 mm | −10 to −1 mm | −9 to −2 mm | −8 to −3 mm | −7 to −3.5 mm |
| ZUP | 20-30 mm | 21-29 mm | 22-28 mm | 23-27 mm | 24-26 mm |
| DELTA1 | 16-29 mm | 17-28 mm | 18-27 mm | 19-26 mm | 20-25 mm |
| DELTA2 | 31-41 mm | 32-40 mm | 33-39 mm | 34-38 mm | 35-37 mm |
| MASS | 180-210 g | 195-209 g | 196-208 g | 197-207 g | 198-205 g |
| IXX | 260-360 | 270-350 | 280-340 | 285-330 | 290-320 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IYY | 245-310 | 250-300 | 255-295 | 260-290 | 265-290 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| IZZ | 430-530 | 430-510 | 430-490 | 440-480 | 450-470 |
| kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | kg · mm2 | |
| CFX | 45-62 mm | 47-59 mm | 49-57 mm | 50-56 mm | 51-56 mm |
| CFY | 9-18 mm | 11-16 mm | 12-15 mm | 12.5-14.5 mm | 13-14 mm |
| CFZ | 35-45 mm | 36-44 mm | 37-43 mm | 38-42 mm | 38-41 mm |
| BP PROJ | −5 to 5 mm | −4 to 4 mm | −3 to 3 mm | −2 to 2 mm | −1.5 to 1.5 |
| mm | |||||
| BODY LIE | 51-63 degrees | 52-61 degrees | 52-60 degrees | 53-59 degrees | 54-58 degrees |
| (CASTING) | |||||
| ASM LIE | 49-59.5 | 50-59 degrees | 51-58 degrees | 52-57 degrees | 53-56 degrees |
| (FCT IN STD) | degrees | ||||
| LOFT | 6-14 degrees | 7-13 degrees | 8-12 degrees | 8.5-12 | 9-12 degrees |
| degrees | |||||
| VOLUME | 390-550 cm3 | 400-520 cm3 | 410-490 cm3 | 420-480 cm3 | 430-470 cm3 |
The construction and material diversity of the golf club head 100 enables the golf club head 100 to have a desirable center-of-gravity (CG) location and peak crown height location. In one example, a y-axis coordinate, on the y-axis of the club head origin coordinate system 185, of the location (PCH) of the peak crown height is between about 26 mm and about 42 mm. In the same or a different example, a distance parallel to the z-axis of the club head origin coordinate system 185, from the ground plane 181, when the golf club head 100 is in the address position, of the location (PCH) of the peak crown height ranges between 60 mm and 70 mm, preferably between 62 mm and 67 mm as described above.
[0690]Additionally, the construction and material diversity of the golf club head 100 enables the golf club head 100 to have desirable mass distribution properties. Referring to
[0691]According to some examples, a first vector distance (V1) from a center-of-gravity of the rearward mass (RMCG) to a CG of the driver-type golf club head is between 49 mm and 64 mm (e.g., 55.7 mm), a second vector distance (V2) from a center-of-gravity of the forward mass (FMCG) to the CG of the driver-type golf club head is between 22 mm and 34 mm (e.g., 29.0 mm), and a third vector distance (V3) from the CG of the rearward mass (RMCG) to the CG of the forward mass (FMCG) is between 75 mm and 82 mm (e.g., 79.75 mm). In certain examples, V1 is no more than 56.3 mm. In some examples, V2 is no less than 23.7 mm, preferably no less than 25 mm, or even more preferably no less than 27 mm. Some additional values of V1 and V2 relative to Zup and CGy values for various examples of the golf club head 100 are provided in Table 13 below. As defined herein, Zup measures the center-of-gravity of the golf club head 100 relative to the ground plane 181 along a vertical axis (e.g., parallel to the z-axis of the club head origin coordinate system 185) when the golf club head 100 is in the proper address position on the ground plane 181. CGy is the coordinate of the center-of-gravity of the golf club head 100 on the y-axis of the club head origin coordinate system 185.
| TABLE 13 | ||||
|---|---|---|---|---|
| Example | Zup | CGy | V1 | V2 |
| 1 | 22-29 mm | 37-46 mm | 53-58 mm | 27-31 mm |
| 2 | 24-30 mm | 33-40 mm | 53-59 mm | 29-35 mm |
| 3 | 22-26 mm | 20-33 mm | 50-55 mm | 24-30 mm |
| 4 | 24-27 mm | 24-35 mm | 50-60 mm | 20-26 mm |
| 5 | 23-25 mm | 20-40 mm | 45-65 mm | 18-30 mm |
Central Region
[0692]Any of the embodiments herein may further include the performance attributes of the striking face disclosed in U.S. Ser. No. 18/888,500, filed Sep. 18, 2024, which is incorporated by reference in its entirety, including, but not limited to, the weighted COR, balance point COR, COR area, and characteristic time attributes. The disclosed cup 104 attributes, as well as the mass distribution disclosed, has demonstrated unexpected improvements to the performance attributes of the striking face associated with the disclosed multi-piece golf club head, which in some embodiments includes aluminum alloy components, bonding tape 174, and/or the disclosed component parts. The disclosed aluminum alloy components, bonding tape 174, and variations/attributes thereof, as well as the mass distribution disclosed, has demonstrated unexpected performance attributes of the striking face, as one skilled in the art will appreciate that incorporation of the bonding tape influences the rigidity and durability of the golf club head, particularly when located in areas subject to deformation and/or deflection of the golf club head at impact.
[0693]
[0694]
[0695]In some embodiments, additional or different striking locations can be used, such as striking locations corresponding to (x, y) coordinates of (0, 0), (−20, 10), (20, 10), (−20, −10), and (20, −10). Additional and different striking locations may also be used, such as for central regions of different shapes and/or sizes.
COR Weighting Factors and Values
[0696]Referring to
[0697]In some embodiments, historical data for all golfers is used to select the weighting factors. Using historical data for all golfers, weighting factors can be selected to fit a large percentage of golfers, including golfers of different skill levels and with different tendencies in striking the golf ball outside of the ideal striking location. In other embodiments, a subset of historical data can be used, such as data for low handicap golfers, high handicap golfers, high lateral dispersion golfers (e.g., for higher MOI heads), low lateral dispersion golfers (e.g., for lower MOI heads), low swing speed golfers, high swings speed golfers, high spin golfers (e.g., for forward CG heads), low spin golfers (e.g., for rearward CG heads), golfers with similar swing flaws (e.g., draw bias heads for over the top producing a slice), golfers with similar shot shapes (e.g., draw, fade, slice, and hook) or another subset of golfers. Using a smaller subset of golfers, weighting factors can be selected to better fit golfers who are categorized as having tendencies fitting the subset.
[0698]In some embodiments, personalized data for an individual golfer is used to select the weighting factors. For example, a golfer can hit a number of golf balls (e.g., 100 balls or another number) and weighting factors can be selected based on the golfer's individual tendencies. Using data for the individual golfer, such as gathered during club fitting, a custom golf club head can be manufactured according to the weighting factors, such as with individualized COR, bulge and roll, and twist profiles for the golfer.
[0699]Ideally, golfers would always strike the golf ball at the geometric center of the face on every impact. However, in practice, golfers tend to strike the golf ball in similar locations outside of the geometric center of the face. For example, many golfers tend to strike the golf ball high and toe-ward on the striking face. Thus, the weighting factors apply more weight to the second striking location 102 higher on the and the fourth striking location toe-ward on the striking face. In this example, the first striking location corresponding to the geometric center of the striking face weighted highest, and the weighting factors can be summed to total 1 (i.e., 100%).
[0700]In some embodiments, the first COR weighting factor at the first striking location 701 is between 0.3 and 0.4, preferably greater than 0.3, more preferably between 0.32 and 0.33, more preferably 0.3267. The second COR weighting factor at the second striking location 702 is between 0.2 and 0.3, preferably greater than 0.2, more preferably between 0.22 and 0.23, more preferably 0.2256. The third COR weighting factor at the third striking location 703 is between 0.1 and 0.2, preferably greater than 0.1, more preferably between 0.135 and 0.145, more preferably 0.1395. The fourth COR weighting factor at the fourth striking location 704 is between 0.2 and 0.3, preferably greater than 0.2, more preferably between 0.22 and 0.23, more preferably 0.2263. The fifth COR weighting factor at the first striking location 705 is between 0.075 and 0.090, preferably greater than 0.08, more preferably between 0.0815 and 0.0824, more preferably 0.0819.
[0701]As discussed above, in some embodiments, the first COR weighting factor can be greater than all other weighting factors. The second COR weighting factor can be greater than the third COR weighting factor, such as between 0.05 and 0.2 greater than the third weighting factor. The fourth COR weighting factor can be greater than the fifth COR weighting factor, such as between 0.001 and 0.2 greater than the fifth weighting factor. The fourth COR weighting factor can be at least two times greater than the fifth COR weighting factor, such as between 0.1 and 0.2 greater than fifth COR weighting factor. The first COR weighting factor can be at least three times greater than the fifth COR weighting factor, such as between 0.2 and 0.3 greater than fifth COR weighting factor. The first COR weighting factor can be at least two times greater than the third COR weighting factor, such as between 0.1 and 0.3 greater than the third COR weighting factor. The first COR weighting factor can be no more than two times greater than the fourth COR weighting factor, such as between 0.01 and 0.3 greater than the fourth COR weighting factor. The third COR weighting factor can be greater than the fifth COR weighting factor, such as between 0.01 and 0.1 greater than the fifth COR weighting factor.
[0702]Each striking location 701, 702, 703, 704, 705 has corresponding COR values. In some embodiments, the first COR value at the first striking location 701 is between 0.805 and 0.840, preferably no less than 0.817, and in some embodiments at least 0.810, 0.820, 0.825, or 0.830. A second COR value at the second striking location 702 is between 0.780 and 0.830, preferably no less than 0.805, and in some embodiments at least 0.810, 0.815, or 0.820. A third COR value at the third striking location 703 is between 0.750 and 0.810, preferably no less than 0.775, 0.785, 0.795, or 0.800. A fourth COR value at the fourth striking location 704 is between 0.760 and 0.815, preferably no less than 0.770, 0.775, 0.780, 0.785, or 0.790. A fifth COR value at the fifth striking location 705 is between 0.720 and 0.800, preferably no less than 0.730, 0.740, 0.750, or 0.760.
[0703]In some embodiments, the second COR value plus the fourth COR value minus the third COR value minus the fifth COR value is greater than zero, such as between 0.0 and 0.165, preferably at least 0.015 COR points. The fourth COR value minus the fifth COR value is at least 0.015 COR points, such as between 0.015 and 0.095. The second COR value minus the fourth COR value is at least 0.007 COR points, such as between 0.007 and 0.060. The third COR value minus the fifth COR value is at least 0.004 COR points, such as between 0.004 and 0.085. In some embodiments, the fourth COR value can be greater than fifth COR value, second COR value can be greater than the fourth COR value, and the second COR value can be greater than the third COR value.
Weighted COR
[0704]As discussed above, the weighting factors and COR values can be used to calculate a weighted COR value for the golf club head. In some embodiments, the weight COR value can be a summation of each of the weighting factors multiplied by its corresponding COR value. For example, the weighted COR value can be equal to the first weighting factor multiplied by the first COR value, plus the second weighting factor multiplied by the second COR value, plus the third weighting factor multiplied by the third COR value, plus the fourth weighting factor multiplied by the fourth COR value, and plus the fifth weighting factor multiplied by the fifth COR value.
[0705]In some embodiments, the weighted COR value is no less than 0.800, such as between 0.800 and 0.840. In one embodiment the weighted COR value is at least 0.802, while in further embodiments it is at least 0.804, 0.806, 0.808, or 0.810. Another series of embodiments caps the weighted COR value to no more than 0.835, 0.830, 0.825, 0.820, or 0.815. In some embodiments, the weighted COR is between about 0.800 and about 0.815, preferably between 0.801 and 0.814, preferably between 0.802 and 0.813, preferably between 0.803 to 0.812.
[0706]Below is a table of weighted COR values for exemplary club heads:
| Example | 701 COR | 702 COR | 703 COR | 704 COR | 705 COR | Weighted COR |
|---|---|---|---|---|---|---|
| 1 | 0.829 | 0.802 | 0.802 | 0.790 | 0.771 | 0.806 |
| 2 | 0.830 | 0.802 | 0.802 | 0.792 | 0.761 | 0.806 |
| 3 | 0.828 | 0.799 | 0.795 | 0.791 | 0.775 | 0.804 |
| 4 | 0.830 | 0.802 | 0.802 | 0.792 | 0.761 | 0.806 |
| 5 | 0.830 | 0.801 | 0.803 | 0.799 | 0.780 | 0.809 |
| 6 | 0.830 | 0.801 | 0.802 | 0.799 | 0.775 | 0.808 |
| 7 | 0.830 | 0.815 | 0.810 | 0.799 | 0.785 | 0.813 |
| 8 | 0.830 | 0.815 | 0.810 | 0.795 | 0.785 | 0.812 |
| 9 | 0.830 | 0.811 | 0.805 | 0.795 | 0.785 | 0.811 |
| 10 | 0.830 | 0.813 | 0.805 | 0.801 | 0.799 | 0.814 |
| 11 | 0.830 | 0.811 | 0.802 | 0.799 | 0.790 | 0.812 |
| 12 | 0.830 | 0.821 | 0.804 | 0.825 | 0.799 | 0.821 |
| 13 | 0.830 | 0.825 | 0.804 | 0.819 | 0.799 | 0.820 |
| 14 | 0.829 | 0.802 | 0.802 | 0.790 | 0.771 | 0.806 |
| 15 | 0.828 | 0.801 | 0.795 | 0.791 | 0.775 | 0.805 |
| 16 | 0.822 | 0.807 | 0.804 | 0.792 | 0.770 | 0.805 |
Balance Point COR
[0707]The disclosed embodiments have also achieved unexpected balance point (BP) COR values. The BP COR corresponds to the BP location of the club head where the club head center of gravity (CG) projects onto the strike face. In such embodiments, the strike face has a balance point (BP) COR between 0.810 and about 0.840, preferably no less than 0.812, 0.814, 0.816, 0.818, 0.820, 0.822, 0.824, 0.826, 0.828, or 0.830. In some embodiments, the BP location does not correspond to the geometric center of the strike face. In some embodiments, the BP location is toe-ward of the geometric center of the strike face (i.e., at a negative location on the x-axis). In some embodiments, the BP location is upward of the geometric center of the strike face (i.e., at a positive location on the y-axis) or lower than the geometric center of the strike face (i.e., at a negative location on the y-axis). Referring back to the tables above, Examples 1, 2, and 3 have a BP COR values of 0.831, 0.830, and 0.829, respectively. In one embodiment the BP location is at least 1 mm from the center face striking location 701, and the balance point (BP) COR is within 0.002 of the center face striking location 701 COR, and is within 0.001 in another embodiment. Similarly, in a further embodiment the BP location is at least 1.5 mm from the center face striking location 701, and the balance point (BP) COR is within 0.002 of the center face striking location 701 COR, and is within 0.001 in another embodiment
COR Area
[0708]
[0709]
[0710]In addition to increasing the overall COR area of the striking face 710, the COR area can be increased in more beneficial locations based on the COR weighting factors, resulting in an asymmetric COR area. For example, the COR area can be increased in Q2 (i.e., high and toward), resulting in a COR area that is asymmetric about a vertical axis and shifted toeward, with a majority of the increase in COR area toeward of the vertical axis through center face. In some embodiments, the COR area can also be increased above a horizontal axis through center face.
[0711]Based on the weighting factors, the COR area of each of the quadrants Q1, Q2, Q3, Q4 can be different. For example, the COR area of Q2 can be greater than Q1, the COR area of Q2 can be greater than Q3, and the COR area of Q2 can be greater than Q4. The combined COR area of Q1 and Q2 can be greater than the combined COR area of Q3 and Q4. The combined COR area of Q2 and Q3 can be greater than the combined COR area of Q1 and Q4. The combined COR area of Q2 and Q4 can be greater than the combined COR area of Q1 and Q3.
[0712]The COR values in each of the quadrants Q1, Q2, Q3, Q4 can also be based on the weighting factors. For example, locations in Q2, such as a first location-10 mm toward and a second location-20 mm toward, can have COR values greater than 0.793, such as between about 0.780 and 0.830. In some embodiments, locations in Q2 and Q3 have COR values greater than Q1 and Q2. In an example, a location-20 mm toeward can have a COR value at least 0.100 greater than 20 mm heelward, while an average COR of the two locations is at least 0.750.
Club Head Testing for Weighted COR
[0713]A method of testing a club head for weighted COR is provided. The method begins by performing initial testing properties of the golf club head, such as inertia, mass properties, center of gravity z-axis (Izz), center of gravity x-axis (Ixx), and displaced water volume.
[0714]Next, the club head is measured for COR values at each of the five striking locations 701, 702, 703, 704, 705. In some embodiments, using the measured COR values (CORN) and corresponding weighting factors (WFN) for the five striking locations 701, 702, 703, 704, 705, and a weighted COR can be calculated using the following equation:
[0715]In the above equation, the weighting factors can be 0.3267, 0.2256, 0.1395, 0.2263, and 0.0819 for the striking locations 701, 702, 703, 704, 705, respectively. In other embodiments, different weighting factors can be used.
[0716]Next, durability testing can be performed on the club head. For example, an initial CT value can be measured at the geometric center of the strike face (e.g., striking location 701). In some embodiments, the initial CT value is at least 236 microseconds (μs) and no more than 257 μs. In further embodiments the initial CT value at striking location 701 is at least 237 μs, 238 μs, 239 μs, 240 μs, 241 μs, 242 μs, 243 μs, 244 μs, 245 μs, or 246 μs. In some embodiments, initial CT values can be measured at other striking locations, such as striking locations 702, 703, 704, 705 and/or other striking locations. The CT testing can be performed within the central region 720, which can be defined by the 40 millimeter (mm) by 20 mm rectangular area centered on the striking face 710, and there is a highest initial CT within the central region 720 and a lowest initial CT within the central region 720, with a CT delta being the difference between the highest initial CT within the central region 720 and the initial CT at the center face striking location 701. In one embodiment the CT delta is no more than 6 μs, while in further embodiments is no more than 5 μs, 4 μs, 3 μs, or 2 μs. These relationships are significantly more than just maximizing one variable, or multiple variables, but rather are a unique balance of tradeoffs enabled by the disclosed construction and mass distribution of the embodiments. For instance, in one embodiment the initial CT at the center face striking location 701 is at least 237 μs, while the highest initial CT within the central region 720 is no more than 254 μs, 252 μs, or 250 μs, while the weighted COR is 0.804-0.812, all while the BP COR is 0.827-0.832 with the BP location at least 1.0 mm from the center face, and while the balance point (BP) COR is within 0.002 of the center face striking location 701 COR.
[0717]After measuring initial CT value(s), the club head it exposed to 500 golf ball impacts at the geometric center of the strike face. The golf ball impacts are performed with a golf ball speed of 52 meters per second. After the 500 golf ball impacts, the central region 720 is golf club head is measured to determine if a change in CT has occurred. For example, different striking locations on the striking face of the club head are tested to determine if any CT values of the striking locations within the central region 720 are greater than 256 μs. Additionally, a 500 impact CT value at the geometric center of the striking face can be measured and compared to the initial CT value to determine an increase CT resulting from the impacts. For example, after 500 impacts, the 500 impact CT value can be larger than the initial CT value, such as by no more than five (5.0) CT points than the initial CT value, preferably no more than four (4.0) CT points greater than the initial CT value, preferably no more than three (3.0) CT points greater than the initial CT value, preferably no more than four (2.0) CT points greater than the initial CT value, preferably no more than one (1.0) CT points greater than the initial CT value, more preferably no more than zero (0.0) CT points greater than the initial CT value. Thus, the disclosed construction and mass distribution of the embodiments may aid in controlling CT creep, or the difference between the 500 impact CT value at a particular location and the initial CT value at the same location.
[0718]The durability testing can be repeated with additional sets of 500 golf ball of impacts, such as after 1000 golf ball of impacts, 1500 golf ball of impacts, 2000 golf ball of impacts, 2500 golf ball of impacts, and 3000 golf ball of impacts. A CT value is measured after each series of golf ball impacts, and each CT value is compared to the initial CT value to determine further increases in CT resulting from the additional impacts. For example, after series of impacts, the measured CT value can be larger than the initial CT value, such as by no more than six (6.0) points, preferably no more than five (5.0) CT points, more preferably no more than four (4.0) CT points greater than the initial CT value. After each test, all measured CT values are less than 257 μs.
[0719]Industry standard values disclosed herein are to be determined via methodologies known to one skilled in the art, and when appropriate via the rules, procedures, and protocols set forth by the United States Golf Association in the versions in effect as of Nov. 20, 2024, including but not limited to the following:
[0720]R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE CLUBHEAD SIZE OF WOOD CLUBS, TPX3003, Rev. 2.1, 9 Apr. 2019.
[0721]R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE FLEXIBILITY OF A GOLF CLUBHEAD, TPX3004, Rev. 2.0, 9 Apr. 2019.
[0722]R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE MOMENT OF INERTIA OF GOLF CLUBHEADS, TPX3005, Rev. 2.0, 1 Dec. 2020.
[0723]R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE COEFFICIENT OF RESTITUTION OF A CLUBHEAD RELATIVE TO A BASELINE PLATE, TPX3009, Rev. 2.0, 9 Apr. 2019.
[0724]R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING IMPACT AREA MARKINGS OF GOLF CLUBS, TPX3001, Rev. 2.0, 1 Dec. 2020.
[0725]United States Golf Association and R&A Rules Limited, PROCEDURE FOR MEASURING THE LENGTH OF GOLF CLUBS (Excluding Putters), USGA-TPX3002, Revision 1.0.0, Jan. 2, 2007.
[0726]R&A Rules Limited and United States Golf Association, OVERALL DISTANCE STANDARD AND SYMMETRY TEST PROTOCOL, TPX3006, Rev. 3.0, 9 Apr. 2019.
[0727]R&A Rules Limited and United States Golf Association, INITIAL VELOCITY TEST PROTOCOL, TPX3007, Rev. 2.1, 9 Apr. 2019.
[0728]R&A Rules Limited and United States Golf Association, GOLF BALL WEIGHT AND SIZE TEST PROTOCOL, TPX3008, Rev. 2.0, 1 Dec. 2020.
[0729]With respect to coefficient of restitution, test equipment shall be manufactured by Automated Design Corporation, Romeoville, IL, Model: Club Head COR Tester, or equivalent.
[0730]The club head origin coordinate system is again illustrated in
[0731]The head origin coordinate system defined with respect to the head origin 205 includes three axes: an origin z-axis extending through the head origin 205 in a vertical direction relative to the ground plane (GP) when the club head is at the normal address position; an origin x-axis extending through the head origin 205 in a toe-to-heel direction parallel to the face, e.g., generally tangential to the face at the origin 205, and perpendicular to the origin z-axis; and an origin y-axis extending through the head origin 205 in a front-to-back direction and perpendicular to the origin x-axis and to the origin z-axis. The origin x-axis and the origin y-axis both extend in horizontal directions relative to the ground plane (GP) when the club head is at normal address position. The origin x-axis extends in a positive direction from the origin 205 to the heel of the club head. The origin y-axis extends in a positive direction from the origin 205 towards the rear of the club head. The origin z-axis extends in a positive direction from the origin 205 towards the crown. Thus, if the club head CG is located 5 mm toward the heel from the head origin 205, and 5 mm below the head origin 205, and 25 mm behind the head origin 205, the head origin x-axis (CGx) coordinate would be 5 mm, the head origin y-axis (CGy) coordinate would be 25 mm, and the head origin z-axis (CGz) coordinate would be −5 mm. An origin x-axis vertical plane, abbreviated OXAVP, is a vertical plane parallel to the SAVP and containing the origin x-axis.
[0732]Just as the CG of the overall golf club head has a CGx coordinate, a CGy coordinate, and a CGz coordinate, each individual cup weight 173, such as the toe cup weight 173T and heel cup weight 173H seen in
[0733]Just as the CG of the overall golf club head has a CGx coordinate, a CGy coordinate, and a CGz coordinate, each individual ring mass element 159, such as the toe ring mass element 159T and heel ring mass element 159H seen in
[0734]As used herein, “Zup” refers to the height of the CG above the ground plane (GP); and references to a Zup of an individual component refers to the height of the CG of the specific component above the ground plane (GP). Another alternative coordinate system uses the club head center-of-gravity (CG) as the origin when the club head is at normal address position. Each center-of-gravity axis passes through the CG. For example, the CG x-axis passes through the center-of-gravity parallel to the ground plane (GP) and parallel to the origin x-axis when the club head is at the normal address position. Similarly, the CG y-axis passes through the center-of-gravity CG parallel to the ground plane (GP) and generally parallel to the origin y-axis, and the CG z-axis passes through the center-of-gravity CG perpendicular to the ground plane (GP) and generally parallel to the origin z-axis when the club head is at normal address position.
[0735]The moment of inertia about the CG z-axis (Izz) is an indication of the ability of a golf club head to resist twisting about the CG z-axis. Greater moments of inertia about the CG z-axis (Izz) provide the golf club head with greater forgiveness on toe-ward or heel-ward off-center impacts with a golf ball. In other words, a golf ball hit by a golf club head on a location of the striking face between the toe and the origin 205 tends to cause the golf club head to twist rearwardly and the golf ball to draw (e.g., to have a curving trajectory from right-to-left for a right-handed swing). Similarly, a golf ball hit by a golf club head on a location of the striking face between the heel and the origin 205 causes the golf club head to twist forwardly and the golf ball to slice (e.g., to have a curving trajectory from left-to-right for a right-handed swing). Increasing the moment of inertia about the CG z-axis (Izz) reduces forward or rearward twisting of the club head, reducing the negative effects of heel or toe mis-hits.
[0736]As the moment of inertia about the CG z-axis (Izz) is an indication of the ability of a club head to resist twisting about the CG z-axis, the moment of inertia about the CG x-axis (Ixx) is an indication of the ability of the club head to resist twisting about the CG x-axis. In general, greater moments of inertia about the CG x-axis (Ixx) improve the forgiveness of the club head on high and low off-center impacts with a golf ball. In other words, a golf ball hit by a club head on a location of the striking surface above the origin 205 causes the club head to twist upwardly and the golf ball to have a higher trajectory than desired. Similarly, a golf ball hit by a club head on a location of the striking face below the origin 205 causes the club head to twist downwardly and the golf ball to have a lower trajectory than desired. Increasing the moment of inertia about the CG x-axis (Ixx) reduces upward and downward twisting of the club head, reducing the negative effects of high and low mis-hits.
[0737]A moment of inertia about the golf club head shaft axis is referred to as the hosel axis moment of inertia (Ih) and is calculated in a similar manner and is an indication of the ability of the club head to resist twisting about the shaft axis, and also serves as a measure of the resistance a golfer senses during a golf swing as they attempt to bring the club head back to a square position to impact a golf ball.
[0738]In addition to redistributing mass within a particular club head envelope as discussed immediately above, the club head center-of-gravity CG location can also be tuned by modifying the club head external envelope. Referring now to
[0739]Key relationships between the components of the golf club head, and the manufacturing process, have been disclosed and are more than mere optimization, maximization, or minimization of a single characteristic or variable, and are often contrary to conventional design thinking yet have been found to achieve a unique balance of the trade-offs associated with competing criteria such as durability, weight distribution, CG placement, impact dynamics, and desired moments of inertia. The aforementioned balance requires trade-offs among the competing characteristics recognizing key points of diminishing returns. Therefore, this disclosure contains a unique combination of relationships that produce enhanced performance, durability, and ease of manufacture, and reduce the negative attributes associated with the weight, placement, and fragility of such components. Further, the relative dimensions, including, but not limited to component masses, overall mass, inertias, length, width, cross-sectional dimensions, thickness, and their relationships to one another and the other design variables disclosed herein, influence the aforementioned criteria. Additionally, many embodiments have identified upper and/or lower limits ranges. For embodiments outside these ranges or relationships, the performance may suffer and adversely impact the goals of the design.
[0740]Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. No. 18/827,140, filed on Sep. 6, 2024, Ser. No. 18/888,500, filed on Sep. 18, 2024, Ser. No. 17/124,134, filed Dec. 16, 2020, Ser. No. 17/560,054, filed Dec. 22, 2021, Ser. No. 17/505,511, filed Oct. 19, 2021, Ser. No. 17/389,167, filed Jul. 19, 2021, Ser. No. 17/321,315, filed May 14, 2021, 18/179848, filed Mar. 7, 2023, Ser. No. 17/124,134, filed Dec. 16, 2020, Ser. No. 17/137,151, filed Dec. 29, 2020, Ser. No. 17/691,649, filed Mar. 10, 2022, 18/510476, filed Nov. 15, 2023, Ser. No. 17/228,511, filed Apr. 12, 2021, Ser. No. 17/224,026, filed Apr. 6, 2021, Ser. No. 17/564,077, filed Dec. 28, 2021, 63/292,708, filed Dec. 22, 2021, 63/478,107, filed Dec. 30, 2022, 63/433,380, filed Dec. 16, 2022, 14/694998, filed Apr. 23, 2015, 18/068347, filed Dec. 19, 2022, Ser. No. 17/547,519, filed Dec. 10, 2021, Ser. No. 17/360,179, filed Jun. 28, 2021, Ser. No. 17/531,979, filed Nov. 22, 2021, Ser. No. 17/722,748, filed Apr. 18, 2022, Ser. No. 17/006,561, filed Aug. 28, 2020, 16/806254, filed Mar. 2, 2020, Ser. No. 17/696,664, filed Mar. 16, 2022, Ser. No. 17/565,580, filed Dec. 30, 2021, Ser. No. 17/727,963, filed Apr. 25, 2022, 16/288499, filed Feb. 28, 2019, Ser. No. 17/530,331, filed Nov. 18, 2021, Ser. No. 17/586,960, filed Jan. 28, 2022, Ser. No. 17/884,027, filed Aug. 9, 2022, 13/842011, filed Mar. 15, 2013, 16/817311, filed Mar. 12, 2020, Ser. No. 17/355,642, filed Jun. 23, 2021, Ser. No. 17/132,645, filed Dec. 23, 2020, Ser. No. 17/390,615, filed Jul. 30, 2021, Ser. No. 17/164,033, filed Feb. 1, 2021, Ser. No. 17/107,474, filed Nov. 30, 2020, Ser. No. 17/526,981, filed Nov. 15, 2021, 16/352537, filed Mar. 13, 2019, Ser. No. 17/156,205, filed Jan. 22, 2021, Ser. No. 17/132,541, filed Dec. 23, 2020, Ser. No. 17/824,727, filed May 25, 2022, Ser. No. 17/722,632, filed Apr. 18, 2022, Ser. No. 17/712,041, filed Apr. 1, 2022, Ser. No. 17/695,194, filed Mar. 15, 2022, Ser. No. 17/686,181, filed Mar. 3, 2022, 63/305,777, filed Feb. 2, 2022, Ser. No. 17/577,943, filed Jan. 18, 2022, Ser. No. 17/570,613, filed Jan. 7, 2022, Ser. No. 17/569,810, filed Jan. 6, 2022, Ser. No. 17/566,833, filed Dec. 31, 2021, Ser. No. 17/566,131, filed Dec. 30, 2021, Ser. No. 17/566,263, filed Dec. 30, 2021, Ser. No. 17/557,759, filed Dec. 21, 2021, Ser. No. 17/558,387, filed Dec. 21, 2021, Ser. No. 17/645,033, filed Dec. 17, 2021, Ser. No. 17/541,107, filed Dec. 2, 2021, Ser. No. 17/526,855, filed Nov. 15, 2021, Ser. No. 17/524,056, filed Nov. 11, 2021, Ser. No. 17/522,560, filed Nov. 9, 2021, Ser. No. 17/515,112, filed Oct. 29, 2021, Ser. No. 17/513,716, filed Oct. 28, 2021, Ser. No. 17/504,335, filed Oct. 18, 2021, Ser. No. 17/504,327, filed Oct. 18, 2021, Ser. No. 17/494,416, filed Oct. 5, 2021, Ser. No. 17/493,604, filed Oct. 4, 2021, 63/261,457, filed Sep. 21, 2021, Ser. No. 17/479,785, filed Sep. 20, 2021, Ser. No. 17/476,839, filed Sep. 16, 2021, Ser. No. 17/477,258, filed Sep. 16, 2021, Ser. No. 17/476,025, filed Sep. 15, 2021, Ser. No. 17/467,709, filed Sep. 7, 2021, Ser. No. 17/403,516, filed Aug. 16,2021, Ser. No. 17/399,823, filed Aug. 11, 2021, 63/227,889, filed Jul. 30, 2021, Ser. No. 17/387,181, filed Jul. 28, 2021, Ser. No. 17/378,407, filed Jul. 16, 2021, Ser. No. 17/368,520, filed Jul. 6, 2021, Ser. No. 17/330,033, filed May 25, 2021, Ser. No. 17/235,533, filed Apr. 20, 2021, Ser. No. 17/233,201, filed Apr. 16, 2021, Ser. No. 17/216,185, filed Mar. 29, 2021, Ser. No. 17/198,030, filed Mar. 10, 2021, Ser. No. 17/191,617, filed Mar. 3, 2021, Ser. No. 17/190,864, filed Mar. 3, 2021, Ser. No. 17/183,905, filed Feb. 24, 2021, Ser. No. 17/183,057, filed Feb. 23, 2021, Ser. No. 17/181,923, filed Feb. 22, 2021, Ser. No. 17/171,678, filed Feb. 9, 2021, Ser. No. 17/171,656, filed Feb. 9, 2021, Ser. No. 17/107,447, filed Nov. 30, 2020, and 63/338,818, filed May 5, 2022, all of which are herein incorporated by reference in their entirety. Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. Pat. No. 9,610,479, issued Apr. 4, 2017, U.S. Pat. No. 11,213,726, issued Jan. 4, 2022, U.S. Pat. No. 8,777,776, issued Jul. 15, 2014, U.S. Pat. No. 7,278,928, issued Oct. 9, 2007, U.S. Pat. No. 7,445,561, issued Nov. 4, 2008, U.S. Pat. No. 9,409,066, issued Aug. 9, 2016, U.S. Pat. No. 8,303,435, issued Nov. 6, 2012, U.S. Pat. No. 7,874,937, issued Jan. 25, 2011, U.S. Pat. No. 8,628,434, issued Jan. 14, 2014, U.S. Pat. No. 8,608,591, issued Dec. 17, 2013, U.S. Pat. No. 8,740,719, issued Jun. 3, 2014, U.S. Pat. No. 9,694,253, issued Jul. 4, 2017, U.S. Pat. No. 9,683,301, issued Jun. 20, 2017, U.S. Pat. No. 9,468,816, issued Oct. 18, 2016, U.S. Pat. No. 8,262,509, issued Sep. 11, 2012, U.S. Pat. No. 7,901,299, issued Mar. 8, 2011, U.S. Pat. No. 8,119,714, issued Feb. 21, 2012, U.S. Pat. No. 8,764,586, issued Jul. 1, 2014, U.S. Pat. No. 8,227,545, issued Jul. 24, 2012, U.S. Pat. No. 8,066,581, issued Nov. 29, 2011, U.S. Pat. No. 10,052,530, issued Aug. 21, 2018, U.S. Pat. No. 10,195,497, issued Feb. 5, 2019, U.S. Pat. No. 10,086,240, issued Oct. 2, 2018, U.S. Pat. No. 9,914,027, issued Mar. 13, 2018, U.S. Pat. No. 9,174,099, issued Nov. 3, 2015, and U.S. Pat. No. 11,219,803, issued Jan. 11, 2022, all of which are herein incorporated by reference in their entirety.
[0741]Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. No. 18/807,487, filed Aug. 16, 2024, 18/102001, filed Jan. 26, 2023, Ser. No. 18/077,794, filed Dec. 8, 2022, Ser. No. 17/963,491, filed Oct. 11, 2022, Ser. No. 18/397,351, filed Dec. 27, 2023, Ser. No. 18/898,332, filed Sep. 26, 2024, Ser. No. 18/540,571, filed Dec. 14, 2023, Ser. No. 18/662,372, filed May 13, 2024, Ser. No. 18/468,273, filed Sep. 15, 2023, Ser. No. 18/743,971, filed Jun. 14, 2024, Ser. No. 18/657,023, filed May 7, 2024, Ser. No. 18/595,140, filed Mar. 4, 2024, Ser. No. 18/355,384, filed Jul. 19, 2023, Ser. No. 18/791,808, filed Aug. 1, 2024, Ser. No. 18/764,001, filed Jul. 3, 2024, Ser. No. 18/939,302, filed Nov. 6, 2024, Ser. No. 17/164,033, filed Feb. 1, 2021, Ser. No. 18/830,380, filed Sep. 10, 2024, Ser. No. 18/892,181, filed Sep. 20, 2024, Ser. No. 17/100,273, filed Nov. 20, 2020, Ser. No. 18/197,594, filed May 15, 2023, Ser. No. 18/604,909, filed Mar. 14, 2024, Ser. No. 18/212,861, filed Jun. 22, 2023, Ser. No. 18/436,878, filed Feb. 8, 2024, Ser. No. 18/534,985, filed Dec. 11, 2023, Ser. No. 17/974,279, filed Oct. 26, 2022, Ser. No. 17/504,327, filed Oct. 18, 2021, Ser. No. 18/822,842, filed Sep. 3, 2024, Ser. No. 18/761,819, filed Jul. 2, 2024, Ser. No. 17/010,395, filed Sep. 2, 2020, Ser. No. 17/878,661, filed Aug. 1, 2022, Ser. No. 18/478,155, filed Sep. 29, 2023, Ser. No. 18/436,841, filed Feb. 8, 2024, Ser. No. 18/504,887, filed Nov. 8, 2023, Ser. No. 17/515,112, filed Oct. 29, 2021, Ser. No. 18/913,535, filed Oct. 11, 2024, Ser. No. 18/124,325, filed Mar. 21, 2023, Ser. No. 17/570,613, filed Jan. 7, 2022, Ser. No. 18/612,969, filed Mar. 21, 2024, Ser. No. 18/468,304, filed Sep. 15, 2023, Ser. No. 18/376,179, filed Oct. 3, 2023, Ser. No. 18/531,430, filed Dec. 6, 2023, 2024-154117, filed Sep. 6, 2024, JP2020100117A, filed Jun. 9, 2020, Ser. No. 17/107,447, filed Nov. 30, 2020, Ser. No. 18/815,207, filed Aug. 26, 2024, Ser. No. 18/792,777, filed Aug. 2, 2024, Ser. No. 18/807,320, filed Aug. 16, 2024, Ser. No. 18/784,461, filed Jul. 25, 2024, Ser. No. 17/526,855, filed Nov. 15, 2021, Ser. No. 18/379,512, filed Oct. 12, 2023, Ser. No. 17/105,109, filed Nov. 25, 2020, Ser. No. 18/110,636, filed Feb. 16, 2023, Ser. No. 18/502,408, filed Nov. 6, 2023, Ser. No. 18/211,751, filed Jun. 20, 2023, Ser. No. 18/135,502, filed Apr. 17, 2023, Ser. No. 18/135,463, filed Apr. 17, 2023, Ser. No. 18/808,923, filed Aug. 19, 2024, Ser. No. 18/825,926, filed Sep. 5, 2024, Ser. No. 18/370,314, filed Sep. 19, 2023, Ser. No. 18/332,099, filed Jun. 9, 2023, Ser. No. 17/975,150, filed Oct. 27, 2022, Ser. No. 18/653,254, filed May 2, 2024, Ser. No. 18/515,737, filed Nov. 21, 2023, Ser. No. 18/936,651, filed Nov. 4, 2024, Ser. No. 18/889,078, filed Sep. 18, 2024, Ser. No. 18/943,215, filed Nov. 11, 2024, Ser. No. 18/911,709, filed Oct. 10, 2024, Ser. No. 18/888,500, filed Sep. 18, 2024, Ser. No. 18/827,140, filed Sep. 6, 2024, Ser. No. 18/817,539, filed Aug. 28, 2024, Ser. No. 18/814,646, filed Aug. 26, 2024, Ser. No. 18/808,224, filed Aug. 19, 2024, Ser. No. 18/800,504, filed Aug. 12, 2024, Ser. No. 18/796,753, filed Aug. 7, 2024, Ser. No. 18/777,649, filed Jul. 19, 2024, Ser. No. 18/736,758, filed Jun. 7, 2024, Ser. No. 18/736,646, filed Jun. 7, 2024, Ser. No. 18/647,379, filed Apr. 26, 2024, Ser. No. 18/544,301, filed Dec. 18, 2023, Ser. No. 18/534,512, filed Dec. 8, 2023, Ser. No. 18/519,327, filed Nov. 27, 2023, Ser. No. 18/518,013, filed Nov. 22, 2023, Ser. No. 18/444,811, filed Feb. 19, 2024, Ser. No. 18/414,128, filed Jan. 16, 2024, Ser. No. 18/406,312, filed Jan. 8, 2024, Ser. No. 18/375,888, filed Oct. 2, 2023, Ser. No. 18/226,294, filed Jul. 26, 2023, Ser. No. 18/207,276, filed Jun. 8, 2023, Ser. No. 18/082,735, filed Dec. 16, 2022, Ser. No. 18/082,271, filed Dec. 15, 2022, Ser. No. 17/734,185, filed May 2, 2022, Ser. No. 17/668,902, filed Feb. 10, 2022, and Ser. No. 17/068,355, filed Oct. 12, 2020, all of which are herein incorporated by reference in their entirety.
[0742]Although not specifically shown, the golf club head 100 of the present disclosure may include other features to promote the performance characteristics of the golf club head 100. For example, the golf club head 100, in some implementations, includes movable weight features similar to those described in more detail in U.S. Pat. Nos. 6,773,360; 7,166,040; 7,452,285; 7,628,707; 7,186,190; 7,591,738; 7,963,861; 7,621,823; 7,448,963; 7,568,985; 7,578,753; 7,717,804; 7,717,805; 7,530,904; 7,540,811; 7,407,447; 7,632,194; 7,846,041; 7,419,441; 7,713,142; 7,744,484; 7,223,180; 7,410,425; and 7,410,426, the entire contents of each of which are incorporated herein by reference in their entirety.
[0743]In certain implementations, for example, the golf club head 100 includes slidable weight features similar to those described in more detail in U.S. Pat. Nos. 7,775,905 and 8,444,505; U.S. patent application Ser. No. 13/898,313, filed on May 20, 2013; U.S. patent application Ser. No. 14/047,880, filed on Oct. 7, 2013; U.S. Patent Application No. 61/702,667, filed on Sep. 18, 2012; U.S. patent application Ser. No. 13/841,325, filed on Mar. 15, 2013; U.S. patent application Ser. No. 13/946,918, filed on Jul. 19, 2013; U.S. patent application Ser. No. 14/789,838, filed on Jul. 1, 2015; U.S. Patent Application No. 62/020,972, filed on Jul. 3, 2014; Patent Application No. 62/065,552, filed on Oct. 17, 2014; and Patent Application No. 62/141,160, filed on Mar. 31, 2015, the entire contents of each of which are hereby incorporated herein by reference in their entirety.
[0744]According to some implementations, the golf club head 100 includes aerodynamic shape features similar to those described in more detail in U.S. Patent Application Publication No. 2013/0123040A1, the entire contents of which are incorporated herein by reference in their entirety.
[0745]In certain implementations, the golf club head 100 includes removable shaft features similar to those described in more detail in U.S. Pat. No. 8,303,431, the contents of which are incorporated by reference herein in in their entirety.
[0746]According to yet some implementations, the golf club head 100 includes adjustable loft/lie features similar to those described in more detail in U.S. Pat. Nos. 8,025,587; 8,235,831; 8,337,319; U.S. Patent Application Publication No. 2011/0312437A1; U.S. Patent Application Publication No. 2012/0258818A1; U.S. Patent Application Publication No. 2012/0122601A1; U.S. Patent Application Publication No. 2012/0071264A1; and U.S. patent application Ser. No. 13/686,677, the entire contents of which are incorporated by reference herein in their entirety.
[0747]Additionally, in some implementations, the golf club head 100 includes adjustable sole features similar to those described in more detail in U.S. Pat. No. 8,337,319; U.S. Patent Application Publication Nos. 2011/0152000A1, 2011/0312437, 2012/0122601A1; and U.S. patent application Ser. No. 13/686,677, the entire contents of each of which are incorporated by reference herein in their entirety.
[0748]In some implementations, the golf club head 100 includes composite face portion features similar to those described in more detail in U.S. patent application Ser. Nos. 11/998,435; 11/642,310; 11/825,138; 11/823,638; 12/004,386; 12/004,387; 11/960,609; 11/960,610; and 7,267,620, which are herein incorporated by reference in their entirety.
[0749]According to one embodiment, a method of making a golf club head, such as the golf club head 100, includes one or more of the following steps: (1) forming a body having a sole opening, forming a composite laminate sole insert, injection molding a thermoplastic composite head component over the sole insert to create a sole insert unit, and joining the sole insert unit to the body; (2) forming a body having a crown opening, forming a composite laminate crown insert, injection molding a thermoplastic composite head component over the crown insert to create a crown insert unit, and joining the crown insert unit to the body; (3) forming a weight track, capable of supporting one or more slidable weights, in the body; (4) forming the sole insert and/or the crown insert from a thermoplastic composite material having a matrix compatible for bonding with the body; (5) forming the sole insert and/or the crown insert from a continuous fiber composite material having continuous fibers selected from the group consisting of glass fibers, aramide fibers, carbon fibers and any combination thereof, and having a thermoplastic matrix consisting of polyphenylene sulfide (PPS), polyamides, polypropylene, thermoplastic polyurethanes, thermoplastic polyureas, polyamide-amides (PAI), polyether amides (PEI), polyetheretherketones (PEEK), and any combinations thereof; (6) forming both the sole insert and the weight track from thermoplastic composite materials having a compatible matrix; (7) forming the sole insert from a thermosetting material, coating a sole insert with a heat activated adhesive, and forming the weight track from a thermoplastic material capable of being injection molded over the sole insert after the coating step; (8) forming the body from a material selected from the group consisting of titanium, one or more titanium alloys, aluminum, one or more aluminum alloys, steel, one or more steel alloys, polymers, plastics, and any combination thereof; (9) forming the body with a crown opening, forming the crown insert from a composite laminate material, and joining the crown insert to the body such that the crown insert overlies the crown opening; (10) selecting a composite head component from the group consisting of one or more ribs to reinforce the golf club head, one or more ribs to tune acoustic properties of the golf club head, one or more weight ports to receive a fixed weight in a sole portion of the golf club head, one or more weight tracks to receive a slidable weight, and combinations thereof; (11) forming the sole insert and the crown insert from a continuous carbon fiber composite material; (12) forming the sole insert and the crown insert by thermosetting using materials suitable for thermosetting, and coating the sole insert with a heat activated adhesive; and (13) forming the body from titanium, titanium alloy or a combination thereof to have the crown opening, the sole insert, and the weight track from a thermoplastic carbon fiber material having a matrix selected from the group consisting of polyphenylene sulfide (PPS), polyamides, polypropylene, thermoplastic polyurethanes, thermoplastic polyureas, polyamide-amides (PAI), polyether amides (PEI), polyetheretherketones (PEEK), and any combinations thereof; and (13) forming a frame with a crown opening, forming a crown insert from a thermoplastic composite material, and joining the crown insert to the body such that the crown insert overlies the crown opening.
[0750]Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. Nos. 63/433,380, 18/082,735, 18/082,271, 63/292,708, 17/547,519, 17/360,179, 17/560,054, 17/124,134, 17/531,979, 17/722,748, 17/505,511, 17/560,054, 17/389,167, 17/006,561, 17/137,151, 16/806,254, 17/321,315, 17/696,664, 17/565,580, 17/727,963, 16/288,499, 17/530,331, 17/586,960, 17/884,027, 13/842,011, 16/817,311, 17/355,642, 17/722,748, 17/132,645, 17/696,664, 17/884,027, 17/390,615, 17/586,960, 17/691,649, 17/224,026, 17/560,054, 17/164,033, 17/107,474, 17/526,981, 16/352,537, 17/156,205, 17/132,541, 17/565,580, 17/360,179, 17/355,642, 17/727,963, 17/824,727, 17/722,632, 17/712,041, 17/696,664, 17/695,194, 17/691,649, 17/686,181, 63/305777, 17/577,943, 17/570,613, 17/569,810, 17/566,833, 17/565,580, 17/566,131, 17/566,263, 17/564,077, 17/560,054, 63/292708, 17/557,759, 17/558,387, 17/645,033, 17/547,519, 17/541,107, 17/530,331, 17/526,981, 17/526,855, 17/524,056, 17/522,560, 17/515,112, 17/513,716, 17/505,511, 17/504,335, 17/504,327, 17/494,416, 17/493,604, 63/261457, 17/479,785, 17/476,839, 17/477,258, 17/476,025, 17/467,709, 17/403,516, 17/399,823, 17/390,615, 63/227889, 17/389,167, 17/387,181, 17/378,407, 17/368,520, 17/360,179, 17/355,642, 17/330,033, 17/235,533, 17/233,201, 17/228,511, 17/224,026, 17/216,185, 17/198,030, 17/191,617, 17/190,864, 17/183,905, 17/183,057, 17/181,923, 17/171,678, 17/171,656, 17/164,033, 17/156,205, 17/564,077, 17/124,134, 17/107,447, 63/292,708, 63/305,777, and 63/338,818, all of which are herein incorporated by reference in their entirety. Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. Pat. Nos. 11,213,726, 8,777,776, 7,278,928, 7,445,561, 9,409,066, 8,303,435, 7,874,937, 8,628,434, 8,608,591, 8,740,719, 8,777,776, 9,694,253, 9,683,301, 9,468,816, 8,777,776, 8,262,509, 7,901,299, 8,119,714, 8,764,586, 8,227,545, 8,066,581, 9,409,066, 10,052,530, 10,195,497, 10,086,240, 9,914,027, 9,174,099, and 11,219,803, all of which are herein incorporated by reference in their entirety. All patent applications, patents, and printed publications cited herein are incorporated herein by reference in their entirety including any definitions, except for any inconsistent or irreconcilable definitions, except for any subject matter disclaimers or disavowals, and except to the extent that the incorporated material is inconsistent with the express disclosure herein, in which case the usage in this disclosure controls. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) shall be considered supplementary to that of this document, and, for the avoidance of doubt, the usage in this document controls.
[0751]Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more embodiments.
[0752]In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.” The term “about” in some embodiments, can be defined to mean within +/−5% of a given value.
[0753]Additionally, examples in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.
[0754]As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
[0755]Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
[0756]As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.
[0757]The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims
1. (canceled)
2. A golf club head, comprising:
a face, a sole, a crown, a leading edge, and a trailing edge wherein:
the face has a roll radius, a face center, the face defines a loft plane that is tangent to the face center, an origin for an x-axis, a y-axis, and a z-axis, wherein the x-axis is tangential to the face at the origin and parallel to a ground plane, the y-axis is perpendicular to the x-axis and extends away from the face center toward the trailing edge and is parallel to the ground plane, and the z-axis extends vertically from the face center and is perpendicular to the ground plane;
a front body portion having a face opening, a lower opening, and formed of a front body metallic material having a front body yield strength of 425-550 MPa, a front body elastic modulus of 55-90 GPa, and a front body shear modulus of 17.5-35 GPa, wherein:
a portion of the front body portion has an anodized oxide layer with an oxide layer thickness of at least 5 micrometers; and
the front body portion has a front body portion interior exposed surface area, and the anodized oxide layer covers at least 50% of the front body portion interior exposed surface area;
a face plate adhesively attached to the front body portion at a face bond region, thereby closing the face opening;
a hosel portion with a hosel bore defining a shaft axis and a shaft axis vertical plane;
an adjustable head-shaft connection assembly coupled to the hosel portion and aligned with the lower opening, wherein the adjustable head-shaft connection assembly comprises a fastener received within a portion of the lower opening, and the adjustable head-shaft connection assembly is operable to releasably attach the golf club head to a golf club shaft and adjust at least one of a loft angle or a lie angle;
at least one aft-body component adhesively attached to the front body portion at an aft-body component bond region;
a rear mass element attached to the golf club head; and
the golf club head has a club head mass of 180-210 grams, a volume of 390-500 cm3, and a maximum distance from the leading edge to the trailing edge measured parallel to the y-axis is 112-127 mm.
3. The golf club head of
4. The golf club head of
5. The golf club head of
6. The golf club head of
7. The golf club head of
8. The golf club head of
9. The golf club head of
a face center vertical plane containing the y-axis separates a toe portion of the golf club head from a heel portion of the golf club head;
the toe portion of the front body portion extends rearward of the leading edge a toe extension setback distance to a finished front body portion rearward toe extension;
the toe portion has a toe curvature radius defined by a first point, a second point, and a third point on a projected outline of the toe portion of the front body portion on the ground plane, where:
the first point is located at an intersection of the projected outline and the shaft axis vertical plane;
the second point is located at an intersection of the projected outline and an offset shaft axis vertical plane located half way between the shaft axis vertical plane and the finished front body portion rearward toe extension;
the third point is located at a rearwardmost point on the projected outline; and
a best fit curve passes through the first point, the second point, and the third point, and the toe curvature radius is a radius of curvature of the best fit curve; and
the toe extension setback distance is ±40% of the toe curvature radius.
10. The golf club head of
11. The golf club head of
12. The golf club head of
13. The golf club head of
14. The golf club head of
15. The golf club head of
a face center horizontal plane passes through the face center and contains the x-axis and the y-axis;
an imaginary line originates at a center of gravity of the golf club head and extends forward to intersect the loft plane at a 90 degree angle;
a BP plane contains the imaginary line and is perpendicular to the loft plane; and
the rear mass element has a mass element center of gravity located below the face center horizontal plane and above the BP plane.
16. The golf club head of
17. The golf club head of
18. The golf club head of
19. The golf club head of
20. A method of manufacturing a portion of a golf club head, the method comprising:
forming a front body portion from an initial workpiece formed of a front body metallic material via a multi-stage forging process, wherein the initial workpiece has a WP volume of 120-275 cc, a WP mass of 300-775 grams, and an initial workpiece hardness of less than 10 HRB (Rockwell Hardness, B scale), wherein the multi-stage forging process includes a first forging step producing a post-first-forge workpiece having a post-first-forge hardness of 35-50 HRB (Rockwell Hardness, B scale), and a second forging step producing a post-second-forge workpiece having a post-second-forge hardness within 15 HRB (Rockwell Hardness, B scale) of the post-first-forge hardness;
heat treating the front body portion to achieve a front body yield strength of 425-550 MPa, a front body elastic modulus of 55-90 GPa, and a front body shear modulus of 17.5-35 GPa; and
forming an anodized oxide layer on at least a portion of an interior surface of the front body portion, the anodized oxide layer having an oxide layer thickness of at least 5 micrometers and covering at least 50% of a front body portion interior surface area, and producing a finished front body portion having a finished front body mass of no more than 100 grams.
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