Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
MULTIPLE MATERIAL GOLF CLUB HEAD
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a golf club head with a face component
composed of a
metal material, and an aft-body composed of a light-weight material. More
specifically, the
present invention relates to a golf club head with face component having a
face insert and an aft-
body composed of a light-weight material.
Description of the Related Art
When a golf club head strikes a golf ball, large impacts are produced that
load the club
head face and the golf ball. Most of the energy is transferred from the head
to the golf ball,
however, some energy is lost as a result of the collision. The golf ball is
typically composed of
polymer cover materials (such as ionomers) surrounding a rubber-like core.
These softer
polymer materials having damping (loss) properties that are strain and strain
rate dependent
which are on the order of 10-100 times larger than the damping properties of a
metallic club face.
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Thus, during impact most of the energy is lost as a result of the high
stresses and deformations
of the golf ball (0.001 to 0.20 inch), as opposed to the small deformations of
the metallic club
face (0.025 to 0.050 inch). A more efficient energy transfer from the club
head to the golf ball
could lead to greater flight distances of the golf ball.
The generally accepted approach has been to increase the stiffness of the club
head face to
reduce metal or club head deformations. However, this leads to greater
deformations in the golf
ball, and thus increases in the energy transfer problem.
Some have recognized the problem and disclosed possible solutions. An example
is
Campau, U.S. Patent Number 4,398,965, for a Method Of Making Iron Golf Clubs
With Flexible
Impact Surface, which discloses a club having a flexible and resilient face
plate with a slot to
allow for the flexing of the face plate. The face plate of Campau is composed
of a ferrous
material, such as stainless steel, and has a thickness in the range of 0.1
inches to 0.125 inches.
Another example is Eggiman, U.S. Patent Number 5,863,261, for a Golf Club Head
With
Elastically Deforming Face And Back Plates, which discloses the use of a
plurality of plates that
act in concert to create a spring-like effect on a golfball during impact. A
fluid is disposed
between at least two of the plates to act as a viscous coupler.
Yet another example is Jepson et al, U.S. Patent Number 3,937,474, for a golf
Club With
A Polyurethane Insert. Jepson discloses that the polyurethane insert has a
hardness between 40
and 75 shore D.
Still another example is Inamori, U.S. Patent Number 3,975,023, for a Golf
Club Head
With Ceramic Face Plate, which discloses using a face plate composed of a
ceramic material
having a high energy transfer coefficient, although ceramics are usually
harder materials. Chen
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et al., U.S Patent Number 5,743,813 for a Golf Club Head, discloses using
multiple layers in the
face to absorb the shock of the golf ball. One of the materials is a non-metal
material.
Lu, U.S. Patent Number 5,499,814, for a Hollow Club Head With Deflecting
Insert Face
Plate, discloses a reinforcing element composed of a plastic or aluminum alloy
that allows for
mino'r deflectiing of the face plate which has a thickness ranging from 0.01
to 0.30 inches for a
variety of materials including stainless 'steel, titanium, KEVLAR , and the
like. Yet another
Campau invention, U.S. Patent Number 3,989,248, for a Golf Club Having Insert
Capable Of
Elastic Flexing, discloses a wood club composed of wood with a metal insert.
Although not intended for flexing of the face plate, Anderson, U.S. Patent
Number
5,344,140, for a Golf Club Head And Method Of Forming Same, discloses use of a
hot forged
material for the face plate. The face plate of Anderson may be composed of
several hot forged
metal materials including steel, copper and titanium. The hot forged plate has
a uniform
thickness of between 0.090 and 0.130 inches.
Another invention directed toward forjed materials in a club head is Su et
al., U.S. Patent
Number 5,776,011 for a Golf Club Head. Su discloses a club head composed of
three pieces
with each piece composed of a forged material. The main objective of Su is to
produce a club
head with greater lofft angle accuracy and reduce structural weaknesses.
:Aizawa, U.S. Patent
Number 5,346,216 for a Golf Club Head, discloses a face plate having a curved
ball hitting
surface.
U.S. Patent 6,146,571 to Vincent, et.al., discloses a method of manufacturing
a golf club
head wherein the walls are obtained by injecting a material such as plastic
over an insert affixed
to a meltable core. The core has a melt point lower than that of the
injectable plastic material so
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that once the core is removed, an inner volume is maintained to form the inner
cavity. The insert
may comprise a resistance element for reinforcing the internal portion of the
front wall of the
shell upon removal of the core where the reinforcement element is comprised of
aluminum with
a laterally extending portion comprised of steel.
U.S. Patent 6,149,534 to Peters, et al., discloses a golf club head having
upper and lower
metal engagement surfaces formed along a single plane interface wherein the
metal of the lower
surface is heavier and more dense than the metal of the upper surface.
U.S. Patents 5,570,886 and 5,547,427 to Rigal, et. al., disclose a golf club
head of molded
thermoplastic having a striking face defined by an impact-resistant metallic
sealing element. The
sealing element defines a front wall of the striking surface of the club head
and extends upward
and along the side of the impact surface to form a neck for attachment of the
shaft to the club
head. The sealing element preferably being between 2.5 and 5 mm in thickness.
U.S. Patent 5,425,538 to Vincent, et al., discloses a hollow golf club head
having a steel
shell and a composite striking surface composed of a number of stacked woven
webs of fiber.
U.S. Patent 5,377,986 to Viollaz, et al., discloses a golf club head having a
body
composed of a series of metal plates and a hitting plate comprised of plastic
'or composite
material wherein the hitting plate is imparted with a forwardly convex shape.
Additionally, U.S.
Patent 5,310,185 to Viollaz, et al., discloses a hollow golf club head having
a body composed of
a series of metal plates, a metal support plate being located on the front
hitting surface to which a
hitting plate comprised of plastic or composite is attached. The metal support
plate has a
forwardly convex front plate associated with a forwardly convex rear plate of
the hitting plate
thereby forming a forwardly convex hitting surface.
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U.S. Patent 5,106,094 to Desboilles, et al., discloses a golf club head having
a metal
striking face plate wherein the striking face plate is a separate unit
attached to the golf club head
with a quantity of filler material in the interior portion of the club head.
U.S. Patent 4,568,088 to Kurahashi discloses a wooden golf club head body
reinforced by
a mixture of wood-plastic composite material. The wood-plastic composite
material being
unevenly distributed such that a higher density in the range of between 5 and
15 mm lies adjacent
to and extends substantially parallel with the front face of the club head.
U.S. Patent 4,021,047 to Mader discloses a golf club wherein the sole plate,
face plate,
heel, toe and hosel portions are formed as a unitary cast metal piece and
wherein a wood or
composite crown is attached to this unitary piece thereby forming a hollow
chamber in the club
head.
U.S. Patent 5,624,331 to Lo, et al. discloses a hollow metal golf club head
where the
metal casing of the head is composed of at least two openings. The head also
contains a
composite material disposed within the head where a portion of the composite
material is located
in the openings of the golf club head casing.
U.S. Patent 1,167,387 to Daniel discloses a hollow golf club head wherein the
shell body
is comprised of metal such as aluminum alloy and the face plate is comprised
of a hard wood
such as beech, persimmon or the like. The face plate is aligned such that the
wood grain presents
endwise at the striking plate.
U.S. Patent 3,692,306 to Glover discloses a golf club head having a bracket
with sole and
striking plates formed integrally thereon. At least one of the plates has an
embedded elongate
tube for securing a removably adjustable weight means.
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U.S. Patent 5,410,798 to Lo discloses a method of manufacturing a composite
golf club
head using a metal casing to which a laminated member is inserted. A sheet of
composite
material is subsequently layered over the openings of the laminated member and
metal casing to
close off the openings in the top of both. An expansible pocket is then
inserted into the hollow
laminated member comprising sodium nitrite, ammonium chloride and water
causing the
member to attach integrally to the metal casing when the head is placed into a
mold and heated.
U.S. Patent 4,877,249 to Thompson discloses a wood golf club head embodying a
laminated upper surface and metallic sole surface having a keel. In order to
reinforce the
laminations and to keep the body from delaminating upon impact with an
unusually hard object,
a bolt is inserted through the crown of the club head where it is connected to
the sole plate at the
keel and tightened to compress the laminations.
U.S. Patent 3,897,066 to Belmont discloses a wooden golf club head having
removably
inserted weight adjustment members. The members are parallel to a central
vertical axis running
from the face section to the rear section of the club head and perpendicular
to the crown to toe
axis. The weight adjustment members may be held in place by the use of
capsules filled with
polyurethane resin, which can also be used to form the faceplate. The capsules
have openings on
a rear surface of the club head with covers to provide access to adjust the-
weight means.
U.S. Patent 2,750,194 to Clark discloses a wooden golf club head with weight
adjustment
means. The golf club head includes a tray member with sides and bottom for
holding the weight
adjustment preferably cast or formed integrally with the heel plate. The heel
plate with attached
weight member is inserted into the head of the golf club via an opening.
U.S: Patent 5,193,311 to Okumoto, et al. discloses a wood type club head body
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comprised primarily of a synthetic resin and a metallic sole plate. The
metallic sole plate has on
its surface for bonding with the head body integrally formed members
comprising a hosel on the
heel side, weights on the toe and rear sides and a beam connecting the weights
and hosel.
Additionally, U.S. Patent 5,516,107 to Okumoto, et al., discloses a golf club
head having an
outer shell, preferably comprised of synthetic resin, and metal weight
member/s located on the
interior of the club head. A foamable material is injected into the hollow
interior of the club to
form the core. Once the foamable material has been injected and the sole plate
is attached, the
club head is heated to cause the foamable material to expand thus holding the
weight member/s
in position in recess/es located in toe, heel and/or back side regions by
pushing the weight
member into the inner surface of the outer shell.
U.S. Patent 4,872,685 to Sun discloses a wood type golf club head wherein a
female unit
is mated with a male unit to form a unitary golf club head. The female unit
comprises the upper
portion of the golf club head and is preferably composed of plastic, alloy, or
wood. The male
unit includes the structural portions of sole plate, a face insert consists of
the striking plate and
weighting elements. The male unit has a substantially greater weight being
preferably composed
of a light metal alloy. The units are mated or held together by bonding and or
mechanical means.
U.S. Patent 5,398,935 to Katayama discloses a wood golf club head having a
striking face
wherein the height of the striking face at a toe end of the golf club head is
nearly equal to or
greater than the height of the striking face at the center of the club head.
U.S. Patent Number 1,780,625 to Mattern discloses a club head with a rear
portion
composed of a light-weight metal such as magnesium. U.S. Patent Number
1,638,916 to
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Butchart discloses a golf club with a balancing member composed of persimmon
or a similar
wood material, and a shell-like body composed of aluminum attached to the
balancing member.
Anderson, U.S. Patent Numbers 5024437, 5094383, 5255918, 5261663 and 5261664
disclose a golf club head having a full body composed of a cast metal material
and a face insert
composed of a hot forged metal material.
Viste, U.S. Patent Number 5,282,624 discloses a golf club head with a cast
metal body
and a forged steel face insert with grooves on the exterior surface and the
interior surface of the
face insert and having a thickness of 3mm.
Rogers, U.S. Patent Number 3,970,236, discloses an iron club head with a
formed metal
face plate insert fusion bonded to a cast iron body.
The Rules of Golf, established and interpreted by the United States Golf
Association
("USGA") and The Royal and Ancient Golf Club of Saint Andrews, set forth
certain
requirements for a golf club head. The requirements for a golf club head are
found in Rule 4 and
Appendix H. A complete description of the Rules of Golf are available on the
USGA web page
at www.usga.org. Although the Rules of Golf do not expressly state specific
parameters for a
golf club face, Rule 4-1 e prohibits the face from having the effect at impact
of a spring with a
golf ball. In 1998, the USGA adopted a test procedure pursuant to Rule 4-1 e
which measures
club face COR. This USGA test procedure, as well as procedures like it, may be
used to measure
club face COR.
Although the prior art has disclosed many variations of multiple material club
heads, the
prior art has failed to provide a multiple material club head with a high
coefficient of restitution
and greater forgiveness for the typical -olfer.
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BRIEF SUMMARY OF THE INVENTION
One aspect of the present invention is a golf club head composed of a metal
face
component having a striking plate insert and light-weight aft body. The golf
club head preferably
has a coefficient of restitution of at least 0.81 under test conditions, such
as those specified by the
USGA. The standard USGA conditions for measuring the coefficient of
restitution is set forth in
the USGA Procedure for Measuring the Velocity Ratio of a Club Head for
Conformance to Rule
4-le, Appendix II. Revision I, August 4,1998 and Revision 0, July 6, 1998,
available from the
USGA.
Yet another aspect of the present invention is a golf club head including a
face component
composed of a metal material and an aft-body composed of a non-metal material.
The face
component has a return portion having an opening and a striking plate insert
covering the
opening. The striking plate portion preferably has a uniform thickness in the
range of 0.010 inch
to 0.250 inch. The return portion has a thickness in the range of 0.010 inch
to 0.200 inch. The
aft body has a crown portion, a sole portion and a ribbon portion. The aft-
body is attached to the
return portion of the face component. The golf club head preferably has a
coefficient of
restitution of 0.81 to 0.94.
Yet another aspect of the present invention is golf club head including a face
component
composed of a metal material and an aft-body composed of a plurality of co-
cured plies of pre-
preg. The face component has a return portion having an opening and a striking
plate insert
covering the opening. The return. portion is composed of a cast metal material
and the striking
plate insert is composed of a forged or formed material. The aft body has a
crown portion, a sole
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portion and a ribbon portion. The aft-body is attached to the return portion
of the face
component. The moment of inertia of the golf club head about the Izz axis
through the center of
gravity is preferably greater than 3000 grams- centimeter squared, and the
moment of inertia
about the Iyy axis through the center of gravity is greater than 1800 grams-
centimeter squared.
Yet another aspect of the present invention is a golf club head having a face
component
composed of a titanium alloy or stainless steel material and an aft body
composed of a plurality
of co-cured plies of pre-preg. The face component has a return portion having
an opening and a
striking plate insert covering the opening. The return portion is composed of
a cast metal
material and the striking plate insert is composed of a forged or formed
material. The striking
plate portion has concentric regions of varying thickness with the thickest
region about the center
of the striking plate portion. The striking plate portion extends from a heel
section of the golf
club head to a toe section of the golf club head and has an aspect ratio no
greater than 1.7. The
return portion extends laterally rearward at least 0.250 inch from a perimeter
of the striking plate
portion. The return portion extends laterally rearward 360 degrees of the
perimeter of the striking
plate portion. The golf club head also has an interior tubing for receiving a
shaft. The interior
tubing engages an upper section of the return portion and a lower section of
the return portion.
The aft body has a thickness ranging from 0.010 inch to 0.100 inch. The aft
body includes a
crown portion, a ribbon portion and a sole portion. The crown portion is
attached to the upper
section of the return portion. The sole portion is attached to the lower
section of the return
portion. A heel end of the ribbon portion is attached to a heel section of the
return portion. A toe
end of the ribbon portion is attached to a toe section of the return portion.
The golf club head has
a hollow interior, a volume ranging from 250 cubic centimeters to 600 cubic
centimeters, a mass
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ranging from 175 grams to 225 grams, and a coefficient of restitution ranging
from 0.81 to 0.94.
Having briefly described the present invention, the above and further objects,
features and
advantages thereof will be recognized by those skilled in the pertinent art
from the following
detailed description of the invention when taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front view of the golf club of the present invention.
FIG. lA is a front view of the golf club of the present invention showing the
measurement for the aspect ratio.
FIG. 2 is a rear view of the golf club head of FIG. 1.
FIG. 3 is toe side view of the golf club head of FIG. 1.
FIG. 4 is a heel side plan view of the golf club head of FIG. 1.
FIG. 5 is a top plan view of'the golf club head of FIG. 1.
FIG. 6 is a bottom view of the golf club head of FIG. 1.
FIG. 7 is an exploded view of the golf club head of the present invention.
FIG. 8 is a top plan view of the golf club head of FIG. 1.
FIG. 8A is a cross-sectional view along line A-A of FIG. 8.
FIG. 8B is an isolated view of circle B of FIG. 8A.
FIG. 9 is an isolated cross-sectional view of the face component overlapping
the aft body.
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FIG. 10 is 'a heel side plan view of a golf club of the present invention
illustrating the Z
axis and X axis.
FIG. 10A is a front plan view of a golf club of the present invention
illustrating the Z axis
and Y axis.
FIG. 11 is a front plan view of a golf club illustrating the test frame
coordinates XT and
YT and transformed head frame coordinates yH and ZH.
FIG. 11A is a toe end view of the golf club illustrating the test frame
coordinate ZT and
transformed head frame coordinates XH and ZH.
FIG. 12 is an isolated view of the interior of an alternative enibodittent of
the face
component of the golf club head of the present invention illustrating the
variatiQns in thickness of
the striking plate portion.
FIG. 12A is an isolated view of the interior of an alternative embodiment of
the face
component of the golf club head of the present invention illustrating the
variations in thickness of
the striking plate portion.
FIG. 13 is an isolated top perspective view of a face component of the golf
club head of
the present invention.
FIG. 13A is an interior view of the face component of FIG. 13.
FIG. 13B is an interior view of the face component of FIG. 13.
FIG. 13C is an exploded view of the face component of FIG. 13.
FIG. 13D is a top plan view of the face component of FIG. 13.
FIG. 13E is a toe side view of the face component of FIG. 13.
FIG. 13F is a heel side view of the face component of FIG. 13.
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FIG. 14 is an isolated top plan view of the aft-body of the golf club head of
the present
invention.
FIG. 14A is an interior view of the aft-body of FIG. 14.
FIG. 14B is a heel side view of the aft-body of FIG. 14.
FIG. 14C is a toe side view of the aft-body of FIG. 14.
FIG. 14D is a bottom plan view of the aft-body of FIG. 14.
FIG. 14E is a rear view of the aft-body of FIG. 14. -
FIG. 14F is an interior view of the aft-body of FIG. 14.
FIG. 14G is an interior view of the aft-body of FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1-8, a golf club is generally designated 40. The golf club
40 has a
golf club head 42 with a hollow interior, not shown. Engaging the club head 42
is a shaft 48 that
has a grip, not shown, at a butt end and is inserted into a hose154 at a tip
end of the shaft 48.
The club head 42 is generally composed of two components, a face component 60,
and an
aft-body 61. The face component 60 has a striking plate insert 72 placed
within an opening 45 of
a return portion 74. The aft-body 61 has a crown portion 62 and a sole portion
64. The club
head 42 may also be partitioned into a heel section 66 nearest the shaft 48, a
toe section 68
opposite the heel section 66, and a rear section 70 opposite the face
component 60.
The face component 60 is generally composed of two pieces of metal, the return
portion
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74 and the striking plate insert 72. The opening 45 is configured for
placement of the striking
plate insert 72 therein. Preferably, the return portion 74 is composed of a
cast metal material and
the striking plate insert 72 is composed of a forged or formed metal material.
More preferably,
the striking plate insert 72 is composed of a forged titanium or stainless
steel material. Such
titanium materials include pure titanium and titanium alloys such as 6-4
titanium alloy, SP-700
titanium alloy (available from Nippon Steel of Tokyo, Japan), DAT 55G titanium
alloy available
from Diado Steel of Tokyo, Japan, Ti 10-2-3 Beta-C titanium alloy available
from RTI
International Metals of Ohio, and the like. Other metals for the striking
plate insert 72 include
other high strength steel alloy metals and amorphous metals. Such steel
materials include 17-
4PH, Custom 450, 455, 465 and 465+ stainless steels, AERMET 100 and AERMET 310
alloy
steels, all available from Carpenter Specialty Alloys, of Pennsylvania, and
C35 maraging steels
available from Allvac of North Carolina. Such amorphous metals include
beryllium based alloys
such as disclosed in U.S. patent 5,288,344, quinary metallic glass alloys such
as disclosed in
U.S. patent Number 5,735,975, and ternary alloys as disclosed in Calculations
of Amorphous-
Forming Composition Range For Ternary Alloy Systems And Analyses Of
Stabilization Of
Amorphous Phase And Amorphous-Forming Ability, Takeuchi and Inoue, Materials
Transactions, Vol. 42, No. 7, p 1435-1444 (2001). An striking plate insert 72
composed of an
amorphous metal is attached through electron beam welding, brazing or press-
fitted for
attachment to the return portion 74.
The return portion 74 may be composed of any of the above-mentioned materials,
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however, it is preferably composed of a cast stainless steel or a cast
titanium alloy such as 6-4
titanium alloy. Further, the return portion 74 may be manufactured through
forging, forming,
machining, casting, powdered metal forming, metal-injection-molding, electro-
chemical milling,
and the like.
FIGS. 13, 13A, 13B, 13C, 13D, 13E and 13F illustrate the face component 60.
The face component 60 has the return portion 74 extending laterally rearward
from the perimeter
of the striking plate insert 72. As shown in FIG.1, the striking plate insert
72 typically has a
plurality of scorelines 75 thereon.
As shown in FIG. 13C, the striking plate insert 72 is welded to the return
portion 74 of
the face component 60. A plurality of tabs 47, preferably three, align the
striking plate insert 72
for the welding process. Alternatively, the striking plate insert 72 is press-
fitted into the opening
45, or fusion bonded to the return portion 74.
In a preferred embodiment, the return portion 74 generally includes an upper
lateral
section 76, a lower lateral section 78, a heel lateral section 80 and a toe
lateral section 82. Thus,
the return 74 preferably ericircles the striking plate insert 72 a fu11360
degrees. However, those
skilled in the pertinent art will recognize that the return portion 74 may
only encompass a partial
section of the striking plate insert 72, such as 270 degrees or 180
degrees;.and may also be
discontinuous.
The upper lateral section 76 extends rearward, towards the aft-body 61, a
predetermined
distance, d, to engage the crown 62. In a preferred embodiment, the
predetermined distance
ranges from 0.2 inch to 1.0 inch, more preferably 0.40 inch to 0.75 inch, and
most preferably
0.68 inch, as measured from the perimeter 73 of the striking plate insert 72
to the rearward edge
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of the upper lateral section 76. In a preferred embodiment, the upper lateral
section 76
has a general curvature from the heel section 66 to the toe section 68. The
upper lateral
section 76 llas a length from the perimeter 73 of the striking plate insert 72
that is
preferably a minimal length near the center of the striking plate insert 72,
and increases
toward the toe section 68 and the heel section 66. However, those skilled in
the relevant
art will recognize that the minimal length may be at the heel section 66 or
the toe
section 68.
The present invention has the face component 60 engage the crown 62 along a
substantially horizontal plane. The crown 62 has a crown undercut portion 62a,
which is
placed under the return portion 74. Such an engagement enhances the
flexibility of the
striking plate insert 72 allowing for a greater coefficient of restitution.
The crown 62
and the upper lateral section 76 are attached to each other as further
explained below.
The heel lateral section 80 is substantially perpendicular to the striking
plate
insert 72, and the heel lateral section 80 covers the hosel 54 before engaging
an
optional ribbon section 90 and a bottom section 91 of the sole portion 64 of
the aft-
body 61. The heel lateral section 80 is attached to the sole 64, both the
ribbon 90 and
the bottom section 91, as explained in greater detail below. The heel lateral
section
80 extends inward a distance, d"', from the perimeter 73 a distance of 0.250
inch to
1.50 inches, more preferably 0.50 inch to 1.0 inch, and most preferably 0.950
inch.
The heel lateral section 80 preferably has a general curvature at its edge.
At the other end of the face component 60 is the toe lateral section 82. The
toe
lateral section 82 is attached to the sole 64, both the ribbon 90 and the
bottom section
91, as explained in greater detail below. The toe lateral section 82 extends
inward a
distance, d", from the perimeter 73 a distance of 0.250 inch to 1.50 inches,
more
preferably 0.75 inch to 1.30 inch, and
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most preferably 1.20 inch. The toe lateral section 82 preferably has a general
curvature at its
edge.
The lower lateral section 78 extends inward, toward the aft-body 61, a
predetermined
distance, d', to engage the sole 64. In a preferred embodiment, the
predetermined distance
ranges from 0.2 inch to 1.25 inches, more preferably 0.50 inch to 1.10 inch,
and most
preferably 0.9 inch, as measured from the perimeter 73 of the striking plate
insert 72 to the
edge of the lower lateral section 78. In a preferred embodiment, the lower
lateral section 78
has a general curvature from the heel section 66 to the toe section 68. The
lower lateral
section 78 has a length from the perimeter 73 of the striking plate insert 72
that is preferably a
minimal length near the center of the striking plate insert 72, and increases
toward the toe
section 68 and the heel section 66. However, those skilled in the relevant art
will recognize
that the minimal length may be at the heel section 66 or the toe section 68.
The sole portion 64 has a sole undercut 64a for placement under the return
portion 74.
The sole 64 and the lower lateral section 78, the heel lateral section 80 and
the toe lateral
section 82 are attached to each other as explained in greater detail below.
The aft-body 61 is preferably composed of a non-metal material, preferably a
composite material such as continuous fiber pre-preg material (including
thermosetting
materials or a thermoplastic materials for the resin). Other materials for the
aft-body 61
include other thermosetting materials or other thermoplastic materials such as
injectable
plastics. The aft-body 61 is preferably manufactured through bladder-molding,
resin transfer
molding, resin infusion, injection molding, compression molding, or a similar
process.
In an attachment process, the face component 60, with an adhesive on the
interior
surface
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CA 02385023 2002-05-06
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of the return portion 74, is placed within a mold with a preform of the aft-
body 61 for bladder
molding. The return portion 74 is placed and fitted into the undercut portions
62a and 64a. Also,
the adhesive may be placed on the undercut portions 62a and 64a. Such
adhesives include
thermosetting adhesives in a liquid or a film medium. A preferred adhesive is
a two part liquid
epoxy sold by 3M of Minneapolis Minnesota under the brand names DP420NS and
DP460NS.
Other alternative adhesives include modified acrylic liquid adhesives such as
DP810NS, also
sold by the 3M company. Alternatively, foam tapes such as Hysol Synspan may be
utilized with
the present invention. During this attachment process, a bladder is placed
within the hollow
interior of the preform and face component 60, and is pressurized within the
mold, which is also
subject to heating. The co-molding process secures the aft-body 61 to the face
component 60.
In another attachment process, the aft-body 61 is first bladder molded and
then is bonded to the
face component 60 using an adhesive, or mechanically secured to the return
portion 74.
As shown in FIG. 9, the return portion 74 overlaps the undercut portions 62a
and 64a a
distance Lo, which preferably ranges from 0.25 inch to 1.00 inch, more
preferably ranges from
0.40 inch to 0.70 inch, and is most preferably 0.40 inch. An annular aap 170
is created between
an edge 190 of the crown portion 62 and the sole portion 64, and an edge 195
of the return
portion 74. The annular gap 170 has a distance Lg that preferably ranges; from
0.020 inch to
0.100 inch, more preferably from 0.050 inch to 0.070 inch, and is most
preferably 0.060 inch. A
projection 175 from an upper surface of the undercut portions 62a and 64a
establishes a
minimum bond thickness between the interior surface of the return portion 74
and the upper
surface of the undercut portions 62a and 64a. The bond thickness preferably
ranges from 0.002
inch to 0.100 inch, more preferably ranges from 0.005 inch to 0.040 inch, and
is most preferably
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CA 02385023 2008-11-24
0.0 15 inch. A liquid adhesive preferably secures the aft body 61 to the face
component 60. A
leading edge 180 of the undercut portions 62a and 64a may be sealed to prevent
the liquid
adhesive from entering the hollow interior 46.
FIGS. 14, 14A, 14B, 14C 14D, 14E, 14F and 14G illustrate a preferred
embodiment of
the aft-body 61. The crown portion 62 of the aft-body 61 is generally convex
toward the sole
portion 64, and engages the ribbon section 90 of sole portion 64 outside of
the engagement with
the face member 60. Those skilled in the pertinent art will recognize that the
sole portion 64 may
not have a ribbon section 90. The crown portion 62 preferably has a thickness
in the range of
0.010 to 0.100 inch, more preferably in the range of 0.025 inch to 0.070 inch,
even more
preferably in the range of 0.028 inch to 0.040 inch, and most preferably has a
thickness of 0.033
inch. The sole portion 64, including the bottom section 91 and the optional
ribbon section 90
which is substantially perpendicular to the bottom section 91, preferably has
a thickness in the
range of 0.010 to 0.100 inch, more preferably in the range of 0.025 inch to
0.070 inch, even
more preferably in the range of 0.028 inch to 0.040 inch, and most preferably
has a thickness of
0.033 inch.
In a preferred embodiment, the aft-body is composed of a plurality of plies of
pre-preg,
typically six or seven plies (preferably ranging from three plies to twenty
plies) such as disclosed
in U.S. Patent Number 6,248,025, entitled Composite Golf Head And Method Of
Manufacturing. The bottom section 91 is generally convex toward the crown
portion 62. The
sole portion 64 of the aft-body 61 optionally has a recess 93 for attachment
of a sole plate 95
thereto. The sole plate is preferably attached with a pressure sensitive
adhesive such as a
polyethylene foam acrylic adhesive sold by the 3M company. The sole plate 95
is preferably
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CA 02385023 2008-11-24
composed of a light weight metal such as aluminum, titanium or titanium alloy.
Alternatively,
the sole plate 95 is composed of a durable plastic material. The sole plate 95
may have graphics
thereon for designation of the brand of club and loft. The sole plate 95 may
alternatively be
welded to the lower lateral section 78 of the return portion 74.
FIG. 8A illustrates the hollow interior 46 of the club head 42 of the present
invention
through a cross-section of the golf club head 42 of FIG. 8. As shown in FIGS.
8A and 8B, the
striking plate insert 72 is preferably attached to the return portion 74 by
welding, illustrated by
weld materia149. The striking plate insert 72 is preferably attached to the
return portion 74 a
distance of greater than 0.25 inch from a leading edge of the golf club head
42. Those skilled in
the pertinent art will recognize that the striking plate insert 72 may also be
press-fitted into the
opening 45 for attachment to the return portion 74, or fusion bonded, or other
well-known
methods.
As shown in FIG. 7, a weighting member 122 is preferably disposed within the
hollow
interior 46 of the club head 42. In a preferred embodiment, the weighting
member 122 is
disposed on the interior surface of the ribbon section 90 of the sole portion
64 in order to increase
the moment of inertia and control the center of gravity of the golf club head
42. However, those
skilled in the pertinent art will recognize that the weighting member 122, and
additional
weighting members 122 may be placed in other locations of the club head 42 in
order to
influence the center of gravity, moment of inertia, or other inherent
properties of the golf club
head 42. The weighting member 122 is preferably tungsten loaded film, tungsten
doped
polymers, or similar weighting mechanisms such as described in U.S. Patent
CA 02385023 2008-11-24
Number 6,386,990 issued on May 14, 2002, entitled A Composite Golf Club Head
With An
Integral Weight Strip. Those skilled in the pertinent an will recognize that
other high density
materials may be utilized as an optional weighting member without departing
from the scope
and spirit of the present invention.
In a preferred embodiment, the weight member 122 is composed of three
weighting
components 122a, 122b and 122c, which are embedded within the plies of pre-
preg of the ribbon
section 90 of the sole portion 64 of the aft-body 61. A heel weight component
122a, a center
weight component 122b and a toe weight component 122c are all disposed within
the plies of
pre-preg that compose the ribbon section 90. Individually, each of the weight
components 122a-
c has a mass ranging from 10 grams to 30 grams, preferably from 14 grams to 25
grams, and
more preferably from 15 grams to 20 grams. Each of the weight components 122a-
c has a
density ranging from 5 grams per cubic centimeters to 20 grams per cubic
centimeters, more
preferably from 7 grams per cubic centimeters to 12 grams per cubic
centimeters, and most
preferably 8.0 grams per cubic centimeters.
Each of the weight components 122a-c is preferably composed of a polymer
material
integrated with a metal material. The metal material is preferably selected
from copper, tungsten,
steel, aluminum, tin, silver, gold, platinum, or the like. A preferred metal
is tungsten due to its
high density. The polymer material is a thermoplastic or thermosetting polymer
material. A
preferred polymer material is polyurethane, epoxy, nylon, polyester, or
similar materials. A most
preferred polymer material is a thermoplastic polyurethane. A preferred weight
component 122a,
122b or 122c is an injection molded thermoplastic polyurethane integrated with
tungsten to have
a density of 8.0 grams per cubic centimeters. In a preferred embodiment, each
of the weight
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components 122a=c are composed of from 50 to 95 volume percent polyurethane
and from 50 to
volume percent tungsten. Also, in a preferred embodiment, each of the weight
components
122a-c are composed of from 10 to 25 weight percent polyurethane and from 90
to 75 weight
percent tungsten.
5 Preferably, the weight components 122a-c extend from approximately the heel
section 66
of the striking plate insert 72 through the rear section 70 to the toe section
68 of the striking plate
portion 72. However, the weight components 122a-c may only extend along the
rear section 70
of the ribbon section 90, the heel section 66 of the ribbon section 90, the
toe section 68 of the
ribbon section 90, or any combination thereof. Also, the weight components
122a-c may be
positioned parallel to each other as opposed to being positioned in series.
Those slcilled in the
pertinent art will recognize that other weighting materials may be utilized
for the weight
components 122a-c without departing from the scope and spirit of the present
invention. The
placement of the weighting components 122a-c allows for the moment of inertia
of the golf club
head 40 to be optimized.
Also shown in FIG. 7 is the hosel 54, which is disposed within the hollow
interior 46, and
is located as a part of the face component 60. The hosel 54 may be composed of
a similar
material to the face component 60, and is preferably secured to the face
component 60 through
welding or the like. The hosel 54 may also be formed with the formation of the
face component
60. Additionally, the hosel may be composed of a non-similar material that is
light weight and
secured using bonding or other mechanical securing techniques. A hollow
interior of the hosel
54 is defined by a hosel wall 120 that forms a tapering tube from the aperture
59 to the sole
potion 64. In a preferred embodiment, the hosel wall 120 does not engage the
heel lateral
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80 thereby leaving a void 115 between the hosel wall 120 and the heel lateral
section 80. The
shaft 48 is disposed within a hosel insert 121 that is disposed within the
hose154. Such a hosel
insert 121 and hose154 are described in U.S. Patent Number 6,352,482 issued on
March 5,
2002, entitled Golf Club With Hosel Liner. Further, the hosel 54 is preferably
located rearward
from the striking plate portion 72 in order to allow for compliance of the
striking plate insert 72
during impact with a golf ball. In one embodiment, the hose154 is disposed
0.125 inch rearward
from the striking plate insert 72.
FIG. 12 illustrates an alternative embodiment of the face component 60 of the
golf club
head 42 of the present invention. FIG. 12 illustrates a face component 60
having variation in the
thickness of the striking plate insert 72. In a preferred embodiment, the
striking plate insert 72
has uniform thickness that ranges from 0.040 inch to 0.200 inch, and is
preferably 0.111 inch for
a titanium alloy striking plate insert 72 and 0.085 inch for a stainless steel
striking plate insert
72. In the alternative embodiment of FIG. 12, the striking plate insert 72 is
partitioned into
elliptical regions, each having a different thickness. In this embodiment, a
central elliptical
region 102 preferably has the greatest thickness that ranges from 0.120 inch
to 0.090 inch,
preferably from 0.115 inch to 0.100 inch, and is most preferably 0.105 inch.
The central
elliptical region 102 preferably has a uniform thickness. A first concentric
region 104 preferably
has the next greatest thickness that ranges from 0.110 inch to 0.076 inch,
preferably from 0.100
inch to 0.086 inch, and is most preferably 0.088 inch. The first concentric
region 104 preferably
has a thickness that transitions from the first concentric region 104
thickness to the periphery
region 110 thickness. A periphery region 110 preferably has the next greatest
thickness that
ranges from 0.082 inch to
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0.062 inch, and is most preferably 0.072 inch. The variation in the thickness
of the striking plate
insert 72 allows for the greatest thickness to be localized in the center 111
of the striking plate
insert 72 thereby maintaining the flexibility of the striking plate insert 72
which corresponds to
less energy loss to a golf ball and a greater coefficient of restitution
without reducing the
durability of the striking plate insert 72.
FIG. 12A illustrates yet another alternative embodiment for the face component
60. In
this embodiment, the striking plate insert 72, has an central elliptical
region 102 which preferably
has the greatest thickness that ranges from 0.120 inch to 0.090 inch,
preferably from 0.115 inch
to 0.100 inch, and is most preferably 0.105 inch. The central elliptical
region 102 preferably has a
uniform thickness. A first concentric region 104 preferably has the next
greatest thickness that
ranges from 0.110 inch to 0.090 inch, preferably from 0.104 inch to 0.094
inch, and is most
preferably 0.098 inch. A second concentric region 106 preferably has the next
greatest thickness
that ranges from 0.100 inch to 0.080 inch, preferably from 0.095 inch to 0.085
inch, and is most
preferably 0.088 inch. A third concentric region 108 preferably has the next
greatest thickness
that ranges from 0.090 inch to 0.070 inch, preferably from 0.083 inch to 0.073
inch, and is most
preferably 0.080 inch. The concentric regions preferably each have a thickness
that transitions
from one adjacent region to another. A periphery region 110 preferably has the
next greatest
thiclrness that rangps from 0.072 inch to 0.061 inch. The periphery region
includes toe periphery
region 110a and heel periphery region I l Ob.
The return portion 74 of the face component 60 is preferably cast from molten
metal in a
method such as the well-known lost-wax casting method. The metal for casting
is preferably
titanium or a titanium alloy such as 6-4 titanium alloy, alpha-beta titanium
alloy or beta titanium
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CA 02385023 2002-05-06
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alloy for forging, and 6-4 titanium for casting. Also, the return portion 74
may be composed of
17-4 steel alloy. Additional methods for manufacturing the return portion 74
of the face
component 60 include fonning the return portion 74 from a flat sheet of metal,
super-plastic
forming the return portion 74 from a flat sheet of metal, machining the return
portion 74 from a
solid block of metal, electrochemical milling the return portion 74 from a
forged pre-form, and
like manufacturing methods.
The present invention is directed at a golf club head that has a high
coefficient of
restitution thereby enabling for greater distance of a golf ball hit with the
golf club head of the
present invention. The coefficient of restitution (also referred to herein as
"COR") is determined
by the following equation:
e EV__v,
U, -U.
wherein U, is the club head velocity prior to impact; U2 is the golf ball
velocity prior to impact
which is zero; vl is the club head velocity just after separation of the golf
ball from the face of the
club head; v, is the golf ball velocity just after separation of the golf ball
from the fuc;, of the club
head; and e is the coefficient of restitution between the golf ball and the
club face.
The values of e are limited between zero and 1.0 for systems with no energy
addition.
The coefficient of restitution, e, for a material such as a soft clay or putty
would be near zero,
while for a perfectly elastic material, where no energy is lost as a result of
deformation, the value
of e would be 1Ø The present invention provides a club head having a
coefficient of restitution
preferably ranging from 0.81 to 0.94, as measured under conventional test
conditions.
The coefficient of restitution of the club head 42 of the present invention
under standard
CA 02385023 2002-05-06
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USGA test conditions with a given ball preferably ranges from approximately
0.80 to 0.94, more
preferably ranges from 0.82 to 0.883 and is most preferably 0.83.
The volume of the club head 42 of the present invention ranges from 250 cubic
centimeters to 600 cubic centimeters, and more preferably ranges from 300
cubic centimeters to
510 cubic centimeters, even more preferably 345 cubic centimeters to 395 cubic
centimeters, and
most preferably 350 cubic centimeters. The volume of the golf club head 42
will also vary
between fairway woods (preferably ranging from 3-woods to eleven woods) with
smaller
volumes and drivers, which will have larger volumes than the fairway woods.
The mass of the club head 42 of the present invention preferably ranges from
165 grams
to 300 grams, more preferably ranges from 175 grams to 205 grams, and most
preferably from
190 grams to 200 grams. Preferably, the face component 60 has a mass ranging
from 50 grams
to 110 grams, more preferably ranging from 65 grams to 95 grams, yet more
preferably from 70
grams to 90 grams, and most preferably 78 grams. The aft-body 61 (without
weighting) has a
mass preferably ranging from 10 grams to 60 grams, more preferably from 15
grams to 50 grams,
and most preferably 35 grams to 40 grams. The weighting member 122 (preferably
composed of
three separate weighting members 122a, 122b and 122c) has a mass preferably
ranging from 30
grams to 120 grams, more preferably from 50 grams to 80 grams, and most
preferably 60 grams.
The interior hosel 54 preferably a mass preferably ranging from 3 graazns to
20 grams, more
preferably from 5 grams to 15 grams, and most preferably 12 grams. The sole
plate 95 preferably
a mass preferably ranging from 3 grams to 20 grams, more preferably from 5
grams to 15 grams,
and most preferably 8 grams. Additionally, epoxy, or other like flowable
materials, in an
amount ranging from 0.5 grams to 5 grams, may be injected into the hollow
interior 46 of the
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CA 02385023 2008-11-24
club head 42 for selective weighting thereof.
The depth of the club head 42 from the striking plate insert 72 to the rear
section of the
crown portion 62 preferably ranges from 3.0 inches to 4.5 inches, and is most
preferably 3.75
inches. The height, H, of the club head 42, as measured while in address
position, preferably
ranges from 2.0 inches to 3.5 inches, and is most preferably 2.50 inches or
2.9 inches. The
width, W, of the club head 42 from the toe section 68 to the heel section 66
preferably ranges
from 4.0 inches to 5.0 inches, and more preferably 4.7 inches.
FIGS. 10 and I OA illustrate the axes of inertia through the center of gravity
of the golf
club head. The axes of inertia are designated X, Y and Z. The X axis extends
from the striking
plate portion 72 through the center of gravity, CG, and to the rear of the
golf club head 42. The
Y axis extends from the toe section 68 of the golf club head 42 through the
center of gravity,
CG, and to the heel section 66 of the golf club head 42. The Z axis extends
from the crown
portion 62 through the center of gravity, CG, and to the sole portion 64.
As defined in Golf Club Design, Fitting, Alteration & Repair, 4th Edition, by
Ralph
Maltby, the center of gravity, or center of mass, of the golf club head is a
point inside of the club
head determined by the vertical intersection of two or more points where the
club head balances
when suspended. A more thorough explanation of this definition of the center
of gravity is
provided in Golf Club Design, Fitting, Alteration & Repair.
The center of gravity and the moment of inertia of a golf club head 42 are
preferably
measured using a test frame (XT, YT, ZT), and then transformed to a head frame
(XH, YH, ZH), as
shown in FIGS. 11 and 11A. The center of gravity of a golf club head may be
obtained using a
center of gravity table having two weight scales thereon, as disclosed in U.S.
Patent Number
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CA 02385023 2008-11-24
6,607,452 issued August 19, 2003, entitled High Moment Of Inertia Composite
Golf Club. If a
shaft is present, it is removed and replaced with a hosel cube that has a
multitude of faces
normal to the axes of the golf club head. Given the weight of the golf club
head, the scales allow
one to determine the weight distribution of the golf club head when the golf
club head is placed
on both scales simultaneously and weighed along a particular direction, the X,
Y or Z direction.
TABLE ONE
Head Volume Mass Head Discreet Mass COR RP Mat SP-mat
Ex. 1 35 cc 198 g 35 g 0.825 17-4 465
TABLE TWO
Head lxx Iyy Izz Ixy Ixz Iyz
Ex.1 2315 2236 3565 196 -37 121
Table One lists the volume of a golf club head 42, the weight of the head
without weight
members, the mass of the weight member 122, the coefficient of restitution
(COR) on a scale
from 0 to 1 using the USGA standard test, the material of the return portion
74 (RP-MAT), and
the material for the striking plate insert 72 (SP-MAT). Example 1 is a 350
cubic centimeter golf
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club head 42. The return portion is composed of a cast 17-4 steel alloy
material, and the striking
plate insert 72 is composed of 465 steel alloy material. The aft body 61 is
composed of a
plurality of co-cured plies of pre-preg.
Table Two lists the moment of inertia for the exemplary golf club head 42 of
Table One.
The moment of inertia is given in grams-centimeter squared ("g-cm2"). For
example 1, the
center of gravity is located at 0.458 inch iiz the X direction, 0.672 inch in
the Y direction, and
1.191 inches in the Z direction.
In general, the moment of inertia, Izz, aboiit the Z axis for the golf club
head 42 of the
present invention will range from 2800g-cm2 to 5000g-cmZ, preferably from
3000g-cm2 to
4500g-cm2 , and most preferably from 3200g-cm2 to 4000g-cm2 . The moment of
inertia, Iyy,
about the Y axis for the golf club head 42 of the present invention will range
from 1500g-cm2 to
2750g-cm2, preferably from 2000g-cmZ to 2400g-cm2 , and most preferably from
2100g-cm2 to
2300g-cmz.
From the foregoing it is believed that those skilled in the pertinent art will
recognize the
meritorious advancement of this invention and will readily understand that
while the present
invention has been described in association with a preferred embodiment
thereof, and other
embodiments illustrated in the accompanying drawings, numerous changos,
modifications and
substitutions of equivalents may be made therein without departing from the
spirit and scope of
this invention which is intended to be unlimited by the foregoing except as
may appear in the
following appended claims. Therefore, the embodiments of the invention in
which an exclusive
property or privilege is claimed are defmed in the following appended claims.
29
