U.S. patent application number 13/015234 was filed with the patent office on 2011-05-26 for face structure for a golf club head.
This patent application is currently assigned to CALLAWAY GOLF COMPANY. Invention is credited to STEVEN M. EHLERS, MATTHEW J. ERICKSON, JOHN B. KOSMATKA, ANTHONY V. NIGRO.
Application Number | 20110124435 13/015234 |
Document ID | / |
Family ID | 40584874 |
Filed Date | 2011-05-26 |
United States Patent
Application |
20110124435 |
Kind Code |
A1 |
EHLERS; STEVEN M. ; et
al. |
May 26, 2011 |
FACE STRUCTURE FOR A GOLF CLUB HEAD
Abstract
A golf club head having a multiple material face is disclosed
herein. The golf club head has a coefficient of restitution value
greater than 0.83 and a characteristic time value of less than 257
milliseconds. The golf club head is preferably composed of a
titanium alloy with a polymer layer disposed over a titanium alloy
front wall. A preferred polymer is a polyurethane polymer.
Inventors: |
EHLERS; STEVEN M.; (POWAY,
CA) ; KOSMATKA; JOHN B.; (ENCINITAS, CA) ;
NIGRO; ANTHONY V.; (OCEANSIDE, CA) ; ERICKSON;
MATTHEW J.; (SAN DIEGO, CA) |
Assignee: |
CALLAWAY GOLF COMPANY
CARLSBAD
CA
|
Family ID: |
40584874 |
Appl. No.: |
13/015234 |
Filed: |
January 27, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12686208 |
Jan 12, 2010 |
7878922 |
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13015234 |
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12416825 |
Apr 1, 2009 |
7645201 |
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12686208 |
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11209244 |
Aug 22, 2005 |
7527565 |
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12416825 |
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10249715 |
May 2, 2003 |
6932716 |
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11209244 |
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10063680 |
May 7, 2002 |
6607451 |
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10249715 |
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09551284 |
Apr 18, 2000 |
6390932 |
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10063680 |
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Current U.S.
Class: |
473/345 ;
473/350 |
Current CPC
Class: |
A63B 53/042 20200801;
A63B 2209/00 20130101; A63B 53/0412 20200801; A63B 53/0462
20200801; A63B 2209/10 20130101; C08L 75/04 20130101; A63B 53/0437
20200801; A63B 53/0466 20130101; A63B 53/0408 20200801; A63B
53/0416 20200801; C08G 18/10 20130101; C08G 18/10 20130101; C08G
18/3206 20130101 |
Class at
Publication: |
473/345 ;
473/350 |
International
Class: |
A63B 53/04 20060101
A63B053/04 |
Claims
1. A wood-type golf club head comprising: a body comprising a
crown, a sole and a front wall, the body having a hollow interior,
the body composed of a titanium alloy material, the body having a
volume ranging from 300 cubic centimeters to 450 cubic centimeters;
wherein a face of the golf club head has an aspect ratio greater
than 0.575; wherein the golf club head has a width extending from a
toe end to a heel end ranging from 4.0 inches to 5.0 inches;
wherein the golf club head has a height extending from the sole to
the crown ranging from 2.0 inches to 3.5 inches; wherein the golf
club head has a coefficient of restitution value ranging from 0.835
to 0.855 and a characteristic time value of less than 257
milliseconds under the standard USGA Pendulum Test.
2. The wood-type golf club head according to claim 1 wherein the
front wall comprises a non-metal layer disposed on an exterior
surface of a metal face wall, the non-metal layer having a
thickness ranging from 0.010 inch to 0.250 inch.
3. The wood-type golf club head according to claim 2 wherein the
non-metal layer is composed of a material selected from the group
consisting of thermoplastic polyurethane, polyether block
copolymer, ionomer, nylon, polyamide and polypropylene.
4. The wood-type golf club head according to claim 2 wherein the
non-metal layer has a thickness ranging from 0.080 inch to 0.120
inch.
5. The wood-type golf club head according to claim 1 wherein the
golf club head has a moment of inertia, Izz, about the Z axis
through the center of gravity of the golf club head that ranges
from 2700 g-cm.sup.2 to 4000 g-cm.sup.2.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation application of
U.S. patent application Ser. No. 12/686,208, filed on Jan. 12,
2010, which is a continuation application of U.S. patent
application Ser. No. 12/416,825, filed on Apr. 1, 2009, now U.S.
Pat. No. 7,645,201, which is continuation application of U.S.
patent application Ser. No. 11/209,244, filed on Aug. 22, 2005, now
U.S. Pat. No. 7,527,565, which is a continuation-in-part
application of U.S. patent application Ser. No. 10/249,715, filed
on May 2, 2003, now U.S. Pat. No. 6,932,716, which is a
continuation-in-part application of U.S. patent application Ser.
No. 10/063,680, filed on May 7, 2002, now U.S. Pat. No. 6,607,451,
which is a continuation application of U.S. patent application Ser.
No. 09/551,284, filed on Apr. 18, 2000, now U.S. Pat. No.
6,390,932.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a method and apparatus for
forming a face structure for a golf club head. More specifically,
the present invention relates to a method and apparatus for forming
a face structure composed of an interconnected reinforcement piece
and a polymer material.
[0005] 2. Description of the Related Art
[0006] Technical innovation in the material, construction and
performance of golf clubs has resulted in a variety of new
products. The advent of metals as a structural material has largely
replaced natural wood for wood-type golf club heads, and is but one
example of this technical innovation resulting in a major change in
the golf industry. In conjunction with such major changes are
smaller scale refinements to likewise achieve dramatic results in
golf club performance. For example, the metals comprising the
structural elements of a golf club head have distinct requirements
according to location in the golf club head. A sole or bottom
section of the golf club head should be capable of withstanding
high frictional forces for contacting the ground. A crown or top
section should be lightweight to maintain a low center of gravity.
A front or face of the golf club head should exhibit high strength
and durability to withstand repeated impact with a golf ball. While
various metals and composites are known for use in the face,
several problems arise from the use of traditional face structure
and materials. In addition, material interaction of the golf club
head and the golf ball during impact is an important factor for
performance of the golf club.
[0007] The golf ball is typically composed of a core-shell
arrangement with a thin polymer shell, or cover material such as
ionomers, surrounding a rubber-like core. These polymeric materials
exhibit compression and shear, stiffness and strength properties
dependent upon strain (load), input frequency (time dependency of
small linear strain), strain rate (time rate of loading including
large nonlinear strains), and temperature. The compression and
shear stiffness properties of polymeric materials are measured and
classified in terms of a storage moduli (E', G') and a loss moduli
(E'', G''), respectively. The storage moduli (E', G') represent the
amount of compression and shear energy, respectively, stored during
a complete loading cycle. For quasi-static loading, it is
equivalent to the well known Young's modulus (E'=E) and shear
modulus (G'=G=E/(2(1+v)), where (v) is the material Poisson ratio.
For most polymers, the storage modulus increases significantly with
strain, input frequency, and strain rate. For example, typical
storage moduli for golf balls at low speed impacts, in the
temperature range (50-100.degree. F.), are E'.sub.ball=450-6,000
lb/in.sup.2 and G'.sub.ball=150-2,000 lb/in.sup.2. During
high-speed impacts, in the temperature range (50-100.degree. F.),
the typical storage moduli are E'.sub.ball=9,000-50,000 lb/in.sup.2
and G'.sub.ball=3,000-16,500 lb/in.sup.2. The low speed impact
represents a putting stroke or a soft pitch shot, while the
high-speed impact represents a golf swing with an iron-type or a
wood-type golf club head.
[0008] The loss moduli (E'', G'') represent the amount of
compression and shear energy, respectively, dissipated during a
cycle. For most polymers, the loss moduli also increase
significantly with strain, input frequency, and strain rate, but
the rate of increase can be very different than the aforementioned
storage moduli. Finally, the magnitude of the loss moduli at a
given strain, strain rate, frequency, or temperature typically vary
from 0.005-2.0 times that of the storage moduli.
[0009] A loss (or damping) factor (.eta..sub.E, .eta..sub.G) or
loss angle (.delta..sub.E, .delta..sub.G) for compression and shear
are commonly defined as the ratio of the corresponding moduli;
.eta. E = Tan .delta. E = E '' E ' , .eta. G = Tan .delta. G = G ''
G ' . ##EQU00001##
[0010] These loss factors are an important measure of the damping
capability (energy loss mechanisms) of the material. For most
ball-type materials, (.eta..sub.E.apprxeq..eta..sub.G) and
magnitudes fall in the range of 0.005 (low energy loss) to 2.0
(high-energy losses), where magnitudes clearly depend upon polymer
composition, strain, input frequency, strain rate, and temperature.
As a comparison, the loss factors (energy loss mechanisms) in a
metallic face of a golf club head are on the order of 10-100 times
smaller than that of a golf ball. For most elastomeric polymer
materials operating below the glass transition region, the Poisson
ratio is fairly constant with (v=0.4-0.5), while for stiff polymers
acting at or above the glass transition region (v=0.3-0.33).
[0011] Thus, during impact of the golf ball with the golf club
head, a significant portion of impact energy is lost as a result of
the large deformations (0.05 to 0.50 inches) and deformation rates
of the high damped golf ball materials, as opposed to the small
deformations of the low damped metallic club face (0.025 to 0.050
inches) materials. A larger portion of this impact energy is lost
in the golf ball because the magnitude of the deformation, the
deformation rate, and energy loss mechanisms are greater for the
golf ball than the face of the golf club head.
[0012] Application of hard polymers to the face of the golf club
head represents a traditional structure of natural wood golf club
heads, where a hard insert material centrally located in the face
of the golf club and requiring an exacting fit between two or more
distinct elements. The hard insert must be manufactured to a close
tolerance to fit within a recess in the face of the golf club, and
high surface hardness is less efficient in transferring energy to
the golf ball during impact with the golf club. A homogeneous face
structure is simpler to manufacture but is limited to the inherent
material properties of the single material comprising the face
structure. The present invention achieves a more efficient energy
transfer during impact while maintaining a simple construction.
[0013] The use of a polymer coating or layer on the face of a metal
driver has been shown to increase durability and the coefficient of
restitution ("COR") of the driver through the compliance of the
polymer layer. However, when a golf ball impacts the face at angles
that are not normal to face, such as the case with lofted drivers,
shear deformation of the polymer coating introduces energy losses
that reduce or eliminate the COR benefit provided by the polymer
coating.
[0014] The United States Golf Association ("USGA") has set forth a
test for determining the flexibility of a golf club head. The test
procedure is available at www.USGA.org under Procedure For
Measuring The Flexibility Of A Golf Clubhead. The test uses a
pendulum testing apparatus to determine the characteristic time
("CT") between a clubhead and a pendulum during impact. In order to
be in conformity with the Rule of Golf as set forth and interpreted
by the USGA, the CT must not be greater than 239 milliseconds plus
a tolerance of 18 milliseconds for a total of 257 milliseconds.
U.S. Pat. No. 6,505,498 and U.S. Patent Publication Number
2004/0182131 each disclose a pendulum testing apparatus which may
be used to determine the CT of a clubhead.
[0015] The CT test replaces a coefficient of restitution ("COR")
test that was previously used by the USGA to render decisions on
the conformity or non-conformity of golf club drivers. The COR test
had a limit of 0.83.
BRIEF SUMMARY OF THE INVENTION
[0016] The present invention provides a wood-type golf club head
that has a COR greater than or equal to 0.83 and a CT less than or
equal to 257 milliseconds.
[0017] One aspect of the present invention is a wood-type golf club
head with a polymer layer disposed on the front wall of a body of
the wood-type golf club head. The polymer layer preferably
comprises a reinforcement structure and a polymer material. The
wood-type golf club head that has a COR greater than or equal to
0.83 and a CT less than or equal to 250 milliseconds.
[0018] Another aspect of the present invention is a golf club head
comprising a body and a polymer layer. The body comprises a crown,
a sole and a front wall. The body has a hollow interior. The body
preferably has a volume ranging from 300 cubic centimeters to 500
cubic centimeters. The body is preferably composed of a titanium
alloy material. The front wall has a recess having a depth ranging
from 0.040 inch to 0.250 inch. The polymer layer is disposed within
the recess of the front wall. The polymer layer comprises a polymer
material with an integrated reinforcement structure composed of
interconnected hexagonal cells. Each hexagonal cell has a cell size
of 0.0625 inch to 0.100 inch. The polymer layer has a thickness
ranging from 0.040 inch to 0.250 inch. The golf club head has a
moment of inertia, Izz, about the Z axis of the center of gravity
of the golf club head ranging from 2700 g-cm.sup.2 to 4000
g-cm.sup.2. The golf club head has a coefficient of restitution
value greater than or equal to 0.83 and a characteristic time value
of less than 257 milliseconds.
[0019] 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
[0020] FIG. 1 is a front view of a wood-type golf club head with a
matrix layer.
[0021] FIG. 1A is a front view of a wood-type golf club head with
an alternative matrix layer.
[0022] FIG. 1B is a front view of a wood-type golf club head with
an alternative matrix layer.
[0023] FIG. 2 is a front view of a wood-type golf club head
illustrating height and width measurements.
[0024] FIG. 3 is a top view of the wood-type golf club head of FIG.
1.
[0025] FIG. 4 is a cross-sectional view of the wood-type golf club
head of FIG. 1 taken along line 4-4 of FIG. 3.
[0026] FIG. 4A is a cross-sectional view of an alternative
embodiment of a wood-type golf club head.
[0027] FIG. 5 is an enlarged isolated view of a matrix layer and a
front wall.
[0028] FIG. 5A is an enlarged isolated view of the alternative
embodiment of FIG. 4A.
[0029] FIG. 6 is an enlarged isolated view of a prior art polymer
layer disposed on a front wall of a loft driver to illustrate the
shear deformation during impact with a golf ball.
[0030] FIG. 7 is a heel-side view of the wood-type golf club head
of FIG. 1.
[0031] FIG. 8 is a toe-side view of the wood-type golf club head of
FIG. 1.
[0032] FIG. 9 is a bottom plan view of the wood-type golf club head
of FIG. 1.
[0033] FIG. 10 is a bottom perspective view of the wood-type golf
club head of FIG. 1.
[0034] FIG. 11 illustrates an alternative embodiment of a matrix
layer.
[0035] FIG. 12 illustrates an alternative embodiment of a matrix
layer.
[0036] FIG. 13 is cross-sectional view of an alternative embodiment
of a wood-type golf club head with a multiple material face.
[0037] FIG. 14 is a graph of micro-strain (y-axis) versus
coefficient of restitution (x-axis) at 85 miles per hour for
titanium plates coated with commercially available polymers.
[0038] FIG. 15 is a graph of micro-strain (y-axis) and coefficient
of restitution (y-axis) versus incoming velocity (x-axis) in miles
per hour for titanium plates having a polymer layer.
[0039] FIG. 16 is a graph of characteristic time (y-axis) versus
velocity.sup.-1/5 (x-axis) for golf club heads having multiple
material faces and single material faces.
[0040] FIG. 17 is a graph of coefficient of restitution (y-axis)
versus incoming velocity (x-axis) in miles per hour for multiple
material faces having a matrix layer.
[0041] FIG. 18 is a graph of ball spin (y-axis) in rotations per
minute versus incoming velocity (x-axis) in miles per hour for
multiple material faces having a matrix layer.
[0042] FIG. 19 is an isolated view of a mold and reinforcement
structure used in manufacturing a polymer layer with a
reinforcement structure.
DETAILED DESCRIPTION OF THE INVENTION
[0043] As shown in FIGS. 1-10, the golf club head of the present
invention is generally designated 20. The golf club head 20 of
FIGS. 1-10 is a driver, however, the golf club head of the present
invention may alternatively be a fairway wood. The golf club head
20 has a body 22 that is preferably composed of a metal material
such as titanium, titanium alloy, or the like, and is most
preferably composed of a cast titanium alloy material. The body 22
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 alloy for forging, and
6-4 titanium for casting. Alternatively, the body 22 is composed of
17-4 steel alloy. Additional methods for manufacturing the body 22
include forming the body 22 from a flat sheet of metal,
super-plastic forming the body 22 from a flat sheet of metal,
machining the body 22 from a solid block of metal, electrochemical
milling the body from a forged pre-form, casting the body using
centrifugal casting, casting the body using levitation casting, and
like manufacturing methods.
[0044] The golf club head 20, when designed as a driver, preferably
has a volume from 200 cubic centimeters to 600 cubic centimeters,
more preferably from 300 cubic centimeters to 450 cubic
centimeters, and most preferably from 350 cubic centimeters to 420
cubic centimeters. A golf club head 20 for a driver with a body 22
composed of a cast titanium alloy most preferably has a volume of
380 cubic centimeters. The volume of the golf club head 20 will
also vary between fairway woods (preferably ranging from 3-woods to
eleven woods) with smaller volumes than drivers.
[0045] The golf club head 20, when designed as a driver, preferably
has a mass no more than 215 grams, and most preferably a mass of
180 to 215 grams. When the golf club head 20 is designed as a
fairway wood, the golf club head preferably has a mass of 135 grams
to 180 grams, and preferably from 140 grams to 165 grams.
[0046] The body 22 has a crown 24, a sole 26, a ribbon 28, and a
multiple material front wall 30. The body 22 optionally has a
recess 32 in the front wall 30. The recess 32 preferably has a
depth, "Dr", as shown in FIG. 4, that ranges from 0.040 inch to
0.250 inch, more preferably from 0.080 inch to 0.120 inch, and is
most preferably 0.100 inch. The body 22 preferably has a hollow
interior 47. The golf club head 20 has a heel end 36, a toe end 38
an aft end 37. A shaft, not shown, is placed within a hosel 49 at
the heel end 36. In a preferred embodiment, the hosel 49 is
internal to the body 22, and the shaft extends to the sole 26.
[0047] The golf club head 20 preferably has a polymer layer 40 that
is disposed on the front wall 30 of the body 22. In a preferred
embodiment, the polymer layer 40 is an insert that is disposed in
the recess 32 of the front wall 30. In an alternative embodiment
shown in FIG. 13, the polymer layer 40 is disposed on the exterior
surface of the front wall 30. A more detailed description of a golf
club head 20 with a polymer layer disposed on the front wall is
disclosed in U.S. Pat. No. 6,607,451, for A Compliant Polymer Face
Golf Club Head, which is hereby incorporated by reference in its
entirety. Yet another detailed description of a golf club head 20
with a polymer layer disposed on the front wall is disclosed in
U.S. Pat. No. 6,428,427, for A Golf Club Head With Coated Striking
Plate, which is also hereby incorporated by reference in its
entirety.
[0048] The polymer layer 40 is preferably composed of a
reinforcement structure 50 and a polymer material 52. As shown in
FIG. 2, the polymer layer 40 has a width Wm that preferably ranges
from 2.0 inches to 4.0 inches. In a preferred embodiment, the
polymer layer 40 has an uniform thickness that ranges from 0.040
inch to 0.250 inch, more preferably a thickness of 0.080 inch to
0.120 inch, and is most preferably 0.100 inch.
[0049] The polymer material 52 for the polymer layer 40 is
preferably a thermoplastic polyurethane material. Polymer materials
that may be utilized in the polymer layer 40 include: polymers from
Bayer Corporation sold under the TEXIN brand such as TEXIN 4215,
TEXIN 4210, TEXIN 270, TEXIN 4210 T2, TEXIN 270 T2, TEXIN 4215 T2
and TEXIN 4215 T3, which are thermoplastic polyurethanes and
thermoplastic polyurethane and polycarbonate blends; polymers from
BASF corporation such as TERLURAN EGP-7, TERLURAN HI-10, TERLURAN
GP-22, which are ABS polymers, ULTRAMID A3HG5, LURANS 778 T1 and
LURAN S 778 T/TE T2, which are ABS and polyamide blends, and TRIAX
1120, which is an ABS and polyamide blend; polymers from Du Pont
Chemicals such as HYTREL 7246 thermoplastic polyester elastomer and
HYLENE 58D polymer and SURLYN ionomers; polymers from GE Polymers
such as NORYL PPX/PPX7115 polyphenylene ether and polystryene
blend, LEXAN EXL 1330 T2, LEXAN EXL 1330 T3, LEXAN ML 6143/C1000,
LEXAN 1330/ML6143, LEXAN ML6143H and LEXAN 1330, which are
amorphous thermoplastic polymers, CYCOLOY C1000HF T1, CYCOLOY
C1000HF T2, CYCOLOY C1000HF T3, CYCOLOY C1000HF T4 AND CYCOLOY
C1000HF T5, which are ABS and polycarbonate blends; polymers from
Atofina corporation sold under the brands ATOFINA 3429, ATOFINA
3467 and ATOFINA 7823 MZ; polymers from BP Chemical sold under the
brand BAREX 210, which is an E acrylonitrile-methyl acrylate
copolymer; polymers from Chevron corporation sold under the brands
BK-12, KR03 and BK10/NAS90 blend; polymers from Exxon Mobil
chemical sold under the brands PP1024E4, PP1043N, PP7033N,
PP7032E2T1, PP7032KN and PP7032E2T2; polymers from Huntsman
Chemical sold under the brand IROGRAN 113557; polymers from RTP
corporation sold under the brands 1299-A 80D w/glass, 1299-B 80D
without glass, RTP 4085 and Nylon 6 with nano; and polymers from
Uniroyal sold under the brand AN2501750 blend T1, AN2501750 blend
T2 and LF750D.
[0050] In a preferred embodiment, the polymer material 52 is
preferably injection molded or compression molded around the
reinforcement structure 50. However, those skilled in the pertinent
art will recognize that other integration methods may be utilized
in combining the reinforcement structure 50 and the polymer
material 52 without departing from the scope and spirit of the
present invention. The polymer layer 40 is applied to the front
wall 30 of the golf club head 20. One application method is to use
an adhesive to adhere an interior surface of the polymer layer 40
to the exterior surface of the front wall 30 within the recess 32.
Another method is to use compressive forces to apply the polymer
layer 40 within the recess 32. Yet another method is to use bolts
to secure the polymer layer 40 within the recess 32. Yet a further
method is to form the polymer layer 40 within the recess 32.
However, those skilled in the pertinent art will recognize other
methods to place the polymer layer 40 on the front wall 30 of the
golf club head 20 without departing from the scope and spirit of
the present invention.
[0051] The reinforcement structure 50 is preferably composed of
aluminum, aramid fiber, fiberglass, carbon or a rigid polyurethane
material, and such reinforcement structures are available from
Hexcel Corporation of Pleasanton, Calif. under the brand HEXCEL
COMPOSITES. The reinforcement structure 50 is preferably a
plurality of interconnected cells 51, with each cell 51 preferably
having a cell size ranging from 0.010 inch to 0.375 inch, more
preferably from 0.0625 inch to 0.125 inch. Each cell 51 is
preferably formed of integrated walls 53. As shown in FIG. 5, the
reinforcement structure 50 preferably has a depth that extends
along the entire depth, "Dm", of the polymer layer 40. In an
alternative embodiment, the reinforcement structure 50 has a depth
that partially extends along the depth of the polymer layer 40,
ranging from 25% to 75% of the depth of the polymer layer 40. As
shown in FIG. 5, each of the walls 53 of the reinforcement
structure 50 preferably has a thickness, "Tr", ranging from 0.0005
inch to 0.01 inch, more preferably from 0.001 inch to 0.005 inch,
and most preferably 0.002 inch.
[0052] In an alternative embodiment shown in FIGS. 4A and 5A, an
outer layer 41 covers the polymer layer 40. The outer layer 41
provides additional protection to the polymer layer 40 during
impact with a golf ball. The outer layer may be composed of any of
the previously disclosed polymer materials. Further, the outer
layer 41 preferably has a thickness ranging from 0.005 inch to
0.100 inch. In a most preferred embodiment, the outer layer 41 is
composed of the same material as the polymer material 52 of the
polymer layer 40.
[0053] As shown in FIGS. 1A and 1B, alternative embodiments of the
polymer layer 40 have a reinforcement structure 50 that is only
present in a portion of the polymer layer 40. In FIG. 1A, the
reinforcement structure is only disposed in the center of the face
of the golf club head 20 in accordance with high impact probability
locations. In FIG. 1B, the reinforcement structure is absent from
the center of the face 45 of the golf club head 20.
[0054] FIGS. 11 and 12 illustrate various grid formations of the
reinforcement structure 50. FIG. 11 has a rectangular grid
formation and FIG. 12 has a triangular grid formation. A preferred
embodiment has a hexagonal grid formation, as shown in FIG. 1.
Those skilled in the pertinent art will recognize that other grid
formations may be used for the reinforcement structure 50 of the
matrix layer 40 without departing from the scope and spirit of the
present invention.
[0055] As shown in FIG. 6, a lofted driver with a polymer layer 52a
on the front wall 30a will experience a shear stress, .tau..sub.o,
from the normal stress, .sigma..sub.o, due to impact with a golf
ball. The shear stress causes shear deformation of the polymer
layer 52a thereby affecting the normal compliance of the polymer
layer 52a, which reduces the increased COR due to the polymer layer
52a. The reinforcement structure 50 of the polymer layer 40 reduces
or eliminates the shear deformation of the polymer material 52
thereby allowing for increased COR and durability.
[0056] The wood-type golf club head 20 preferably 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 = v 2 - v 1 U 1 - U 2 ##EQU00002##
[0057] wherein U.sub.1 is the club head velocity prior to impact;
U.sub.2 is the golf ball velocity prior to impact which is zero;
v.sub.1 is the club head velocity just after separation of the golf
ball from the face of the club head; v.sub.2 is the golf ball
velocity just after separation of the golf ball from the face of
the club head; and e is the coefficient of restitution between the
golf ball and the club face.
[0058] 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 1.0. The present invention
provides a wood-type golf club head 20 preferably having a
coefficient of restitution preferably ranging from 0.80 to 0.87,
and more preferably from 0.82 to 0.86, as measured under standard
USGA test conditions. FIGS. 14 and 15 illustrate the COR values for
club heads with polymer layers.
[0059] The wood-type golf club head 20 preferably has a CT value,
under standard USGA conditions which are hereby incorporated by
reference in their entirety, that is equal to or less than 257
milliseconds at 1 meter/second. As shown in FIG. 16, a CALLAWAY
GOLF.RTM. ERC.RTM. II Driver, which is a clubhead with a forged
titanium alloy face, has a COR of 0.851 (squares) and has a CT
value greater than 257 milliseconds. A CALLAWAY GOLF.RTM.
STEELHEAD.RTM. Driver, which is a clubhead with a stainless steel
face, has a COR of 0.780 (circles) and a CT value less than 257
milliseconds. A clubhead of the present invention (triangles) with
a multiple material face (titanium alloy front wall covered with a
cycoloy polymer layer) has a COR of 0.832 and a CT value less than
257 milliseconds. A clubhead of the present invention (diamonds)
with a multiple material face (titanium alloy front wall covered
with an Irograin polymer layer) has a COR of 0.835 and a CT value
less than 257 milliseconds.
[0060] As shown in FIGS. 17 and 18, a polymer layer 40 with a
reinforcement structure 50 can increase COR and reduce spin.
[0061] As shown in FIG. 3, the depth, "D", of the club head 20 from
the front wall 30 to the aft-end 37 preferably ranges from 3.0
inches to 4.5 inches, and is most preferably 3.75 inches. As shown
in FIG. 2, the height, "H", of the club head 20, 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 20 from the toe end 38 to the heel end
36 preferably ranges from 4.0 inches to 5.0 inches, and more
preferably 4.7 inches. [0062] a. The face 45 of the golf club head
20 preferably has a large aspect ratio. The aspect ratio as used
herein is defined as the height, "H", of the face 45 divided by the
width, "W", of the face 45. The width, W, is measured between the
farthest limits of the face 45 from the heel end 36 to the toe end
38. The measured width, W, does not include any portion of the body
22 that may be on the front of the club head 20 but not part of the
face 45. The face 45 includes the front wall 30 and matrix layer
40. The height, H, is measured from between the farthest limits of
the face 45 from the crown 24 to the sole 26. As with the width, W,
the height, H, does not include any portion of the body 22 that may
be on the front of the club head 20 but not part of the face
45.
[0063] In one embodiment, the width W is 3.35 inches and the height
H is 2.0 inches giving an aspect ratio of 0.6. The face 45 of the
golf club head 20 preferably has an aspect ratio that is greater
than 0.575. The aspect ratio of the face 45 preferably ranges from
0.575 to 0.8, and is most preferably from 0.6 to 0.7. A discussion
of the aspect ratio of the face of a golf club head is disclosed in
Kosmatka, U.S. Pat. No. 6,338,683 for Striking Plate For A Golf
Club Head, which is hereby incorporated by reference in its
entirety.
[0064] The center of gravity and the moments of inertia of the golf
club head 20 may be calculated as disclosed in U.S. Pat. No.
6,607,452, entitled High Moment Of Inertia Composite Golf Club, and
hereby incorporated by reference in its entirety. In general, the
moment of inertia, Izz, about the Z axis for the golf club head 20
will preferably range from 2700 g-cm.sup.2 to 4000 g-cm.sup.2, more
preferably from 3000 g-cm.sup.2 to 3800 g-cm.sup.2. The moment of
inertia, Iyy, about the Y axis for the golf club head 20 will
preferably range from 1500 g-cm.sup.2 to 3500 g-cm.sup.2.
[0065] Further, the golf club head 20 preferably has superior
products of inertia wherein at least one of the products inertia,
Ixy, Ixz and Iyz, of the golf club head 20 has an absolute value
less than 100 g-cm.sup.2, and more preferably two or three products
of inertia, Ixy, Ixz and Iyz, of the golf club head 20 have an
absolute value less than 100 g-cm.sup.2. A discussion of the
products of inertia is disclosed in Cackett, et al., U.S. Pat. No.
6,425,832 for Large Volume Driver Head With High Moments Of
Inertia, which is hereby incorporated by reference in its
entirety.
[0066] FIG. 19 illustrates a mold 300 and reinforcement structure
50 used in a method of forming a polymer layer 40 with a
reinforcement structure 50. The reinforcement structure 50 is
placed within a recess 302 of the mold 300. An injectable polymer
material is then injected into each cell of the reinforcement
structure 50. The material viscosity of the injectable polymer
material is preferably 5 grams per 10 minutes to 25 grams per 10
minutes. The injection pressure preferably ranges from 800 to 2000
pounds per square inch. The reinforcement structure 50 is
preferably held within the recess 302 with a bracing resin, which
is preferably composed of the same material of the injectable
polymer material. The materials disclosed above are preferably
utilized as the injectable polymer material.
[0067] 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 changes, 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 defined in
the following appended claims.
* * * * *
References