U.S. patent application number 15/876877 was filed with the patent office on 2018-05-24 for golf club heads and methods to manufacture golf club heads.
The applicant listed for this patent is Parsons Xtreme Golf, LLC. Invention is credited to Michael R. Nicolette, Robert R. Parsons, Bradley D. Schweigert.
Application Number | 20180140910 15/876877 |
Document ID | / |
Family ID | 62144029 |
Filed Date | 2018-05-24 |
United States Patent
Application |
20180140910 |
Kind Code |
A1 |
Parsons; Robert R. ; et
al. |
May 24, 2018 |
GOLF CLUB HEADS AND METHODS TO MANUFACTURE GOLF CLUB HEADS
Abstract
Embodiments of golf club heads and methods to manufacture golf
club heads are generally described herein. In one example, a golf
club head may include a body portion comprising a first material.
The body portion may have a toe portion, a heel portion, a top
portion, a sole portion, a back portion, a front portion having a
face portion. The golf club head may include an interior cavity
partially, substantially, or entirely filled with a cavity filling
material associated with a coefficient of restitution greater than
or equal to 0.7 when an initial velocity is greater than or equal
to 100 feet per second. Further, the golf club head may include a
mass portion comprising a second material, which may be different
than the first material. Other examples and embodiments may be
described and claimed.
Inventors: |
Parsons; Robert R.;
(Scottsdale, AZ) ; Nicolette; Michael R.;
(Scottsdale, AZ) ; Schweigert; Bradley D.;
(Anthem, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Parsons Xtreme Golf, LLC |
Scottsdale |
AZ |
US |
|
|
Family ID: |
62144029 |
Appl. No.: |
15/876877 |
Filed: |
January 22, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15841022 |
Dec 13, 2017 |
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15876877 |
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15701131 |
Sep 11, 2017 |
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15685986 |
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15628251 |
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15685986 |
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15209364 |
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Mar 29, 2017 |
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62502442 |
May 5, 2017 |
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62596312 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A63B 53/0466 20130101;
A63B 2053/0491 20130101; A63B 60/002 20200801; A63B 60/54 20151001;
A63B 53/0408 20200801; A63B 2209/00 20130101; A63B 53/0487
20130101; A63B 53/0475 20130101; A63B 2053/0479 20130101; A63B
53/0445 20200801; A63B 53/047 20130101 |
International
Class: |
A63B 53/04 20150101
A63B053/04 |
Claims
1. A golf club head comprising: a polymer material associated with
a coefficient of restitution (COR) greater than or equal to 0.75
and a Shore D hardness of at least 25; a body portion comprising a
first material, the body portion comprising a toe portion, a heel
portion, a top portion, a sole portion, a front portion, a back
portion, an opening, and an interior cavity partially or entirely
filled with the polymer material through the opening, the first
material having a density between 7.0 grams per cubic centimeter
and 8.3 grams per cubic centimeter; and a mass portion comprising a
second material different from the first material, the mass portion
located farther from the heel portion than the toe portion, and the
mass portion located at a different location than the opening.
2. A golf club head as defined in claim 1, wherein the first
material comprises a stainless steel material comprising one or
more of: a tensile strength between 600 million Newtons per square
meter (600 Megapascals) and 800 million Newtons per square meter
(800 Megapascals); a yield strength between 500 million Newtons per
square meter (500 Megapascals) and 700 million Newtons per square
meter (700 Megapascals); a hardness of between 10 Rockwell Hardness
in the C scale (HRC) and 40 HRC; or an elongation of between 5% and
40%.
3. A golf club head as defined in claim 1 wherein the polymer
material comprises a thermoset material.
4. A golf club head as defined in claim 1, wherein the polymer
material comprises a thermoset material having a Shore D hardness
of greater than or equal to 40 and less than or equal to 80.
5. A golf club head as defined in claim 1, wherein the polymer
material comprises a thermoset material having a density of greater
than or equal to 1.0 g/cm.sup.3 and less than or equal to 2.0
g/cm.sup.3.
6. A golf club head as defined in claim 1, wherein the polymer
material comprises a thermoset material associated with a COR
greater than or equal to 0.8.
7. A golf club head comprising: a body portion comprising a
material associated with a first density, the body portion having a
toe portion, a heel portion, a top portion, a sole portion, a front
portion, and a back portion; a thermoset material having a
coefficient of restitution (COR) greater than or equal to 0.75; an
interior cavity at least 50% filled with the thermoset material; an
opening connected to the interior cavity; and a mass portion
comprising a material associated with a second density different
than the first density, the mass portion located at or below a
horizontal midplane of the body portion and located farther from
the heel portion than the toe portion, and the mass portion located
at a different location than the opening.
8. A golf club head as defined in claim 7, wherein the thermoset
material comprises a thermoset material having a COR greater than
or equal to 0.8.
9. A golf club head as defined in claim 7 further comprising a face
portion coupled to the body portion, the face portion having a face
portion thickness, and wherein a ratio of a width of the thermoset
material and a face portion thickness of the golf club head is
greater than or equal to 0.2 and less than or equal to 5.0.
10. A golf club head as defined in claim 7, wherein the thermoset
material comprises a thermoset material having a Shore D hardness
of greater than or equal to 25 and less than or equal to 65.
11. A golf club head as defined in claim 7, wherein the thermoset
material comprises a thermoset material having a density of greater
than or equal to 1.0 g/cm.sup.3 and less than or equal to 2.0
g/cm.sup.3.
12. A golf club head as defined in claim 7, wherein the interior
cavity is filled with the thermoset material below the horizontal
midplane of the golf club head.
13. A golf club head comprising: a cavity filling material
associated with a coefficient of restitution (COR) greater than or
equal to 0.8; a body portion having a toe portion, a heel portion,
a top portion, a sole portion, a front portion, a back portion, and
an interior cavity at least partially filled with the cavity
filling material; a port located at or proximate to the toe
portion, the port being configured to receive the cavity filling
material; a face portion having a thickness of less than or equal
to about 1.9 millimeters (0.075 inch); and a mass portion located
at a different location than the port.
14. A golf club head as defined in claim 13, wherein the mass
portion is partially or entirely located above a horizontal
midplane.
15. A golf club head as defined in claim 13, wherein the mass
portion is partially or entirely located below the horizontal
midplane.
16. A golf club head as defined in claim 13, wherein the cavity
filling material is configured to bond to the face portion.
17. A golf club head as defined in claim 13, wherein the mass
portion is located closer to the heel portion than the toe
portion.
18. A golf club head as defined in claim 13 further comprising a
hosel portion, wherein the mass portion is located at or proximate
to the hosel portion.
19. A golf club head as defined in claim 13, wherein the interior
cavity comprises a first width above a horizontal midplane of the
golf club head, a second width below the horizontal midplane, and a
third width between the first width and the second width, wherein
the third width is greater than the first width and greater than
the second width.
20. A golf club head as defined in claim 13, wherein the interior
cavity comprises a first width above a horizontal midplane of the
golf club head, a second width below the horizontal midplane, and a
third width between the first width and the second width, wherein
the third width is greater than the first width and greater than
the second width, and wherein the third width is below the
horizontal midplane and above the mass portion.
Description
CROSS REFERENCE
[0001] This application is a continuation-in-part of application
Ser. No. 15/841,022, filed Dec. 13, 2017, which is a continuation
of application Ser. No. 15/701,131, filed Sep. 11, 2017, which is a
continuation-in-part of application Ser. No. 15/685,986, filed Aug.
24, 2017, which is a continuation of application Ser. No.
15/628,251, filed Jun. 20, 2017, which is a continuation of
application Ser. No. 15/209,364, filed on Jul. 13, 2016, which is a
continuation of International Application No. PCT/US15/16666, filed
Feb. 19, 2015, which claims the benefits of U.S. Provisional
Application No. 61/942,515, filed Feb. 20, 2014, U.S. Provisional
Application No. 61/945,560, filed Feb. 27, 2014, U.S. Provisional
Application No. 61/948,839, filed Mar. 6, 2014, U.S. Provisional
Application No. 61/952,470, filed Mar. 13, 2014, U.S. Provisional
Application No. 61/992,555, filed May 13, 2014, U.S. Provisional
Application No. 62/010,836, filed Jun. 11, 2014, U.S. Provisional
Application No. 62/011,859, filed Jun. 13, 2014, and U.S.
Provisional Application No. 62/032,770, filed Aug. 4, 2014.
[0002] U.S. application Ser. No. 15/209,364, filed on Jul. 13,
2016, is also a continuation of application Ser. No. 14/618,501,
filed Feb. 10, 2015, now U.S. Pat. No. 9,427,634, which is a
continuation of application Ser. No. 14/589,277, filed Jan. 5,
2015, now U.S. Pat. No. 9,421,437, which is a continuation of
application Ser. No. 14/513,073, filed Oct. 13, 2014, now U.S. Pat.
No. 8,961,336, which is a continuation of application Ser. No.
14/498,603, filed Sep. 26, 2014, now U.S. Pat. No. 9,199,143, which
claims the benefit of U.S. Provisional Application No. 62/041,538,
filed Aug. 25, 2014.
[0003] This application is also a continuation-in-part of
application Ser. No. 15/683,564, filed Aug. 22, 2017, which is a
continuation of application Ser. No. 15/598,949, filed May 18,
2017, which is a continuation of application Ser. No. 14/711,596,
filed May 13, 2015, now U.S. Pat. No. 9,675,853, which claims the
benefits of U.S. Provisional Application No. 62/118,403, filed Feb.
19, 2015, and U.S. Provisional Application No. 62/159,856, filed
May 11, 2015.
[0004] This application is also a continuation-in-part of
application Ser. No. 15/842,632, filed Dec. 14, 2017, which is a
continuation of application Ser. No. 15/263,018, filed Sep. 12,
2016, now U.S. Pat. No. 9,878,220, which is a continuation of
application Ser. No. 15/043,090, filed Feb. 12, 2016, now U.S. Pat.
No. 9,468,821, which claims the benefits of U.S. Provisional
Application No. 62/209,780, filed Aug. 25, 2015, and U.S.
Provisional Application No. 62/277,636, filed Jan. 12, 2016.
[0005] This application is also a continuation-in-part of
application Ser. No. 15/842,583, filed Dec. 14, 2017, which is a
continuation of application Ser. No. 15/631,610, filed Jun. 23,
2017, which is a continuation of application Ser. No. 15/360,707,
filed Nov. 23, 2016, which is a continuation of application Ser.
No. 15/043,106, filed Feb. 12, 2016, now U.S. Pat. No. 9,533,201,
which claims the benefits of U.S. Provisional Application No.
62/275,443, filed Jan. 6, 2016, and U.S. Provisional Application
No. 62/276,358, filed Jan. 8, 2016.
[0006] This application is also a continuation-in-part of
application Ser. No. 15/703,639, filed Sep. 13, 2017, which is a
continuation-in-part of application Ser. No. 15/484,794, filed Apr.
11, 2017, now U.S. Pat. No. 9,814,952, which claims the benefit of
U.S. Provisional Application No. 62/321,652, filed Apr. 12,
2016.
[0007] This application is a continuation-in-part of application
Ser. No. 15/842,591, filed Dec. 14, 2017, which is a continuation
of application Ser. No. 15/687,317, filed Aug. 25, 2017, which is a
continuation of application Ser. No. 15/188,718, filed Jun. 21,
2016, now U.S. Pat. No. 9,610,481, which claims the benefit of U.S.
Provisional Application No. 62/343,739, filed May 31, 2016.
[0008] This application is a continuation-in-part of application
Ser. No. 15/462,281, filed Mar. 17, 2017, which claims the benefit
of U.S. Provisional Application No. 62/433,661, filed Dec. 13,
2016.
[0009] This application claims the benefit of U.S. Provisional
Application No. 62/478,474, filed Mar. 29, 2017.
[0010] This application is also a continuation-in-part of
application Ser. No. 29/616,949, filed Sep. 11, 2017.
[0011] This application is a continuation-in-part of application
Ser. No. 15/802,819, filed Nov. 3, 2017, which is a continuation of
application Ser. No. 15/793,648, filed Oct. 25, 2017, which is a
continuation of application Ser. No. 15/791,020, filed Oct. 23,
2017, which is a continuation of application Ser. No. 15/785,001,
filed Oct. 16, 2017, which claims the benefits of U.S. Provisional
Application No. 62/502,442, filed May 5, 2017, U.S. Provisional
Application No. 62/508,794, filed May 19, 2017, U.S. Provisional
Application No. 62/512,033, filed May 28, 2017, and U.S.
Provisional Application No. 62/570,493, filed Oct. 10, 2017.
[0012] This application claims the benefit of U.S. Provisional
Application No. 62/536,345, filed Jul. 24, 2017.
[0013] This application is also a continuation-in-part of
application Ser. No. 29/622,326, filed Oct. 16, 2017.
[0014] This application claims the benefits of U.S. Provisional
Application No. 62/543,786, filed Aug. 10, 2017, U.S. Provisional
Application No. 62/548,263, filed Aug. 21, 2017, U.S. Provisional
Application No. 62/549,142, filed Aug. 23, 2017, U.S. Provisional
Application No. 62/596,312, filed Dec. 8, 2017, U.S. Provisional
Application No. 62/611,768, filed Dec. 29, 2017, U.S. Provisional
Application No. 62/615,603, filed Jan. 10, 2018, U.S. Provisional
Application No. 62/616,896, filed Jan. 12, 2018, and U.S.
Provisional Application No. 62/617,986, filed Jan. 16, 2018.
[0015] The disclosures of all of the above referenced applications
are incorporated herein by reference.
COPYRIGHT AUTHORIZATION
[0016] The present disclosure may be subject to copyright
protection. The copyright owner has no objection to the facsimile
reproduction by anyone of the present disclosure and its related
documents, as they appear in the Patent and Trademark Office patent
files or records, but otherwise reserves all applicable
copyrights.
FIELD
[0017] The present disclosure generally relates to golf equipment,
and more particularly, to golf club heads and methods to
manufacturing golf club heads.
BACKGROUND
[0018] Various materials (e.g., steel-based materials,
titanium-based materials, tungsten-based materials, etc.) may be
used to manufacture golf club heads. By using multiple materials to
manufacture golf club heads, the position of the center of gravity
(CG) and/or the moment of inertia (MOI) of the golf club heads may
be optimized to produce certain trajectory and spin rate of a golf
ball.
DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 depicts a front view of a golf club head according to
an embodiment of the apparatus, methods, and articles of
manufacture described herein.
[0020] FIG. 2 depicts a rear view of the example golf club head of
FIG. 1.
[0021] FIG. 3 depicts a top view of the example golf club head of
FIG. 1.
[0022] FIG. 4 depicts a bottom view of the example golf club head
of FIG. 1.
[0023] FIG. 5 depicts a left view of the example golf club head of
FIG. 1.
[0024] FIG. 6 depicts a right view of the example golf club head of
FIG. 1.
[0025] FIG. 7 depicts a cross-sectional view of the example golf
club head of FIG. 1 along line 7-7.
[0026] FIG. 8 depicts a cross-sectional view of the example golf
club head of FIG. 1 along line 8-8.
[0027] FIG. 9 depicts a cross-sectional view of the example golf
club head of FIG. 1 along line 9-9.
[0028] FIG. 10 depicts another rear view of the example golf club
head of FIG. 1.
[0029] FIG. 11 depicts a top view of a mass portion associated with
the example golf club head of FIG. 1.
[0030] FIG. 12 depicts a side view of a mass portion associated
with the example golf club head of FIG. 1.
[0031] FIG. 13 depicts a side view of another mass portion
associated with the example golf club head of FIG. 1.
[0032] FIG. 14 depicts a rear view of a body portion of the example
golf club head of FIG. 1.
[0033] FIG. 15 depicts a cross-sectional view of a face portion of
the example golf club head of FIG. 1.
[0034] FIG. 16 depicts a cross-sectional view of another face
portion of the example golf club head of FIG. 1.
[0035] FIG. 17 depicts one manner in which the example golf club
head described herein may be manufactured.
[0036] FIG. 18 depicts another cross-sectional view of the example
golf club head of FIG. 4 along line 18-18.
[0037] FIG. 19 depicts a cross-sectional view of the example golf
club head of FIG. 1.
[0038] FIG. 20 depicts another manner in which an example golf club
head described herein may be manufactured.
[0039] FIG. 21 depicts yet another manner in which an example golf
club head described herein may be manufactured.
[0040] FIG. 22 depicts a front view of a golf club head according
to an embodiment of the apparatus, methods, and articles of
manufacture described herein.
[0041] FIG. 23 depicts a rear view of the example golf club head of
FIG. 22.
[0042] FIG. 24 depicts yet another manner in which an example golf
club head described herein may be manufactured.
[0043] FIG. 25 depicts yet another manner in which an example golf
club head described herein may be manufactured.
[0044] FIG. 26 depicts an example of curing a bonding agent.
[0045] FIG. 27 is a perspective cross-sectional view of a golf club
head according to an embodiment of the apparatus, methods, and
articles of manufacture described herein.
[0046] FIG. 28 is a perspective cross-sectional view of a golf club
head according to an embodiment of the apparatus, methods, and
articles of manufacture described herein.
[0047] FIG. 29 is a perspective cross-sectional view of a golf club
head according to an embodiment of the apparatus, methods, and
articles of manufacture described herein.
[0048] FIG. 30 depicts yet another manner in which an example golf
club head described herein may be manufactured.
[0049] For simplicity and clarity of illustration, the drawing
figures illustrate the general manner of construction, and
descriptions and details of well-known features and techniques may
be omitted to avoid unnecessarily obscuring the present disclosure.
Additionally, elements in the drawing figures may not be depicted
to scale. For example, the dimensions of some of the elements in
the figures may be exaggerated relative to other elements to help
improve understanding of embodiments of the present disclosure.
DESCRIPTION
[0050] In general, golf club heads and methods to manufacture golf
club heads are described herein. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0051] In the example of FIGS. 1-14, a golf club head 100 may
include a body portion 110 (FIG. 14) having a toe portion 140, a
heel portion 150, a front portion 160 with a face portion 162
(e.g., a strike face) having a front surface 164 and a back surface
166, a back portion 170, a top portion 180, and a sole portion 190.
The toe portion 140, the heel portion 150, the front portion 160,
the back portion 170, the top portion 180, and/or the sole portion
190 may partially overlap each other. For example, a portion of the
toe portion 140 may overlap portion(s) of the front portion 160,
the back portion 170, the top portion 180, and/or the sole portion
190. In a similar manner, a portion of the heel portion 150 may
overlap portion(s) of the front portion 160, the back portion 170,
the top portion 180, and/or the sole portion 190. In another
example, a portion of the back portion 170 may overlap portion(s)
of the toe portion 140, the heel portion 150, the top portion 180,
and/or the sole portion 190. The apparatus, methods, and articles
of manufacture described herein are not limited in this regard.
[0052] The golf club head 100 may be an iron-type golf club head
(e.g., a 1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron,
a 7-iron, an 8-iron, a 9-iron, etc.) or a wedge-type golf club head
(e.g., a pitching wedge, a lob wedge, a sand wedge, an n-degree
wedge such as 44 degrees (.degree.), 48.degree., 52.degree.,
56.degree., 60.degree., etc.). Although FIGS. 1-10 may depict a
particular type of club head, the apparatus, methods, and articles
of manufacture described herein may be applicable to other types of
club heads (e.g., a driver-type club head, a fairway wood-type club
head, a hybrid-type club head, a putter-type club head, etc.). The
golf club head 100 may have a club head volume less than or equal
to 300 cubic centimeters (cm.sup.3 or cc). In one example, the golf
club head 100 may have a club head volume greater than or equal to
20 cc and less than or equal to 90 cc. In another example, the golf
club head 100 may have a club head volume greater than or equal to
100 cc and less than or equal to 200 cc. Alternatively, the golf
club head 100 may have a club head volume greater than 300 cc. In
one example, the golf club head 100 may have a club head volume of
about 460 cc. In another example, the golf club head 100 may have a
club head volume greater than 500 cc. The club head volume of the
golf club head 1900 may be determined by using the weighted water
displacement method (i.e., Archimedes Principle). For example,
procedures defined by golf standard organizations and/or governing
bodies such as the United States Golf Association (USGA) and/or the
Royal and Ancient Golf Club of St. Andrews (R&A) may be used
for measuring the club head volume of the golf club head 100. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0053] The toe portion 140 may include a portion of the body
portion 110 opposite of the heel portion 150. The heel portion 150
may include a hosel portion 155 configured to receive a shaft (not
shown) with a grip (not shown) on one end and the golf club head
100 on the opposite end of the shaft to form a golf club. The front
surface 164 of the face portion 162 may include one or more score
lines, slots, or grooves 168 extending to and/or between the toe
portion 140 and the heel portion 150. While the figures may depict
a particular number of grooves, the apparatus, methods, and
articles of manufacture described herein may include more or less
grooves. The face portion 162 may be used to impact a golf ball
(not shown). The face portion 162 may be an integral portion of the
body portion 110. Alternatively, the face portion 162 may be a
separate piece or an insert coupled to the body portion 110 via
various manufacturing methods and/or processes (e.g., a bonding
process such as adhesive, a welding process such as laser welding,
a brazing process, a soldering process, a fusing process, a
mechanical locking or connecting method, any combination thereof,
or other suitable types of manufacturing methods and/or processes).
The face portion 162 may be associated with a loft plane that
defines the loft angle of the golf club head 100. The loft angle
may vary based on the type of golf club (e.g., a long iron, a
middle iron, a short iron, a wedge, etc.). In one example, the loft
angle may be between five degrees and seventy-five degrees. In
another example, the loft angle may be between twenty degrees and
sixty degrees. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0054] The back portion 170 may include a portion of the body
portion 110 opposite of the front portion 160. In one example, the
back portion 170 may be a portion of the body portion 110 behind
the back surface 166 of the face portion 162. As shown in FIG. 6,
for example, the back portion 170 may be a portion of the body
portion 110 behind a plane 171 defined by the back surface 166 of
the face portion 162. In another example, the plane 171 may be
parallel to the loft plane of the face portion 162. As mentioned
above, for example, the face portion 162 may be a separate piece or
an insert coupled to the body portion 110. Accordingly, the back
portion 170 may include remaining portion(s) of the body portion
110 other than the face portion 162. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0055] Further, the body portion 110 may include one or more ports,
which may be exterior ports and/or interior ports (e.g., located
inside the body portion 110). The interior walls of the body
portion 110 may include one or more ports. In one example, the back
portion 170 may include one or more ports (e.g., inside an interior
cavity, generally shown as 700 in FIG. 7). In another example, the
body portion 110 may include one or more ports along a periphery of
the body portion 110. As illustrated in FIG. 14, for example, the
body portion 110 may include one or more ports on the back portion
170, generally shown as a first set of ports 1420 (e.g., shown as
ports 1421, 1422, 1423, and 1424) and a second set of ports 1430
(e.g., shown as ports 1431, 1432, 1433, 1434, 1435, 1436, and
1437). In another example, one or more ports may be on a back wall
portion 1410 of the back portion 170. One or more ports may be
associated with a port diameter, which may be defined as the
largest distance to and/or between opposing ends or boundaries of a
port. For example, a port diameter for a rectangular port (e.g., a
slot, slit, or elongated rectangular opening) may refer to a
diagonal length of a rectangle. In another example, a port diameter
of an elliptical port may refer to the major axis of an ellipse. As
shown in FIG. 14, for example, each port may have a circular shape
with a port diameter equivalent to a diameter of a circle. In one
example, the port diameter of the first set of ports 1420 and/or
the second set of ports 1430 may be about 0.25 inch (6.35
millimeters). Any two adjacent ports of the first set of ports 1420
may be separated by less than or equal to the port diameter. In a
similar manner, any two adjacent ports of the second set of ports
1430 may be separated by less than or equal to the port diameter.
Some adjacent ports may be separated by greater than the port
diameter. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0056] The body portion 110 may include one or more mass portions,
which may be integral mass portion(s) or separate mass portion(s)
that may be coupled to the body portion 110. In the illustrated
example as shown in FIG. 2, the body portion 110 may include a
first set of mass portions 120 (e.g., shown as mass portions 121,
122, 123, and 124) and a second set of mass portions 130 (e.g.,
shown as mass portions 131, 132, 133, 134, 135, 136, and 137).
While the above example, may describe a particular number or
portions of mass portions, a set of mass portions may include a
single mass portion or a plurality of mass portions. For example,
the first set of mass portions 120 may be a single mass portion. In
a similar manner, the second set of mass portions 130 may be a
single mass portion. Further, the first set of mass portions or the
second set of mass portions 130 may be a portion of the physical
structure of the body portion 110. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0057] The body portion 110 may be made of a first material whereas
the first set of mass portions 120 and/or the second set of mass
portions 130 may be made of a second material. The first and second
materials may be similar or different materials. For example, the
body portion 110 may be partially or entirely made of a steel-based
material (e.g., 17-4 PH stainless steel, Nitronic.RTM. 50 stainless
steel, alloy steel 8620, maraging steel or other types of stainless
steel), a titanium-based material, an aluminum-based material
(e.g., a high-strength aluminum alloy or a composite aluminum alloy
coated with a high-strength alloy), any combination thereof,
non-metallic materials, composite materials, and/or other suitable
types of materials. In one example, one or more mass portions of
the first set of mass portions 120 and/or the second set of mass
portions 130 may be partially or entirely made of a high-density
material such as a tungsten-based material or other suitable types
of materials. In another example, one more mass portions of the
first set of mass portions 120 and/or the second set of mass
portions 130 may be partially or entirely made of other suitable
metal material such as a stainless steel-based material, a
titanium-based material, an aluminum-based material, any
combination thereof, and/or other suitable types of materials.
Further, one or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may be made
of different types of materials (e.g., metal core and polymer
sleeve surrounding the metal core). The body portion 110, the first
set of mass portions 120, and/or the second set of mass portions
130 may be partially or entirely made of similar or different
non-metal materials (e.g., composite, plastic, polymer, etc.). The
apparatus, methods, and articles of manufacture are not limited in
this regard.
[0058] The body portion (e.g., one generally shown as 110 in FIG.
1) and/or any other portion of a golf club head (e.g., one
generally shown as 100 in FIG. 1) according to any of the examples
described herein may be constructed from stainless steel material
to resist corrosion (e.g., corrosion resistant). In one example,
all or one or more portions of the body portion 110 and/or any
other portion of the golf club head 100 may be constructed by a
forging process. Accordingly, stainless steel material from which
all or portions of the body portion and/or any other portion of the
golf club head are constructed may be a forgeable stainless steel
material. The apparatus, methods, and articles of manufacture are
not limited in this regard.
[0059] The apparatus, methods, and articles of manufacture
described herein may use stainless steel material with various
ranges of material properties, such as density, tensile strength,
yield strength, hardness, elongation, etc. (e.g., different type,
grade, alloy, etc. of stainless steel material). In one example,
the density of stainless steel material may be between and
including 7.0 g/cm.sup.3 and 8.3 g/cm.sup.3. In another example,
the density of stainless steel material may be between and
including 7.6 g/cm.sup.3 and 8.1 g/cm.sup.3. In yet another
example, the density of stainless steel material may be between and
including 7.2 g/cm.sup.3 and 7.8 g/cm.sup.3. In yet another
example, the density of stainless steel material may be between and
including 7.3 g/cm.sup.3 and 7.7 g/cm.sup.3. In yet another
example, the density of stainless steel material may be between and
including 7.1 g/cm.sup.3 and 7.6 g/cm.sup.3. In yet another
example, the density of stainless steel material may be between and
including 7.4 g/cm.sup.3 and 8.3 g/cm.sup.3. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0060] In one example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a tensile strength between and including 600 MPa and 800 MPa
(10.sup.6 Pascal=10.sup.6 N/m.sup.2). In another example, all or at
least one or more portions of the body portion 110 may be
constructed with stainless steel material having a tensile strength
between and including 620 MPa and 780 MPa. In yet another example,
the all or at least one or more portions of the body portion 110
may be constructed with stainless steel material having a tensile
strength between and including 660 MPa and 720 MPa. In yet another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having a
tensile strength between and including 680 MPa and 790 MPa. In yet
another example, all or at least one or more portions of the body
portion 110 may be constructed with stainless steel material having
a tensile strength between and including 640 MPa and 760 MPa. In
yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a tensile strength between and including 670 MPa and 770
MPa. The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0061] In one example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 500 MPa and 700 MPa.
In another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 520 MPa and 680 MPa.
In yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 560 MPa and 620 MPa.
In yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 580 MPa and 690 MPa.
In yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 540 MPa and 660 MPa.
In yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a yield strength between and including 570 MPa and 670 MPa.
The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0062] In one example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a hardness between and including 10 and 40 HRC (Rockwell
Hardness in the C scale). In another example, all or at least one
or more portions of the body portion 110 may be constructed with
stainless steel material having a hardness between and including 15
and 35 HRC. In yet another example, all or at least one or more
portions of the body portion 110 may be constructed with stainless
steel material having a hardness between and including 22 and 28
HRC. In yet another example, all or at least one or more portions
of the body portion 110 may be constructed with stainless steel
material having a hardness between and including 12 and 38 HRC. In
yet another example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having a hardness between and including 17 and 33 HRC. In yet
another example, all or at least one or more portions of the body
portion 110 may be constructed with stainless steel material having
a hardness between and including 11 and 31 HRC. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0063] In one example, all or at least one or more portions of the
body portion 110 may be constructed with stainless steel material
having an elongation between and including 5% and 40%. In another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having an
elongation between and including 10% and 32%. In yet another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having an
elongation between and including 13% and 28%. In yet another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having an
elongation between and including 18% and 37%. In yet another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having an
elongation between and including 14% and 33%. In yet another
example, all or at least one or more portions of the body portion
110 may be constructed with stainless steel material having an
elongation between and including 7% and 36%. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0064] One or more ports may be configured to receive a mass
portion having a similar shape as the port. For example, a
rectangular port may receive a rectangular mass portion. In another
example, an elliptical port may receive an elliptical mass portion.
As shown in FIGS. 10 and 14, for example, the first and second sets
of ports 1420 and 1430, respectively, may be cylindrical ports
configured to receive one or more cylindrical mass portions. In
particular, one or more mass portions of the first set 120 (e.g.,
generally shown as mass portions 121, 122, 123, and 124) may be
disposed in a port located at or proximate to the toe portion 140
and/or the top portion 180. For example, the mass portion 121 may
be partially or entirely disposed in the port 1421. One or more
mass portions of the second set 130 (e.g., generally shown as mass
portions 131, 132, 133, 134, 135, 136, and 137) may be disposed in
a port located at or proximate to the toe portion 140 and/or the
sole portion 190. For example, the mass portion 135 may be
partially or entirely disposed in the port 1435. The first set of
mass portions 120 and/or the second set of mass portions 130 may be
coupled to the body portion 110 with various manufacturing methods
and/or processes (e.g., a bonding process, a welding process, a
brazing process, a mechanical locking method, any combination
thereof, or other suitable manufacturing methods and/or
processes).
[0065] Alternatively, the golf club head 100 may not include (i)
the first set of mass portions 120, (ii) the second set of mass
portions 130, or (iii) both the first and second sets of mass
portions 120 and 130, respectively. In particular, the body portion
110 may not include ports at or proximate to the top portion 180
and/or the sole portion 190. For example, the mass of the first set
of mass portions 120 (e.g., 3 grams) and/or the mass of the second
set of mass portions 130 (e.g., 16.8 grams) may be integral part(s)
of the body portion 110 instead of separate mass portion(s). In one
example, the body portion 110 may include interior and/or exterior
integral mass portions at or proximate to the toe portion 140
and/or at or proximate to the heel portion 150. In another example,
a portion of the body portion 110 may include interior and/or
exterior integral mass portions extending to and/or between the toe
portion 140 and the heel portion 150. The first and/or second set
of mass portions 120 and 130, respectively, may affect the mass,
the center of gravity (CG), the moment of inertia (MOI), or other
physical properties of the golf club head 100. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0066] One or more mass portions of the first set of mass portions
120 and/or the second set of mass portions 130 may have similar or
different physical properties (e.g., color, marking, shape, size,
density, mass, volume, external surface texture, materials of
construction, etc.). Accordingly, the first set of mass portions
120 and/or the second set of mass portions 130 may contribute to
the ornamental design of the golf club head 100. In the illustrated
example as shown in FIG. 11, one or more mass portions of the first
set of mass portions 120 and/or the second set of mass portions 130
may have a cylindrical shape (e.g., a circular cross section).
Alternatively, one or more mass portions of the first set 120 may
have a first shape (e.g., a cylindrical shape) whereas one or more
mass portions of the second set 130 may have a second shape (e.g.,
a cubical shape). In another example, the first set of mass
portions 120 may include two or more mass portions with different
shapes (e.g., the mass portion 121 may be a first shape whereas the
mass portion 122 may be a second shape different from the first
shape). Likewise, the second set of mass portions 130 may also
include two or more mass portions with different shapes (e.g., the
mass portion 131 may be a first shape whereas the mass portion 132
may be a second shape different from the first shape). In another
example, one or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may have a
different color(s), marking(s), shape(s), density or densities,
mass(es), volume(s), material(s) of construction, external surface
texture(s), and/or any other physical property as compared to one
or more mass portions of the first set of mass portions 120 and/or
the second set of mass portions 130. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0067] Although the above examples may describe mass portions
having a particular shape, the apparatus, methods, and articles of
manufacture described herein may include mass portions of other
suitable shapes (e.g., a portion of or a whole sphere, cube, cone,
cylinder, pyramid, cuboidal, prism, frustum, rectangular,
elliptical, or other suitable geometric shape). While the above
examples and figures may depict multiple mass portions as a set of
mass portions, two or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may be a
single piece of mass portion. In one example, the first set of mass
portions 120 may be a single piece of mass portion instead of a
series of four separate mass portions. In another example, the
second set of mass portions 130 may be a single piece of mass
portion instead of a series of seven separate mass portions. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0068] Referring to FIGS. 12 and 13, for example, the first set of
mass portions 120 and/or the second set of mass portions 130 may
include threads, generally shown as 1210 and 1310, respectively, to
engage with correspondingly configured threads in the ports to
secure in the ports of the back portion 170 (e.g., generally shown
as 1420 and 1430 in FIG. 14). Accordingly, one or more mass
portions as described herein may be shaped similar to and function
as a screw or threaded fastener for engaging threads in a port. For
example, one or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may be a
screw. One or more mass portions of the first set of mass portions
120 and/or the second set of mass portions 130 may not be readily
removable from the body portion 110 with or without a tool.
Alternatively, one or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may be
readily removable (e.g., with a tool) so that a relatively heavier
or lighter mass portion may replace one or more mass portions of
the first and second sets of mass portions 120 and 130,
respectively. In another example, one or more mass portions of the
first set of mass portions 120 and/or the second set of mass
portions 130 may be secured in the ports of the back portion 170
with epoxy or adhesive so that the one or more mass portions of the
first set of mass portions 120 and/or the second set of mass
portions 130 may not be readily removable. In yet another example,
one or more mass portions of the first set of mass portions 120
and/or the second set of mass portions 130 may be secured in the
ports of the back portion 170 with both epoxy and threads so that
the one more mass portions of the first set of mass portions 120
and/or the second set of mass portions 130 may not be readily
removable. In yet another example, one or more mass portions
described herein may be press fit in a port. In yet another
example, one or more mass portions described herein may be formed
inside a port by injection molding. For example, a liquid metallic
material (i.e., molten metal) or a plastic material (e.g. rubber,
foam, or any polymer material) may be injected into a port. After
the liquid material is cooled and/or cured inside the port, the
resulting solid material (e.g., a metal material, a plastic
material, or a combination thereof), may be a mass portion. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0069] As mentioned above, one or more mass portions of the first
set of mass portions 120 and/or the second set of mass portions 130
may be similar in some physical properties but different in other
physical properties. For example, a mass portion may be made from
an aluminum-based material or an aluminum alloy whereas another
mass portion may be made from a tungsten-based material or a
tungsten alloy. In another example, a mass portion may be made from
a polymer material whereas another mass portion may be made from a
steel-based material. In yet another example, as illustrated in
FIGS. 11-13, one or more mass portions of the first set of mass
portions 120 and/or the second set of mass portions 130 may have a
diameter 1110 of about 0.25 inch (6.35 millimeters) but one or more
mass portions of the first set of mass portions 120 and/or the
second set of mass portions 130 may be different in height. In
particular, one or more mass portions of the first set of mass
portions 120 may be associated with a first height 1220 (FIG. 12),
and one or more mass portions of the second set of mass portions
130 may be associated with a second height 1320 (FIG. 13). The
first height 1220 may be relatively shorter than the second height
1320. In one example, the first height 1220 may be about 0.125 inch
(3.175 millimeters) whereas the second height 1320 may be about 0.3
inch (7.62 millimeters). In another example, the first height 1220
may be about 0.16 inch (4.064 millimeters) whereas the second
height 1320 may be about 0.4 inch (10.16 millimeters).
Alternatively, the first height 1220 may be equal to or greater
than the second height 1320. Although the above examples may
describe particular dimensions, one or more mass portions described
herein may have different dimensions. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0070] Referring to FIG. 10, for example, the golf club head 100
may be associated with a ground plane 1010, a horizontal midplane
1020, and a top plane 1030. In particular, the ground plane 1010
may be a tangential plane to the sole portion 190 of the golf club
head 100 when the golf club head 100 is at an address position
(e.g., the golf club head 100 is aligned to strike a golf ball). A
top plane 1030 may be a tangential plane to the top portion of the
180 of the golf club head 100 when the golf club head 100 is at the
address position. The ground and top planes 1010 and 1030,
respectively, may be substantially parallel to each other. The
horizontal midplane 1020 may be vertically halfway between the
ground and top planes 1010 and 1030, respectively.
[0071] As described herein, the golf club head 100 may be an
iron-type golf club head (e.g., a 1-iron, a 2-iron, a 3-iron, a
4-iron, a 5-iron, a 6-iron, a 7-iron, an 8-iron, a 9-iron, etc.) or
a wedge-type golf club head (e.g., a pitching wedge, a lob wedge, a
sand wedge, an n-degree wedge such as 44 degrees (.degree.),
48.degree., 52.degree., 56.degree., 60.degree., etc.). The body
portion 110 of the golf club head 100 or any of the golf club heads
described herein may include a visual indicator to indicate a
particular type of iron-type golf club head or wedge-type golf club
head. In particular, the visual indicator 111 may be a number
located on a periphery of the body portion 110. For example, the
visual indicator 111 may be located on the periphery of the body
portion 110 at or proximate to the sole portion 190 and/or the toe
portion 140. The visual indicator 111 may avoid or substantially
avoid contact with the ground plane 1010 at an address position
and/or the ground when the golf club head 100 strikes a golf ball.
The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0072] The body portion 110 may include any number of ports (e.g.,
no ports, one port, two ports, etc.) above the horizontal midplane
1020 and/or below the horizontal midplane 1020. In one example, the
body portion 110 may include a greater number of ports below the
horizontal midplane 1020 than above the horizontal midplane 1020.
In the illustrated example as shown in FIG. 14, the body portion
110 may include four ports (e.g., generally shown as ports 1421,
1422, 1423, and 1424) above the horizontal midplane 1020 and seven
ports (e.g., generally shown as ports 1431, 1432, 1433, 1434, 1435,
1436, and 1437) below the horizontal midplane 1020. In another
example (not shown), the body portion 110 may include two ports
above the horizontal midplane 1020 and five ports below the
horizontal midplane 1020. In yet another example (not shown), the
body portion 110 may not have any ports above the horizontal
midplane 1020 but have one or more ports below the horizontal
midplane 1020. Accordingly, the body portion 110 may have more
ports below the horizontal midplane 1020 than above the horizontal
midplane 1020. Further, the body portion 110 may include a port at
or proximate to the horizontal midplane 1020 with a portion of the
port above the horizontal midplane 1020 and a portion of the port
below the horizontal midplane 1020. Accordingly, the port may be
(i) above the horizontal midplane 1020, (ii) below the horizontal
midplane 1020, or (iii) both above and below the horizontal
midplane 1020. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0073] To provide optimal perimeter weighting for the golf club
head 100, the first set of mass portions 120 (e.g., generally shown
as mass portions 121, 122, 123, and 124) may be configured to
counter-balance the mass of the hosel 155. For example, as shown in
FIG. 10, the first set of mass portions 120 (e.g., generally shown
as mass portions 121, 122, 123 and 124) may be located at or near
the periphery of the body portion 110 and extend to and/or between
the top portion 180 and the toe portion 140. In other words, the
first set of mass portions 120 may be located on the golf club head
100 at a generally opposite location relative to the hosel 155. In
another example, at least a portion of the first set of mass
portions 120 may extend at or near the periphery of the body
portion 110 and extend along a portion of the top portion 180. In
yet another example, at least a portion of the first set of mass
portions 120 may extend at or near the periphery of the body
portion 110 and extend along a portion of the toe portion 140.
Further, the first set of mass portions 120 may be above the
horizontal midplane 1020 of the golf club head 100. For example,
the first set of mass portions 120 may be at or near the horizontal
midplane 1020. In another example, a portion of the first set of
mass portions 120 may be at or above the horizontal midplane 1020
and another portion of the first set of mass portions 120 may be at
or below the horizontal midplane 1020. Accordingly, a set of mass
portions, which may be a single mass portion, may have portions
above the horizontal midplane 1020 and below the horizontal
midplane 1020. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0074] At least a portion of the first set of mass portions 120 may
be at or near the toe portion 140 to increase the MOI of the golf
club head 100 about a vertical axis of the golf club head 100 that
extends through the CG of the golf club head 100. Accordingly, the
first set of mass portions 120 may be at or near the periphery of
the body portion 110 and extend through the top portion 180 and/or
the toe portion 140 to counter-balance the mass of the hosel 155
and/or increase the MOI of the golf club head 100. The locations of
the first set of mass portions 120 (i.e., the locations of the
first set of ports 1420) and the physical properties and materials
of construction of the first set of mass portions 120 may be
determined to optimally affect the mass, mass distribution, CG,
MOI, structural integrity and/or or other static and/or dynamic
characteristics of the golf club head 100. The apparatus, methods,
and articles of manufacture described herein are not limited in
this regard.
[0075] The second set of mass portions 130 (e.g., generally shown
as mass portions 131, 132, 133, 134, 135, 136, and 137) may be
configured to place the CG of the golf club head 100 at an optimal
location and optimize the MOI of the golf club head 100. Referring
to FIG. 10, all or a substantial portion of the second set of mass
portions 130 may be generally at or near the sole portion 190. For
example, the second set of mass portions 130 (e.g., generally shown
as mass portions 131, 132, 133, 134, 135, 136, and 137) may be at
or near the periphery of the body portion 110 and extend from the
sole portion 190 to the toe portion 140. As shown in the example of
FIG. 10, the mass portions 131, 132, 133, and 134 may be located at
or near the periphery of the body portion 110 and extend along the
sole portion 190 to lower the CG of the golf club head 100. The
mass portions 135, 136 and 137 may be located at or near the
periphery of the body portion 110 and extend to and/or between the
sole portion 190 and the toe portion 140 to lower the CG and
increase the MOI of the golf club head 100. For example, the MOI of
the golf club head 100 about a vertical axis extending through the
CG may increase. To lower the CG of the golf club head 100, all or
a portion of the second set of mass portions 130 may be located
closer to the sole portion 190 than to the horizontal midplane
1020. For example, the mass portions 131, 132, 133, 134, 135, and
136 may be closer to the sole portion 190 than to the horizontal
midplane 1020. The locations of the second set of mass portions 130
(i.e., the locations of the second set of ports 1430) and the
physical properties and materials of construction of the second set
of mass portions 130 may be determined to optimally affect the
mass, mass distribution, CG, MOI, structural integrity and/or or
other static and/or dynamic characteristics of the golf club head
100. The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0076] Turning to FIGS. 7-9, for example, one or more mass portions
of the first set of mass portions 120 and/or the second set of mass
portions 130 may be located away from the back surface 166 of the
face portion 162 (e.g., not directly coupled to each other). That
is, one or more mass portions of the first set of mass portions 120
and/or the second set of mass portions 130 and the back surface 166
may be partially or entirely separated by an interior cavity 700 of
the body portion 110. As shown in FIG. 14, for example, one or more
ports of the first and second sets of ports 1420 and 1430 may
include an opening (e.g., generally shown as 720 and 730) and a
port wall (e.g., generally shown as 725 and 735). The port walls
725 and 735 may be integral portions of the back wall portion 1410
(e.g., a section of the back wall portion 1410) or the body portion
110 depending on the location of each port. The opening 720 may be
configured to receive a mass portion such as mass portion 121. The
opening 730 may be configured to receive a mass portion such as
mass portion 135. The opening 720 may be located at one end of the
port 1421, and the port wall 725 may be located or proximate to at
an opposite end of the port 1421. In a similar manner, the opening
730 may be located at one end of the port 1435, and the port wall
735 may be located at or proximate to an opposite end of the port
1435. The port walls 725 and 735 may be separated from the face
portion 162 (e.g., separated by the interior cavity 700). The port
wall 725 may have a distance 726 from the back surface 166 of the
face portion 162 as shown in FIG. 9. The port wall 735 may have a
distance 736 from the back surface 166 of the face portion 162. The
distances 726 and 736 may be determined to optimize the location of
the CG of the golf club head 100 when the first and second sets of
ports 1420 and 1430, respectively, receive mass portions as
described herein. According to one example, the distance 736 may be
greater than the distance 726 so that the CG of the golf club head
100 may be moved toward the back portion 170. As a result, a width
740 of a portion of the interior cavity 700 below the horizontal
midplane 1020 may be greater than a width 742 of the interior
cavity 700 above the horizontal midplane 1020. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0077] As described herein, the CG of the golf club head 100 may be
relatively farther back away from the face portion 162 and
relatively lower towards a ground plane (e.g., one shown as 1010 in
FIG. 10) with all or a substantial portion of the second set of
mass portions 130 being at or closer to the sole portion 190 than
to the horizontal midplane 1020 and the first and second sets of
mass portions 120 and 130, respectively being away from the back
surface 166 than if the second set of mass portions 130 were
directly coupled to the back surface 166. The body portion 110 may
include any number of mass portions (e.g., no mass portions, one
mass portion, two mass portions, etc.) and/or any configuration of
mass portions (e.g., mass portion(s) integral with the body portion
110) above the horizontal midplane 1020 and/or below the horizontal
midplane 1020. The locations of the first and second sets of ports
1420 and 1430 and/or the locations (e.g., internal mass portion(s),
external mass portion(s), mass portion(s) integral with the body
portion 110, etc.), physical properties and materials of
construction of the first set of mass portions 120 and/or the
second set of mass portions 130 may be determined to optimally
affect the mass, mass distribution, CG, MOI characteristics,
structural integrity and/or or other static and/or dynamic
characteristics of the golf club head 100. Different from other
golf club head designs, the interior cavity 700 of the body portion
110 and the location of the first set of mass portions 120 and/or
the second set of mass portion 130 along the periphery of the golf
club head 100 may result in a golf ball traveling away from the
face portion 162 at a relatively higher ball launch angle and a
relatively lower spin rate. As a result, the golf ball may travel
farther (i.e., greater total distance, which includes carry and
roll distances). The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0078] While the figures may depict ports with a particular
cross-section shape, the apparatus, methods, and articles of
manufacture described herein may include ports with other suitable
cross-section shapes. In one example, the ports of the first and/or
second sets of ports 1420 and 1430 may have U-like cross-section
shape. In another example, the ports of the first and/or second set
of ports 1420 and 1430 may have V-like cross-section shape. One or
more of the ports associated with the first set of mass portions
120 may have a different cross-section shape than one or more ports
associated with the second set of mass portions 130. For example,
the port 1421 may have a U-like cross-section shape whereas the
port 1435 may have a V-like cross-section shape. Further, two or
more ports associated with the first set of mass portions 120 may
have different cross-section shapes. In a similar manner, two or
more ports associated with the second set of mass portions 130 may
have different cross-section shapes. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0079] The first and second sets of mass portions 120 and 130,
respectively, may be similar in mass (e.g., all of the mass
portions of the first and second sets 120 and 130, respectively,
weigh about the same). Alternatively, the first and second sets of
mass portions 120 and 130, respectively, may be different in mass
individually or as an entire set. In particular, one or more mass
portions of the first set of mass portions 120 (e.g., generally
shown as 121, 122, 123, and 124) may have relatively less mass than
one or more portions of the second set of mass portions 130 (e.g.,
generally shown as 131, 132, 133, 134, 135, 136, and 137). For
example, the second set of mass portions 130 may account for more
than 50% of the total mass from mass portions of the golf club head
100. As a result, the golf club head 100 may be configured to have
at least 50% of the total mass from mass portions disposed below
the horizontal midplane 1020. Two or more mass portions in the same
set may be different in mass. In one example, the mass portion 121
of the first set 120 may have a relatively lower mass than the mass
portion 122 of the first set 120. In another example, the mass
portion 131 of the second set 130 may have a relatively lower mass
than the mass portion 135 of the second set 130. Accordingly, more
mass may be distributed away from the CG of the golf club head 100
to increase the MOI about the vertical axis through the CG. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0080] In one example, the golf club head 100 may have a mass in
the range of about 220 grams to about 330 grams based on the type
of golf club (e.g., a 4-iron versus a lob wedge). The body portion
110 may have a mass in the range of about 200 grams to about 310
grams with the first set of mass portions 120 and/or the second set
of mass portions 130 having a mass of about 20 grams (e.g., a total
mass from mass portions). One or more mass portions of the first
set of mass portions 120 and/or the second set of mass portions 130
may have a mass greater than or equal to about 0.1 gram and less
than or equal to about 20 grams. In one example, one or more mass
portions of the first set 120 may have a mass of about 0.75 gram
whereas one or more mass portions of the second set 130 may have a
mass of about 2.4 grams. The sum of the mass of the first set of
mass portions 120 or the sum of the mass of the second set of mass
portions 130 may be greater than or equal to about 0.1 grams and
less than or equal to about 20 grams. In one example, the sum of
the mass of the first set of mass portions 120 may be about 3 grams
whereas the sum of the mass of the first set of mass portions 130
may be about 16.8 grams. The total mass of the second set of mass
portions 130 may weigh more than five times as much as the total
mass of the first set of mass portions 120 (e.g., a total mass of
the second set of mass portions 130 of about 16.8 grams versus a
total mass of the first set of mass portions 120 of about 3 grams).
The golf club head 100 may have a total mass of 19.8 grams from the
first and second sets of mass portions 120 and 130, respectively
(e.g., sum of 3 grams from the first set of mass portions 120 and
16.8 grams from the second set of mass portions 130). Accordingly,
in one example, the first set of mass portions 120 may account for
about 15% of the total mass from mass portions of the golf club
head 100 whereas the second set of mass portions 130 may be account
for about 85% of the total mass from mass portions of the golf club
head 100. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0081] By coupling the first set of mass portions 120 and/or the
second set of mass portions 130, respectively, to the body portion
110 (e.g., securing the first set of mass portions 120 and/or the
second set of mass portions 130 in the ports on the back portion
170), the location of the CG and the MOI) of the golf club head 100
may be optimized. In particular, as described herein, the first set
of mass portions 120 may lower the location of the CG towards the
sole portion 190 and further back away from the face portion 162.
Further, the first set of mass portions 120 and/or the second set
of mass portions 130 may increase the MOI as measured about a
vertical axis extending through the CG (e.g., perpendicular to the
ground plane 1010). The MOI may also be higher as measured about a
horizontal axis extending through the CG (e.g., extending towards
the toe and heel portions 150 and 160, respectively, of the golf
club head 100). As a result, the club head 100 may provide a
relatively higher launch angle and a relatively lower spin rate
than a golf club head without the first and/or second sets of mass
portions 120 and 130, respectively. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0082] Although the figures may depict the mass portions as
separate and individual parts that may be visible from an exterior
of the golf club head 100, the two or more mass portions of the
first set of mass portions 120 and/or the second set of mass
portions 130 may be a single piece of mass portion that may be an
exterior mass portion or an interior mass portion (i.e., not
visible from an exterior of the golf club head 100). In one
example, all of the mass portions of the first set 120 (e.g.,
generally shown as 121, 122, 123, and 124) may be combined into a
single piece of mass portion (e.g., a first mass portion). In a
similar manner, all of the mass portions of the second set 130
(e.g., generally shown as 131, 132, 133, 134, 135, 136, and 137)
may be combined into a single piece of mass portion as well (e.g.,
a second mass portion). In this example, the golf club head 100 may
have only two mass portions. In another example (not shown), the
body portion 110 may not include the first set of mass portions
120, but include the second set of mass portions 130 in the form of
a single piece of internal mass portion that may be farther from
the heel portion 150 than the toe portion 140. In yet another
example (not shown), the body portion 110 may not include the first
set of mass portions 120, but include the second set of mass
portions 130 with a first internal mass portion farther from the
heel portion 150 than the toe portion 140 and a second internal
mass portion farther from the toe portion 140 than the heel portion
150. The first internal mass portion and the second internal mass
portion may be (i) integral parts of the body portion 110 or (ii)
separate from the body portion 110 and coupled to the body portion
110. The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0083] While the figures may depict a particular number of mass
portions, the apparatus, methods, and articles of manufacture
described herein may include more or less number of mass portions.
In one example, the first set of mass portions 120 may include two
separate mass portions instead of three separate mass portions as
shown in the figures. In another example, the second set of mass
portions 130 may include five separate mass portions instead of
seven separate mass portions as shown in the figures. Alternatively
as mentioned above, the apparatus, methods, and articles of
manufacture described herein may not include any separate mass
portions (e.g., the body portion 110 may be manufactured to include
the mass of the separate mass portions as integral part(s) of the
body portion 110). The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0084] Referring to FIGS. 7-9, for example, the body portion 110
may be a hollow body including the interior cavity 700 extending
between the front portion 160 and the back portion 170. Further,
the interior cavity 700 may extend between the top portion 180 and
the sole portion 190. The interior cavity 700 may be associated
with a cavity height 750 (H.sub.C), and the body portion 110 may be
associated with a body height 850 (H.sub.B). While the cavity
height 750 and the body height 850 may vary between the toe and
heel portions 140 and 150, the cavity height 750 may be at least
50% of a body height 850 (H.sub.C>0.5*H.sub.B). For example, the
cavity height 750 may vary between 70%-85% of the body height 850.
With the cavity height 750 of the interior cavity 700 being greater
than 50% of the body height 850, the golf club head 100 may produce
relatively more consistent feel, sound, and/or result when the golf
club head 100 strikes a golf ball via the face portion 162 than a
golf club head with a cavity height of less than 50% of the body
height. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0085] In one example, the interior cavity 700 may be unfilled
(i.e., empty space). The body portion 110 with the interior cavity
700 may weigh about 100 grams less than the body portion 110
without the interior cavity 700. Alternatively, the interior cavity
700 may be partially or entirely filled with a cavity filling or
filler material (i.e., a cavity filling portion), which may include
one or more similar or different types of materials. In one
example, the filler material may include an elastic polymer or an
elastomer material (e.g., a viscoelastic urethane polymer material
such as Sorbothane.RTM. material manufactured by Sorbothane, Inc.,
Kent, Ohio), a thermoplastic elastomer material (TPE), a
thermoplastic polyurethane material (TPU), other polymer
material(s), bonding material(s) (e.g., adhesive), and/or other
suitable types of materials that may absorb shock, isolate
vibration, and/or dampen noise. For example, at least 50% of the
interior cavity 700 may be filled with a TPE material to absorb
shock, isolate vibration, and/or dampen noise when the golf club
head 100 strikes a golf ball via the face portion 162. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0086] In another example, the filler material may be a polymer
material such as an ethylene copolymer material that may absorb
shock, isolate vibration, and/or dampen noise when the golf club
head 100 strikes a golf ball via the face portion 162. In
particular, at least 50% of the interior cavity 700 may be filled
with a high density ethylene copolymer ionomer, a fatty acid
modified ethylene copolymer ionomer, a highly amorphous ethylene
copolymer ionomer, an ionomer of ethylene acid acrylate terpolymer,
an ethylene copolymer comprising a magnesium ionomer, an injection
moldable ethylene copolymer that may be used in conventional
injection molding equipment to create various shapes, an ethylene
copolymer that can be used in conventional extrusion equipment to
create various shapes, an ethylene copolymer having high
compression and low resilience similar to thermoset polybutadiene
rubbers, and/or a blend of highly neutralized polymer compositions,
highly neutralized acid polymers or highly neutralized acid polymer
compositions, and fillers. For example, the ethylene copolymer may
include any of the ethylene copolymers associated with DuPont.TM.
High-Performance Resin (HPF) family of materials (e.g., DuPont.TM.
HPF AD1172, DuPont.TM. HPF AD1035, DuPont.RTM. HPF 1000 and
DuPont.TM. HPF 2000), which are manufactured by E.I. du Pont de
Nemours and Company of Wilmington, Del. The DuPont.TM. HPF family
of ethylene copolymers are injection moldable and may be used with
conventional injection molding equipment and molds, provide low
compression, and provide high resilience, i.e., relatively high
coefficient of restitution (COR). The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0087] For example, the filler material may have a density of less
than or equal to 1.5 g/cm.sup.3. The filler material may have a
compression deformation value ranging from about 0.0787 inch (2 mm)
to about 0.1968 inch (5 mm). The filler material may have a surface
Shore D hardness ranging from 40 to 60. As mentioned above, the
filler material may be associated with a relatively high
coefficient of restitution (COR). The filler material may be
associated with a first COR (COR.sub.1) and the face portion 2462
may be associated with a second COR (COR.sub.2), which may be
similar or different from the first COR. The first and second CORs
may be associated with a COR ratio (e.g., COR.sub.12
ratio=COR.sub.1/COR.sub.2 or COR.sub.21 ratio=COR.sub.2/COR.sub.1).
In one example, the COR ratio may be less than two (2). In another
example, the COR ratio may be in a range from about 0.5 to about
1.5. In yet another example, the COR ratio may be in a range from
about 0.8 to about 1.2. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0088] The golf club head 100 may be associated with a third COR
(COR.sub.3), which may be similar or different from the first COR
and/or the second COR. As mentioned above, the filler material may
be associated with the first COR. The first and third CORs may be
associated with a COR ratio (e.g., COR.sub.13
ratio=COR.sub.1/COR.sub.3 or COR.sub.31 ratio=COR.sub.3/COR.sub.1).
In one example, the COR ratio may be less than two (2). In another
example, the COR ratio may be in a range from about 0.5 to about
1.5. In yet another example, the COR ratio may be in a range from
about 0.8 to about 1.2. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0089] The CORs of the filler material, the face portion 162,
and/or the golf club head 100 (e.g., the first COR (COR.sub.1), the
second COR (COR.sub.2), and/or the third COR (COR.sub.3),
respectively) may be measured by methods similar to methods that
measure the COR of a golf ball and/or a golf club head as defined
by one or more golf standard organizations and/or governing bodies
(e.g., United States Golf Association (USGA)). In one example, an
air cannon device may launch or eject an approximately 1.55 inch
(38.1 mm) spherical sample of the filler material at an initial
velocity toward a steel plate positioned at about 4 feet (1.2
meters) away from the air cannon device. The sample may vary in
size, shape or any other configuration. A speed monitoring device
may be located at a distance in a range from 2 feet (0.6 meters) to
3 feet (0.9 meters) from the air cannon device. The speed
monitoring device may measure a rebound velocity of the sample of
the filler material after the sample of the filler material strikes
the steel plate. In one example, the rebound velocity may be
greater than or equal to 2 meters per second (m/s). In another
example, the rebound velocity may be greater than or equal to 2.5
m/s. In yet another example, the rebound velocity may be greater
than or equal to 3 m/s. The COR may be the rebound velocity divided
by the initial velocity. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0090] In one example, an air cannon device may launch or eject a
testing golf ball (e.g., as defined by the USGA) at an initial
velocity toward a plate-shaped sample of the filler material with a
rigid backing (e.g., a metal plate) positioned at about 4 feet (1.2
meters) away from the air cannon device. The plate-shaped sample of
the filler material may have sufficient thickness depending on the
elasticity of the filler material so that the striking golf ball
compresses the filler material within the elastic range of the
filler material. The thickness of the plate-shaped sample of the
filler material may vary based on the elasticity of the filler
material. For example, the plate-shaped sample of the filler
material may have a thickness ranging from about 1 inch to about 5
inches. A speed monitoring device may be located at a distance in a
range from 2 feet (0.6 meters) to 3 feet (0.9 meters) from the air
cannon device. The speed monitoring device may measure a rebound
velocity of the golf ball after the golf ball strikes the
plate-shaped sample of the filler material. The method of measuring
COR of the filler material may be repeated with multiple samples of
the same brand and model of golf balls (i.e., identical or
substantially identical golf balls). In one example, the rebound
velocity may be greater than or equal to 2 meters per second (m/s).
In another example, the rebound velocity may be greater than or
equal to 2.5 m/s. In yet another example, the rebound velocity may
be greater than or equal to 3 m/s. The COR may be the rebound
velocity divided by the initial velocity. The apparatus, methods,
and articles of manufacture described herein are not limited in
this regard.
[0091] In another example, a drop test procedure may be used to
determine the COR of the filler material. An approximately 1.68
inch (42.6 mm) spherical sample of the filler material may be
dropped onto a horizontally positioned steel plate from a certain
drop distance. A bounce distance, which is the distance by which
the spherical sample of the filler material bounces from the steel
plate may be measured. The COR may be the bounce distance divided
by the drop distance. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0092] In yet another example, a drop test procedure may be used to
determine the COR of the filler material. A USGA testing golf ball
may be dropped onto a horizontally positioned plate-shaped sample
of the filler material with a rigid backing (e.g., a metal plate)
from a certain drop distance. The plate-shaped sample of the filler
material may have sufficient thickness depending on the elasticity
of the filler material so that the dropped golf ball compresses the
filler material within the elastic range of the filler material. In
one example, the plate-shaped sample of the filler material may
have a thickness ranging from about 1 inch to about 5 inches. A
bounce distance, which may be the distance by which the golf ball
bounces from the plate-shaped filler material is then measured. The
method of measuring COR of the filler material may be repeated with
multiple samples of the same brand and model of golf balls (i.e.,
identical or substantially identical golf balls). The COR may be
the bounce distance divided by the drop distance. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0093] In one example, the filler material may have a COR value in
a range from approximately 0.50 to approximately 0.95 when measured
with an initial velocity in a range from 100 ft/s (30.48 m/s) to
250 ft/s (76.2 m/s). In another example, the filler material may
have a COR value in a range from approximately 0.65 to
approximately 0.85 when measured with an initial velocity in a
range from 100 ft/s (30.48 m/s) to 150 ft/s (45.72 m/s). In another
example, the filler material may have a COR value in a range from
approximately 0.75 to approximately 0.8 when measured with an
initial velocity in a range 100 ft/s (30.48 m/s) to 150 ft/s (45.72
m/s). In another example, the filler material may have a COR value
in a range from approximately 0.55 to approximately 0.90 when
measured with an initial velocity in a range from 100 ft/s (30.48
m/s) and 250 ft/s (76.2 m/s). In another example, the filler
material may have a COR value in a range from approximately 0.75 to
approximately 0.85 when measured with an initial velocity in a
range 110 ft/s (33.53 m/s) to 200 ft/s (60.96 m/s). In yet another
example, the filler material may have a COR value in a range from
approximately 0.8 to approximately 0.9 when measured with an
initial velocity of about 125 ft/s (38.1 m/s). Further, the filler
material may have a COR value greater than or equal to 0.8 at an
initial velocity of about 143 ft/s (43.6 m/s). While a particular
example may be described above, other methods may be used to
measure the CORs of the filler material, the face portion 162,
and/or the golf club head 100. The apparatus, methods, and articles
of manufacture described herein are not limited in this regard.
[0094] When the face portion 162 of the golf club head 100 strikes
a golf ball, the face portion 162 and the filler material may
deform and/or compress. The kinetic energy of the impact may be
transferred to the face portion 162 and/or the filler material. For
example, some of the kinetic energy may be transformed into heat by
the filler material or work done in deforming and/or compressing
the filler material. Further, some of the kinetic energy may be
transferred back to the golf ball to launch the golf ball at a
certain velocity. A filler material with a relatively higher COR
may transfer relatively more kinetic energy to the golf ball and
dissipate relatively less kinetic energy. Accordingly, a filler
material with a relatively high COR may generate relatively higher
golf ball speeds because a relatively greater part of the kinetic
energy of the impact may be transferred back to the golf ball to
launch the golf ball from the golf club head 100.
[0095] The filler material may include a bonding portion. In one
example, the bonding portion may be one or more bonding agents
including thermoset polymers having bonding properties (e.g., one
or more adhesive or epoxy materials). For example, the bonding
agent may assist in bonding or adhering the filler material to at
least the back surface 166 of the face portion 162. The bonding
agent may also absorb shock, isolate vibration, and/or dampen noise
when the golf club head 100 strikes a golf ball via the face
portion 162. Further, the bonding agent may be an epoxy material
that may be flexible or slightly flexible when cured. In one
example, the filler material may include any of the 3M.TM.
Scotch-Weld.TM. DP100 family of epoxy adhesives (e.g., 3M.TM.
Scotch-Weld.TM. Epoxy Adhesives DP100, DP100 Plus, DP100NS and
DP100FR), which are manufactured by 3M corporation of St. Paul,
Minn. In another example, the filler material may include 3M.TM.
Scotch-Weld.TM. DP100 Plus Clear adhesive. In yet another example,
the filler material may include low-viscosity, organic,
solvent-based solutions and/or dispersions of polymers and other
reactive chemicals such as MEGUM.TM., ROBOND.TM., and/or THIXON.TM.
materials manufactured by the Dow Chemical Company, Auburn Hills,
Mich. In yet another example, the filler material may be
LOCTITE.RTM. materials manufactured by Henkel Corporation, Rocky
Hill, Conn. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0096] Further, the filler material may include a combination of
one or more bonding agents such as any of the bonding agents
described herein and one or more polymer materials such as any of
the polymer materials described herein. In one example, the filler
material may include one or more bonding agents that may be used to
bond the polymer material to the back surface 166 of the face
portion 162. The one or more bonding agents may be applied to the
back surface 166 of the face portion 162. The filler material may
further include one or more polymer materials may partially or
entirely fill the remaining portions of the interior cavity 700.
Accordingly, two or more separate materials may partially or
entirely fill the interior cavity 700. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0097] The filler material may only include one or more polymer
materials that adhere to inner surface(s) of the interior cavity
700 without a separate bonding agent (e.g., an adhesive or epoxy
material). For example, the filler material may include a mixture
of one or more polymer materials and one or more bonding agents
(e.g., adhesive or epoxy material(s)). Accordingly, the mixture
including the one or more polymer materials and the one or more
bonding agents may partially or entirely fill the interior cavity
700 and adhere to inner surface(s) of the interior cavity 700. In
another example, the interior cavity 700 may be partially or
entirely filled with one or more polymer materials without any
bonding agents. In yet another example, the interior cavity 700 may
be partially or entirely filled with one or more bonding agents
and/or adhesive materials such as an adhesive or epoxy material.
The apparatus, methods, and articles of manufacture described
herein are not limited in this regard.
[0098] Turning to FIG. 15, for example, a thickness of the face
portion 162 may be a first thickness 1510 (T.sub.1) or a second
thickness 1520 (T.sub.2). The first thickness 1510 may be a
thickness of a section of the face portion 162 adjacent to a groove
168 whereas the second thickness 1520 may be a thickness of a
section of the face portion 162 below the groove 168. For example,
the first thickness 1510 may be a maximum distance between the
front surface 164 and the back surface 166. The second thickness
1520 may be based on the groove 168. In particular, the groove 168
may have a groove depth 1525 (D.sub.groove). The second thickness
1520 may be a maximum distance between the bottom of the groove 168
and the back surface 166. The sum of the second thickness 1520 and
the groove depth 1525 may be substantially equal to the first
thickness 1510 (e.g., T.sub.2+D.sub.groove=T.sub.1). Accordingly,
the second thickness 1520 may be less than the first thickness 1510
(e.g., T.sub.2.ltoreq.T.sub.1).
[0099] To lower and/or move the CG of the golf club head 100
further back, mass from the front portion 160 of the golf club head
100 may be removed by using a relatively thinner face portion 162.
For example, the first thickness 1510 or the second thickness 1520
may be less than or equal to 0.1 inch (2.54 millimeters). In
another example, the first thickness 1510 may be about 0.075 inch
(1.905 millimeters) (e.g., T.sub.1=0.075 inch). With the support of
the back wall portion 1410 to form the interior cavity 700 and
filling at least a portion of the interior cavity 700 with an
elastic polymer material, the face portion 162 may be relatively
thinner (e.g., T.sub.1<0.075 inch) without degrading the
structural integrity, sound, and/or feel of the golf club head 100.
In one example, the first thickness 1510 may be less than or equal
to 0.060 inch (1.524 millimeters) (e.g., T1.ltoreq.0.060 inch). In
another example, the first thickness 1510 may be less than or equal
to 0.040 inch (1.016 millimeters) (e.g., T.sub.1.ltoreq.0.040
inch). Based on the type of material(s) used to form the face
portion 162 and/or the body portion 110, the face portion 162 may
be even thinner with the first thickness 1510 being less than or
equal to 0.030 inch (0.762 millimeters) (e.g., T.sub.1.ltoreq.0.030
inch). The groove depth 1525 may be greater than or equal to the
second thickness 1520 (e.g., D.sub.groove.gtoreq.T.sub.2). In one
example, the groove depth 1525 may be about 0.020 inch (0.508
millimeters) (e.g., D.sub.groove=0.020 inch). Accordingly, the
second thickness 1520 may be about 0.010 inch (0.254 millimeters)
(e.g., T.sub.2=0.010 inch). In another example, the groove depth
1525 may be about 0.015 inch (0.381 millimeters), and the second
thickness 1520 may be about 0.015 inch (e.g.,
D.sub.groove=T.sub.2=0.015 inch). Alternatively, the groove depth
1525 may be less than the second thickness 1520 (e.g.,
D.sub.groove<T.sub.2). Without the support of the back wall
portion 1410 and the elastic polymer material to fill in the
interior cavity 700, a golf club head may not be able to withstand
multiple impacts by a golf ball on a face portion. In contrast to
the golf club head 100 as described herein, a golf club head with a
relatively thin face portion but without the support of the back
wall portion 1410 and the elastic polymer material to fill in the
interior cavity 700 (e.g., a cavity-back golf club head) may
produce unpleasant sound (e.g., a tinny sound) and/or feel during
impact with a golf ball. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0100] Based on manufacturing processes and methods used to form
the golf club head 100, the face portion 162 may include additional
material at or proximate to a periphery of the face portion 162.
Accordingly, the face portion 162 may also include a third
thickness 1530, and a chamfer portion 1540. The third thickness
1530 may be greater than either the first thickness 1510 or the
second thickness 1520 (e.g., T.sub.3>T.sub.1>T.sub.2). In
particular, the face portion 162 may be coupled to the body portion
110 by a welding process. For example, the first thickness 1510 may
be about 0.030 inch (0.762 millimeters), the second thickness 1520
may be about 0.015 inch (0.381 millimeters), and the third
thickness 1530 may be about 0.050 inch (1.27 millimeters).
Accordingly, the chamfer portion 1540 may accommodate some of the
additional material when the face portion 162 is welded to the body
portion 110.
[0101] As illustrated in FIG. 16, for example, the face portion 162
may include a reinforcement section, generally shown as 1605, below
one or more grooves 168. In one example, the face portion 162 may
include a reinforcement section 1605 below each groove.
Alternatively, face portion 162 may include the reinforcement
section 1605 below some grooves (e.g., every other groove) or below
only one groove. The face portion 162 may include a first thickness
1610, a second thickness 1620, a third thickness 1630, and a
chamfer portion 1640. The groove 168 may have a groove depth 1625.
The reinforcement section 1605 may define the second thickness
1620. The first and second thicknesses 1610 and 1620, respectively,
may be substantially equal to each other (e.g., T.sub.1=T.sub.2).
In one example, the first and second thicknesses 1610 and 1620,
respectively, may be about 0.030 inch (0.762 millimeters) (e.g.,
T.sub.1=T.sub.2=0.030 inch). The groove depth 1625 may be about
0.015 inch (0.381 millimeters), and the third thickness 1630 may be
about 0.050 inch (1.27 millimeters). The groove 168 may also have a
groove width. The width of the reinforcement section 1605 may be
greater than or equal to the groove width. The apparatus, methods,
and articles of manufacture described herein are not limited in
this regard.
[0102] Alternatively, the face portion 162 may vary in thickness at
and/or between the top portion 180 and the sole portion 190. In one
example, the face portion 162 may be relatively thicker at or
proximate to the top portion 180 than at or proximate to the sole
portion 190 (e.g., thickness of the face portion 162 may taper from
the top portion 180 towards the sole portion 190). In another
example, the face portion 162 may be relatively thicker at or
proximate to the sole portion 190 than at or proximate to the top
portion 180 (e.g., thickness of the face portion 162 may taper from
the sole portion 190 towards the top portion 180). In yet another
example, the face portion 162 may be relatively thicker between the
top portion 180 and the sole portion 190 than at or proximate to
the top portion 180 and the sole portion 190 (e.g., thickness of
the face portion 162 may have a bell-shaped contour). The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard. As described herein, the interior
cavity 700 may be partially or fully filled with a filler material,
which may be a polymer material, a bonding agent (such as an
adhesive or epoxy material), or a combination of polymer
material(s) and bonding agent(s) to at least partially provide
structural support for the face portion 162. In particular, the
filler material may also provide vibration and/or noise dampening
for the body portion 110 when the face portion 162 strikes a golf
ball. Alternatively, the filler material may only provide vibration
and/or noise dampening for the body portion 110 when the face
portion 162 strikes a golf ball. In one example, the body portion
110 of the golf club head 100 (e.g., an iron-type golf club head)
may have a body portion volume (V.sub.b) between about 2.0 cubic
inches (32.77 cubic centimeters) and about 4.2 cubic inches (68.83
cubic centimeters). The volume of the filler material filling the
interior cavity (V.sub.e), such as the interior cavity 700, may be
between 0.5 and 1.7 cubic inches (8.19 and 27.86 cubic centimeters,
respectively). A ratio of the filler material volume (V.sub.e) to
the body portion volume (V.sub.b) may be expressed as:
0.2 .ltoreq. V e V b .ltoreq. 0.5 ##EQU00001##
[0103] Where: [0104] V.sub.e is the filler material volume in units
of in.sup.3, and [0105] V.sub.b is the body portion volume in units
of in.sup.3.
[0106] In another example, the ratio of the filler material volume
(V.sub.e) to the body portion volume (V.sub.b) may be between about
0.2 and about 0.4. In yet another example, the ratio of the filler
material volume (V.sub.e) to the body portion volume (V.sub.b) may
be between about 0.25 and about 0.35. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0107] Based on the amount of filler material filling the interior
cavity, for example, the thickness of the face portion may be
between about 0.025 inches (0.635 millimeters) and about 0.1 inch
(2.54 millimeters). In another example, the thickness of the face
portion (T.sub.f) may be between about 0.02 inches (0.508
millimeters) and about 0.09 inches (2.286 millimeters). The
thickness of the face portion (T.sub.f) may depend on the volume of
the filler material in the interior cavity (V.sub.e), such as the
interior cavity 700. The ratio of the thickness of the face portion
(T.sub.f) to the volume of the filler material (V.sub.e) may be
expressed as:
0.01 .ltoreq. T f V e .ltoreq. 0.2 ##EQU00002##
[0108] Where: [0109] T.sub.f is the thickness of the face portion
in units of inches, and [0110] V.sub.e is the filler material
volume in units of in.sup.3.
[0111] In one example, the ratio of the thickness of the face
portion (T.sub.f) to the volume of the filler material (V.sub.e)
may be between 0.02 and 0.09. In another example, the ratio of the
thickness of the face portion (T.sub.f) to the volume of the filler
material (V.sub.e) may be between 0.04 and 0.14. The thickness of
the face portion (T.sub.f) may be the same as T.sub.1 and/or
T.sub.2 mentioned above. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0112] The thickness of the face portion (T.sub.f) may depend on
the volume of the filler material in the interior cavity (V.sub.e),
such as the interior cavity 700, and the body portion volume
(V.sub.b). The volume of the filler material (V.sub.e) may be
expressed as:
V.sub.e=a*V.sub.b+b+c*T.sub.f
a.apprxeq.0.48
b.apprxeq.-0.38
0.ltoreq.c.ltoreq.10
[0113] Where: [0114] V.sub.e is the filler material volume in units
of in.sup.3, [0115] V.sub.b is the body portion volume in units of
in.sup.3, and [0116] T.sub.f is the thickness of the face portion
in units of inches.
[0117] As described herein, for example, the body portion volume
(V.sub.b) may be between about 2.0 cubic inches (32.77 cubic
centimeters) and about 4.2 cubic inches (68.83 cubic centimeters).
In one example, the thickness of the face portion (T.sub.f) may be
about 0.03 inches (0.762 millimeters). In another example, the
thickness of the face portion (T.sub.f) may be about 0.06 inches
(1.524 millimeters). In yet another example, the thickness of the
face portion (T.sub.f) may be about 0.075 inches (1.905
millimeters). The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0118] Further, the volume of the filler material (V.sub.e) when
the interior cavity is fully filled with the filler material may be
similar to the volume of the interior cavity (V.sub.c).
Accordingly, when the interior cavity is fully filled with a filler
material, the volume of the filler material (V.sub.e) in any of the
equations provided herein may be replaced with the volume of the
interior cavity (V.sub.c). Accordingly, the above equations
expressed in terms of the volume of the interior cavity (V.sub.c)
may be expressed as:
0.2 .ltoreq. Vc Vb .ltoreq. 0.5 ##EQU00003## 0.01 .ltoreq. Tf Vc
.ltoreq. 0.2 ##EQU00003.2## Vc = a Vb + b .+-. c Tf ##EQU00003.3##
a .apprxeq. 0.48 ##EQU00003.4## b .apprxeq. - 0.38 ##EQU00003.5## 0
.ltoreq. c .ltoreq. 10 ##EQU00003.6##
[0119] Where: [0120] V.sub.c is the volume of the interior cavity
in units of in.sup.3, [0121] V.sub.b is the body portion volume in
units of in.sup.3, and [0122] T.sub.f is the thickness of the face
portion in units of inches.
[0123] As described herein, the filler material may include a
bonding agent that may be bonded to the back surface 166 of the
face portion 162 to attach the remaining portions of the filler
material to the back surface 166 of the face portion 162, dampen
noise and vibration, provide a certain feel and sound for the golf
club head, and/or at least partially structurally support the face
portion 162. The thickness of the bonding agent and/or a portion of
the filler material may depend on a thickness of the face portion
162. In one example, a relationship between a thickness of the face
portion 162 and a thickness of a bonding agent and/or a portion of
the filler material may be expressed as:
0.1 .ltoreq. T f T a .ltoreq. 4.0 ##EQU00004##
[0124] Where: [0125] T.sub.f is the thickness of the face portion
in units of inches, and [0126] T.sub..alpha. is the thickness of
the bonding agent and/or the thickness of the filler material in
units of inches.
[0127] In one example, the bonding agent and/or the filler material
may have a thickness ranging from 0.02 inch (0.51 millimeters) to
0.2 inch (5.08 millimeters). In another example, the bonding agent
and/or the filler material may be have a thickness ranging from
0.04 inch (0.1.02 millimeters) to 0.08 inch (2.03 millimeters). In
another example, the bonding agent and/or the filler material may
be have a thickness ranging from 0.03 inch (0.76 millimeters) to
0.06 inch (1.52 millimeters). In yet another example, the bonding
agent and/or the filler material may have a thickness ranging from
0.01 inch (0.25 millimeters) to 0.3 inch (7.62 millimeters). The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0128] FIG. 17 depicts one manner in which the example golf club
head described herein may be manufactured. In the example of FIG.
17, the process 1700 may begin with providing one or more mass
portions, generally shown as the first and second sets of mass
portions 120 and 130, respectively (block 1710). The first set of
mass portions 120 and/or the second set of mass portions 130 may be
made of a first material such as a tungsten-based material, a
titanium-based material, a steel-based material, an aluminum-based
material, a non-metal material, any combination thereof, or other
suitable type of materials. In one example, the mass portions of
the first and second sets 120 and 130, respectively, may be
tungsten-alloy screws.
[0129] The process 1700 may provide a body portion 110 having the
face portion 162, the interior cavity 700, and the back portion 170
with two or more ports, generally shown as 1420 and 1430 (block
1720). The body portion 110 may be made of a second material, which
may be different than the first material or similar to the first
material. The body portion 110 may be manufactured using an
investment casting process, a billet forging process, a stamping
process, a computer numerically controlled (CNC) machining process,
a die casting process, any combination thereof, or other suitable
manufacturing processes. In one example, the body portion 110 may
be made of 17-4 PH stainless steel using a casting process. In
another example, the body portion 110 may be made of other suitable
type of stainless steel (e.g., Nitronic.RTM. 50 stainless steel
manufactured by AK Steel Corporation, West Chester, Ohio) using a
forging process. By using Nitronic.RTM. 50 stainless steel to
manufacture the body portion 110, the golf club head 100 may be
relatively stronger and/or more resistant to corrosion than golf
club heads made from other types of steel. One or more ports of the
body portion 110 may include an opening and a port wall. For
example, the port 1421 may include the opening 720 and the port
wall 725 with the opening 720 and the port wall 725 being on
opposite ends of each other. The interior cavity 700 may separate
the port wall 725 of the port 1421 and the back surface 166 of the
face portion 162. In a similar manner, the port 1435 may include
the opening 730 and the port wall 735 with the opening 730 and the
port wall 735 being on opposite ends of each other. The interior
cavity 700 may separate the port wall 735 of the port 1435 and the
back surface 166 of the face portion 162.
[0130] The process 1700 may couple one or more mass portions of the
first and second sets of mass portions 120 and 130 into one of the
one or more ports (blocks 1730). In one example, the process 1700
may insert and secure the mass portion 121 in the port 1421, and
the mass portion 135 in the port 1435. The process 1700 may use
various manufacturing methods and/or processes to secure the first
set of mass portions 120 and/or the second set of mass portions 130
in the ports such as the ports 1421 and 1435 (e.g., epoxy, welding,
brazing, mechanical lock(s), any combination thereof, etc.).
[0131] The process 1700 may partially or entirely fill the interior
cavity 700 with a filler material, which may be one or a
combination of a polymer material (e.g., an ethylene copolymer
material such as DuPont.TM. HPF family of materials) (block 1740)
and/or a bonding agent (e.g., an adhesive or epoxy material such as
3M.TM. Scotch-Weld.TM. Epoxy Adhesives DP100, DP100 Plus, DP100NS
and DP100FR). In one example, the filler material may fill at least
50% of the interior cavity 700. As mentioned above, the filler
material may absorb shock, isolate vibration, and/or dampen noise
in response to the golf club head 100 striking a golf ball. In one
example, the interior cavity 700 may be filled with filler
material, which may be a polymer material, a thermoplastic
elastomer material, a thermoplastic polyurethane material, a
bonding agent, and/or a combination thereof. In another example,
the interior cavity 700 may be entirely filled with a bonding
agent. As illustrated in FIG. 18, for example, the golf club head
100 may include one or more ports (e.g., one shown as 1431 in FIG.
14) with a first opening 1830 and a second opening 1835. The second
opening 1835 may be used to access the interior cavity 700. In one
example, the process 1700 (FIG. 17) may fill the interior cavity
700 with a filler material by injecting the filler material into
the interior cavity 700 from the first opening 1830 via the second
opening 1835. The first and second openings 1830 and 1835,
respectively, may be same or different in size and/or shape. While
the above example may describe and depict a particular port with a
second opening, any other ports of the golf club head 100 may
include a second opening (e.g., the port 1421). The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0132] Referring back to FIG. 17, the example process 1700 is
merely provided and described in conjunction with other figures as
an example of one way to manufacture the golf club head 100. While
a particular order of actions is illustrated in FIG. 17, these
actions may be performed in other temporal sequences. For example,
two or more actions depicted in FIG. 17 may be performed
sequentially, concurrently, or simultaneously. In one example,
blocks 1710, 1720, 1730, and/or 1740 may be performed
simultaneously or concurrently. Although FIG. 17 depicts a
particular number of blocks, the process may not perform one or
more blocks. In one example, the interior cavity 700 may not be
filled (i.e., block 1740 may not be performed). The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard. Referring back to FIGS. 1-14, the face
portion 162 may include a non-smooth back surface to improve
adhesion and/or mitigate delamination between the face portion 162
and the elastic polymer material used to fill the interior cavity
700 (e.g., FIG. 7). Various methods and/or processes such as an
abrasive blasting process (e.g., a bead blasting process, a sand
blasting process, other suitable blasting process, or any
combination thereof) and/or a milling (machining) process may be
used to form the back surface 166 into a non-smooth surface. For
example, the back surface 166 may have with a surface roughness
(Ra) ranging from 0.5 to 250 .mu.in (0.012 to 6.3 .mu.m). The
apparatus, methods, and articles of manufacture are not limited in
this regard.
[0133] Referring to FIG. 19, for example, the golf club head 100
may include the face portion 162, a bonding portion 1910, and a
polymer material 1920. The bonding portion 1910 may provide
connection, attachment and/or bonding of the polymer material 1920
to the face portion 162. In one example, the bonding portion 1910
and/or the polymer material 1920 may define a filler material as
described herein. The bonding portion 1910 may be a bonding agent
such as any of adhesive or epoxy materials described herein, a
tacky material, a combination of bonding agents, a bonding
structure or attachment device (i.e., a physical and/or mechanical
structure or device), a combination of bonding structures and/or
attachment devices, and/or a combination of one or more bonding
agents, one or more bonding structures and/or one or more
attachment devices. The bonding portion 1910 may be integral with
the polymer material 1920 to partially or entirely fill the
interior cavity 700. In other words, the polymer material 1920 may
include inherent bonding properties. For example, the bonding
portion 1910 may be a bonding agent mixed with the polymer material
1910 to provide bonding of the mixture to the back surface 166 of
the face portion 162 and/or other inner surface(s) of the body
portion 110. In one example, the bonding portion may include one or
more surface textures or surface structures on the back surface 166
of the face portion 162 to assist in adhesion of the polymer
material to the back surface 166 of the face portion. The
apparatus, methods, and articles of manufacture are not limited in
this regard.
[0134] For example, the golf club head 100 may include a bonding
agent such as any adhesive or epoxy materials described herein to
improve adhesion and/or mitigate delamination between the face
portion 162 and the polymer material 1920 used to fill the interior
cavity 700 of the golf club head 100 (e.g., FIG. 7). The bonding
portion 1910 may be applied to the back surface 166 of the face
portion 162 to bond the polymer material 1920 to the face portion
162 (e.g., extending between the back surface 166 and the polymer
material 1920). For example, the bonding portion 1910 may be
applied before or during when the interior cavity 700 is filled
with the polymer material 1920 via an injection molding process or
other suitable process. The apparatus, methods, and articles of
manufacture are not limited in this regard.
[0135] FIG. 20 depicts one manner to partially or entirely fill the
interior cavity 700 of the golf club head 100 or any of the golf
club heads described herein with a filler material. The process
2000 may begin with heating the golf club head 100 to a certain
temperature (block 2010). In one example, the golf club head 100
may be heated to a temperature ranging between 150.degree. C. and
250.degree. C., which may depend on factors such as the
vaporization temperature of the one or more components of the
filler material to be injected in the interior cavity 700. The
filler material may then be heated to a certain temperature (block
2020). In one example, the filler material may be a non-foaming and
injection-moldable thermoplastic elastomer (TPE) material.
Accordingly, the filler material may be heated to reach a liquid or
a flowing state prior to being injected into the interior cavity
700. The temperature at which the filler material may be heated may
depend on the type of polymer material used to form the filler
material. The heated filler material may be injected into the
interior cavity 700 to partially or fully fill the interior cavity
700 (block 2030). The filler material may be injected into the
interior cavity 700 from one or more of the ports described herein
(e.g., one or more ports of the first and second sets of ports 1420
and 1430, respectively, shown in FIG. 14). One or more other ports
may allow the air inside the interior cavity 700 displaced by the
filler material to vent from the interior cavity 700. In one
example, the golf club head 100 may be oriented horizontally as
shown in FIG. 14 during the injection molding process. The filler
material may be injected into the interior cavity 700 from ports
1431 and 1432. The ports 1421, 1422 and/or 1423 may serve as air
ports for venting the displaced air from the interior cavity 700.
Thus, regardless of the orientation of the golf club head 100
during the injection molding process, the filler material may be
injected into the interior cavity 700 from one or more lower
positioned ports while one or more upper positioned ports may serve
as air vents. The mold (e.g., the golf club head 100) may then be
cooled passively (e.g., at room temperature) or actively so that
the filler material reaches a solid state and adheres to the back
surface 166 of the face portion 162. The filler material may
directly adhere to the back surface 166 of the face portion 162.
Alternatively, the filler material may adhere to the back surface
166 of the face portion 162 with the aid of the one or more
structures on the back surface 166 and/or the bonding portion 1910
shown in FIG. 19 (e.g., a bonding agent as described herein). The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0136] As described above, the filler material may be heated to a
liquid state (i.e., non-foaming) and solidifies after being
injection molded in the interior cavity 700. A filler material with
a low modulus of elasticity may provide vibration and/or noise
dampening for the face portion 162 when the face portion 162
impacts a golf ball. For example, a polymer material that foams
when heated may provide vibration and/or noise dampening. However,
such a foaming polymer material may not have sufficient rigidity to
provide structural support to a relatively thin face portion
because of possible excessive deflection and/or compression of the
polymer material when absorbing the impact of a golf ball. In one
example, the one or more components of the filler material that is
injection molded in the interior cavity 700 may have a relatively
high modulus of elasticity to provide structural support to the
face portion 162 and yet elastically deflect to absorb the impact
forces experienced by the face portion 162 when striking a golf
ball. Thus, a non-foaming and injection moldable polymer material
with a relatively high modulus of elasticity may be used for
partially or entirely filling the interior cavity 700 to provide
structural support and reinforcement for the face portion 162 in
addition to providing vibration and noise dampening. That is, the
non-foaming and injection moldable polymer material may be a
structural support portion for the face portion 162. The apparatus,
methods, and articles of manufacture are not limited in this
regard.
[0137] As described herein, the filler material may include a
bonding portion. The bonding portion may include an adhesive or
epoxy material with a thickness to provide structural support for
the face portion 162. Accordingly, the filler material may include
a foaming polymer material to provide vibration and noise dampening
whereas the bonding portion may provide structural support for the
face portion 162. The thickness of the bonding portion may depend
on a thickness and physical properties of the face portion 162 as
described herein. The apparatus, methods, and articles of
manufacture are not limited in this regard.
[0138] As described herein, the filler material may include a
bonding agent (e.g., an adhesive or epoxy material) and a polymer
material. FIG. 21 depicts one manner in which a bonding agent as
described herein may be applied to a golf club head prior to
partially or entirely filling the interior cavity 700. In the
example of FIG. 21, the process 2100 may begin with injecting a
bonding agent on the back surface 166 of the face portion 162
(block 2110). The bonding agent may be injected on the back surface
166 prior to or after heating the golf club head as described above
depending on the properties of the bonding agent. The bonding agent
may be injected through one or more of the first set of ports 1420
and/or the second set of ports 1430. The bonding agent may be
injected on the back surface 166 through several or all of the
first set of ports 1420 and the second set of ports 1430. For
example, an injection instrument such as a nozzle or a needle may
be inserted into each port until the tip or outlet of the
instrument is near the back surface 166. The bonding agent may then
be injected on the back surface 166 from the outlet of the
instrument. Additionally, the instrument may be moved, rotated
and/or swiveled while inside the interior cavity 700 so that the
bonding agent is injected onto an area of the back surface 166
surrounding the instrument. For example, the outlet of the
injection instrument may be moved in a circular pattern while
inside a port to inject the bonding agent in a corresponding
circular pattern on the back surface 166. Each of the first set of
ports 1420 and the second set of ports 1430 may be utilized to
inject a bonding agent on the back surface 166. However, utilizing
all of first ports 1420 and/or the second set of ports 1430 may not
be necessary. For example, using every other adjacent port may be
sufficient to inject a bonding agent on the entire back surface
166. In another example, ports 1421, 1422 1431, 1433 and 1436 may
be used to inject the bonding agent on the back surface 166. The
apparatus, methods, and articles of manufacture are not limited in
this regard.
[0139] The process 2100 may also include spreading the bonding
agent on the back surface 166 (block 2120) after injection of the
bonding agent onto the back surface 166 so that a generally uniform
coating of the bonding agent is provided on the back surface 166.
According to one example, the bonding agent may be spread on the
back surface 166 by injecting air into the interior cavity 700
through one or more of the first set of ports 1420 and the second
set of ports 1430. The air may be injected into the interior cavity
700 and on the back surface 166 by inserting an air nozzle into one
or more of the first set of ports 1420 and the second set of ports
1430. According to one example, the air nozzle may be moved,
rotated and/or swiveled at a certain distance from the back surface
166 so as to uniformly blow air onto the bonding agent to spread
the bonding agent on the back surface 166 for a uniform coating or
a substantially uniform coating of the bonding agent on the back
surface 166. The apparatus, methods, and articles of manufacture
are not limited in this regard.
[0140] The example process 2100 is merely provided and described in
conjunction with other figures as an example of one way to
manufacture the golf club head 100. While a particular order of
actions is illustrated in FIG. 21, these actions may be performed
in other temporal sequences. Further, two or more actions depicted
in FIG. 21 may be performed sequentially, concurrently, or
simultaneously. The process 2100 may include a single action of
injecting and uniformly or substantially uniformly coating the back
surface 166 with the bonding agent. In one example, the bonding
agent may be injected on the back surface 166 by being converted
into fine particles or droplets (i.e., atomized) and sprayed on the
back surface 166. Accordingly, the back surface 166 may be
uniformly or substantially uniformly coated with the bonding agent
in one action (i.e., a substantially uniform coating of bonding
agent particles, droplets or beads). A substantially uniform
coating of the back surface 166 with the bonding agent may be
defined as a coating having slight non-uniformities due to the
injection process or the manufacturing process. However, such
slight non-uniformities may not affect the bonding of the polymer
material to the back surface 166 with the bonding agent as
described herein. For example, spraying the bonding agent on the
back surface 166 may result in overlapping regions of the bonding
agent having a slightly greater coating thickness than other
regions of the bonding agent on the back surface 166. The
apparatus, methods, and articles of manufacture are not limited in
this regard.
[0141] As described herein, any two or more of the mass portions
may be configured as a single mass portion. In the example of FIGS.
22 and 23, a golf club head 2200 may include a body portion 2210
and one or more mass portions, generally shown as a first set of
mass portions 2220 (e.g., shown as mass portions 2221, 2222, 2223,
and 2224) and a second mass portion 2230. The body portion 2210 may
be made of a first material whereas the first set of mass portions
2220 and/or the second mass portion 2230 may be made of a second
material. The first and second materials may be similar or
different materials. The first and second materials of the body
portion 2210 and/or the first and second mass portions 2220 and
2230, respectively, may be similar to the first and second
materials of the golf club head 100. The body portion 2210 may
include a toe portion 2240, a heel portion 2250, a front portion
(not shown), a back portion 2270 with a back wall portion 2310, a
top portion 2280, and a sole portion 2290. The heel portion 2250
may include a hosel portion 2255 configured to receive a shaft (not
shown) with a grip (not shown) on one end, and the golf club head
2200 on the opposite end of the shaft to form a golf club. The
front portion may be similar to the front portion 160 of the golf
club head 100. Further, the golf club head 2200 may be the same
type of golf club head as any of the golf club heads described
herein. The apparatus, methods, and articles of manufacture are not
limited in this regard.
[0142] The body portion 2210 may include one or more ports along a
periphery of the body portion 2210, generally shown as a first set
of ports 2320 (e.g., shown as ports 2321, 2322, 2323, and 2324) and
a second port 2330. Each port of the first set of ports 2320 may be
associated with a port diameter and at least one port of the first
set of ports 2320 may be separated from an adjacent port similar to
any of the ports described herein. The apparatus, methods, and
articles of manufacture are not limited in this regard.
[0143] One or more mass portion of the first set of mass portions
2220 (e.g., shown as mass portions 2221, 2222, 2223, and 2224) may
be disposed in a port of the first set of ports 2320 (e.g., shown
as ports 2321, 2322, 2323, and 2324) located at or proximate to the
toe portion 2240 and/or the top portion 2280 on the back portion
2270. The physical properties and/or configurations of the first
set of ports 2320 and the first set of mass portions 2220 may be
similar to the golf club head 100. The apparatus, methods, and
articles of manufacture are not limited in this regard.
[0144] The second port 2330 may have any configuration and/or
extend to and/or between the toe portion 2240 and the heel portion
2250. As illustrated in FIG. 22, for example, the second port 2330
may be a recess extending from the toe portion 2240 or a location
proximate to the toe portion 2240 to the sole portion 2290 or a
location proximate to the sole portion 2290. Accordingly, the
second port 2330 may resemble an L-shaped recess. The second mass
portion 2230 may resemble the shape of the second port 2330 and may
be disposed in the second port 2330. The second mass portion 2230
may be partially or fully disposed in the second port 2330. The
second mass portion 2230 may have any shape such as oval,
rectangular, triangular, or any geometric or non-geometric shape.
The second port 2330 may be shaped similar to the second mass
portion 2230. However, portion(s) of the second mass portion 2230
that are inserted in the second port 2330 may have similar shapes
as the second port 2330. In one example (not shown), the second
port 2330 may have a generally rectangular shape and located at or
near the sole portion 2290 extending to and/or between the toe
portion 2240 and the heel portion 2250. Accordingly, at least a
portion of the second mass portion 2230 may have a similar shape as
the second port 2330. As described herein, any of the mass portions
described herein, including the first mass portions 2220 and the
second mass portion 2230 may be coupled to the back portion 2270 of
the body portion 2210 with various manufacturing methods and/or
processes (e.g., a bonding process, a welding process, a brazing
process, a mechanical locking method, any combination thereof, or
other suitable manufacturing methods and/or processes). The second
mass portion 2230 may be a polymer material that may be injection
molded into the second port 2330 as described herein. Also as
described herein, any of the mass portions described herein
including the mass portion 2230 may be integral with the body
portion 2210. The apparatus, methods, and articles of manufacture
are not limited in this regard.
[0145] The second mass portion 2230 may affect the location of the
CG of the golf club head 100 and the MOI of the golf club head
about a vertical axis that extends through the CG of the golf club
head 2200. All or a substantial portion of the second mass portion
2230 may be generally near the sole portion 2290. For example, the
second mass portion 2230 may be near the periphery of the body
portion 2210 and extend to and/or between the sole portion 2290 and
the toe portion 2240. As shown in the example of FIG. 23, the
second mass portion 2230 may be located at or proximate to the
periphery of the body portion 2210 and partially or substantially
extend at or proximate to the sole portion 2290. A portion of the
second mass portion 2230 may be located near the periphery of the
body portion 2210 and extend to and/or between the sole portion
2290 and the toe portion 2240 to lower the CG and increase the MOI
of the golf club head 2200 about a vertical axis that extends
through the CG. To lower the CG of the golf club head 2200, all or
a portion of the second mass portion 2230 may be located closer to
the sole portion 2290 than to a horizontal midplane 2360 of the
golf club head 2200. The horizontal midplane 2360 may be vertically
halfway between the ground and top planes 2355 and 2365,
respectively. The location of the second mass portion 2230 (i.e.,
the location of the second port 2330) and the physical properties
and materials of construction of the mass portions of the second
port 2230 may be determined to optimally affect the mass, mass
distribution, CG, MOI characteristics, structural integrity and/or
or other static and/or dynamic characteristics of the golf club
head 2200. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0146] To balance the mass of a golf club head, such as any of the
golf club heads described herein, a golf club head may include one
or more hosel mass portions. In one example, the golf club head
2200 may include hosel mass portions 2267 and 2269. The hosel mass
portion 2267 may be permanently attached to the hosel portion 2255
whereas the hosel mass portion 2269 may be removable and
exchangeable with other hosel mass portions to balance the mass of
the golf club head 2200 at the hosel portion 2255. The hosel mass
portions 2267 and 2269 may be a third set of mass portions for the
golf club head 2200. In one example, the hosel mass portions 2267
and 2269 and the first set of mass portions 2220 may be
collectively the first set of mass portions. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0147] While the figures may depict a particular number of mass
portions in the hosel portion 2255 (e.g., two shown as mass
portions 2267 and 2269), the apparatus, methods, and articles of
manufacture described herein may include separate mass portions or
a single mass portion (e.g., the mass portions 2267 and 2269 may be
a single mass portion). The mass portions 2267 and/or 2269 may be
the same or different material than the body portion 2210 and/or
other mass portions of the golf club head 2200 (e.g., generally
shown as 2220 and 2230). The mass of each of the mass portions 2267
and 2269 may be greater than, less than, or equal to the mass of
any other mass portions of the golf club head 2200 (e.g., generally
shown as 2220 and 2230). Further, the hosel portion 2255 may
include one or more ports configured to receive and/or engage one
or more mass portions. In one example, a port (e.g. one shown as
2271 in FIG. 23) in the hosel portion 2255 may be connected to an
interior cavity (e.g., one schematically shown as 700 in FIG. 7) of
the golf club head. The port 2271 in the hosel portion 2255 may
include an opening (e.g., one shown as 1835 in FIG. 18).
Accordingly, the interior cavity may be partially or entirely
filled through an opening of the port 2271 in the hosel portion
2255. For example, the polymer material may be injected into the
interior cavity. The mass portions 2267 and/or 2269 may enclose the
port 2271 in the hosel portion 2255. In one example, the mass
portions 2267 and/or 2269 may be a screw to engage the port 2271 in
the hosel portion 2255. In another example, the mass portions 2267
and/or 2269 may not include any threads (i.e., the mass portions
2267 and/or 2269 may be coupled to the port 2271 in the hosel
portion 2255 with or without adhesive. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0148] For brevity, the description of processes described herein
with reference to FIGS. 24-26 may be provided in reference to the
golf club head 100. However, any apparatus, methods, and articles
of manufacture described herein is applicable to any of the golf
club heads described herein. FIG. 24 depicts one manner that the
interior cavity of any of the golf club heads described herein may
be partially or entirely filled with one or more filler materials
such as any of the filler materials described herein. The example
process 2400 may begin with bonding a bonding agent to the back
surface 166 of the face portion 162 of the golf club head 100
(block 2410). The bonding agent may have an initial bonding state,
which may be a temporary bonding state, and a final bonding state,
which may be a permanent bonding state. The initial bonding state
and the final bonding states may be activated when the bonding
agent is exposed to heat, radiation, and/or other chemical
compounds. For example, as described herein, the bonding agent may
be an epoxy having an initial cure state and a final cure state
that are activated by the epoxy being heated to different
temperatures for a period of time, respectively, by conduction,
convention, and/or radiation. In another example, the bonding agent
may be a bonding material that is activated to an initial bonding
state and a final bonding state by being exposed to different doses
and/or duration of ultraviolet radiation, respectively. In another
example, the bonding agent may be a bonding material that is
activated to an initial bonding state and a final bonding state by
being exposed to different compounds or different amounts of the
same compound, respectively. According to the process 2400, the
bonding agent may be bonded to the back surface 166 of the face
portion 162 by being activated to the initial bonding state. A
polymer material is then injected in the interior cavity 700 of the
golf club head 100 (block 2420). The example process 2400 then
includes bonding the polymer material to the bonding agent (block
2430). Bonding the polymer material to the bonding agent may
include activating the bonding agent to the final bonding state to
permanently bond the polymer material to the bonding agent and to
permanently bond the bonding agent to the back surface 166 of the
face portion 162. The example process 2400 is merely provided and
described in conjunction with other figures as an example of one
way to manufacture the golf club head 100. While a particular order
of actions is illustrated in FIG. 24, these actions may be
performed in other temporal sequences. Further, two or more actions
depicted in FIG. 24 may be performed sequentially, concurrently, or
simultaneously.
[0149] FIG. 25 depicts one manner that the interior cavity 700 of
the golf club head 100 or any of the golf club heads described
herein may be partially or entirely filled with one or more filler
materials such any of the filler materials described herein. The
process 2500 may begin with applying a bonding agent (e.g., a
bonding portion 1910 of FIG. 19) to the back surface 166 of the
face portion 162 of the golf club head 100 (block 2510). The
bonding agent may be any type of adhesive and/or other suitable
materials. In one example, the bonding agent may be an epoxy. Prior
to applying the bonding agent, the golf club head 100 may be
cleaned to remove any oils, other chemicals, debris or other
unintended materials from the golf club head 100 (not shown). The
bonding agent may be applied on the back surface 166 as described
herein depending on the properties of the bonding agent. The
bonding agent may be applied to the back surface 166 of the face
portion 162 through one or more of the first set of ports 1420
and/or the second set of ports 1430. For example, the bonding agent
may be in liquid form and injected on the back surface 166 through
several or all of the first set of ports 1420 and the second set of
ports 1430. An injection instrument (not shown) such as a nozzle or
a needle may be inserted into each port until the tip or outlet of
the injection instrument is near the back surface 166. The bonding
agent may then be injected on the back surface 166 from the outlet
of the injection instrument. Additionally, the injection instrument
may be moved, rotated, and/or swiveled while inside the interior
cavity 700 so that the bonding agent may be injected onto an area
of the back surface 166 surrounding the injection instrument. For
example, the outlet of the injection instrument may be moved in a
circular pattern while inside a port to inject the bonding agent in
a corresponding circular pattern on the back surface 166. Each of
the first set of ports 1420 and the second set of ports 1430 may be
utilized to inject a bonding agent on the back surface 166.
However, utilizing all of first ports 1420 and/or the second set of
ports 1430 may not be necessary. For example, using every other
adjacent port may be sufficient to inject a bonding agent on the
entire back surface 166. In another example, ports 1421, 1422 1431,
1433 and 1436 may be used to inject the bonding agent on the back
surface 166. The apparatus, methods, and articles of manufacture
are not limited in this regard.
[0150] The example process 2500 may also include spreading or
overlaying the bonding agent on the back surface 166 (not shown)
after injecting the bonding agent onto the back surface 166 so that
a generally uniform coating of the bonding agent is provided on the
back surface 166. According to one example, the bonding agent may
be spread on the back surface 166 by injecting air into the
interior cavity 700 through one or more ports of the first set of
ports 1420 and/or the second set of ports 1430. The air may be
injected into the interior cavity 700 and on the back surface 166
by inserting an air nozzle into one or more ports of the first set
of ports 1420 and/or the second set of ports 1430. According to one
example, the air nozzle may be moved, rotated and/or swiveled at a
certain distance from the back surface 166 to uniformly blow air
onto the bonding agent and spread the bonding agent on the back
surface 166 for a uniform coating or a substantially uniform
coating of the bonding agent on the back surface 166. Further, the
golf club head 100 may be pivoted back and forth in one or several
directions so that the bonding agent may spread along a portion or
substantially the entire area of the back surface 166 of the face
portion 162. In one example, the golf club head 100 may be vibrated
with the back surface 166 of the face portion 162 in a generally
horizontal orientation so that the bonding agent may spread or
overlay on the back surface 166 in a uniform coating manner or a
substantially uniform coating manner. The apparatus, methods, and
articles of manufacture are not limited in this regard.
[0151] The example process 2500 is merely provided and described in
conjunction with other figures as an example of one way to
manufacture the golf club head 100 or any of the golf club heads
described herein. While a particular order of actions is
illustrated in FIG. 25, these actions may be performed in other
temporal sequences. Further, two or more actions depicted in FIG.
25 may be performed sequentially, concurrently, or simultaneously.
The example process 2500 may include a single action (not shown) of
injecting and uniformly or substantially uniformly coating the back
surface 166 with the bonding agent. In one example, the bonding
agent may be injected on the back surface 166 by being converted
into fine particles or droplets (i.e., atomized) and sprayed on the
back surface 166. Accordingly, the back surface 166 may be
uniformly or substantially uniformly coated with the bonding agent
in one action. A substantially uniform coating of the bonding agent
on the back surface 166 may be defined as a coating having slight
non-uniformities due to the injection process or the manufacturing
process. However, such slight non-uniformities may not affect the
bonding of the elastic polymer material or elastomer material to
the back surface 166 with the bonding agent as described herein.
For example, spraying the bonding agent on the back surface 166 may
result in overlapping regions of the bonding agent having a
slightly greater coating thickness than other regions of the
bonding agent on the back surface 166. The apparatus, methods, and
articles of manufacture are not limited in this regard.
[0152] In one example as shown in FIG. 26, the bonding agent may be
an epoxy having different curing states based on the temperature
and the amount of time to which the epoxy may be exposed. The
bonding agent may have an uncured state, an initial cure state, and
a final cure state. In one example, the uncured state may be a
liquid state, the initial cure state may be gel or a
semi-solid/semi-liquid state, and the final cure state may be a
solid state. The bonding agent may transition from the uncured
state to the initial cure state when the bonding agent is heated to
a temperature between an initial cure state temperature
(Temp.sub.i) and a final cure state temperature (Temp.sub.f) for a
period of time. Accordingly, an initial cure state temperature
range may be defined by temperatures that are greater than or equal
to the initial cure state temperature Temp.sub.i and less than the
final cure state temperature Temp.sub.f. The bonding agent may
transition from the initial cure state to the final cure state when
the bonding agent may be heated to a temperature greater than or
equal to the final cure state temperature Temp.sub.f for a period
of time. Accordingly, a final cure state temperature range may be
defined by temperatures that are greater than or equal to the final
cure state temperature Temp.sub.f. The initial cure state
temperature Temp.sub.i and the final cure state temperature
Temp.sub.f may vary based on the amount of time that the bonding
agent may be heated. In particular, a transition from the uncured
state to the initial cure state and a transition from the initial
cure state to the final cure state may be dictated by certain
temperature and time profiles based on the properties of the
bonding agent. At a temperature below the initial cure temperature
Temp.sub.i, the bonding agent may be in the uncured state (e.g., a
liquid state). In the initial cure state, the bonding agent may
form an initial bond with an object and become pliable to be
manipulated (e.g., moved, spread, overlay, etc.) without obtaining
full cross linking or forming a permanent bond. In other words, the
bonding agent may form an initial bond with an object and be
manipulated without forming a permanent bond. In the final cure
state, the bond of the bonding agent (e.g., cross linking for a
bonding agent that includes epoxy) may be complete or become
permanently set.
[0153] The bonding agent may be applied to the back surface 166 of
the face portion 162 when the bonding agent is in the uncured
state, which may be a liquid state. Subsequently, the golf club
head 100 and/or the bonding agent may be heated to a first
temperature Temp.sub.1 that is greater than or equal to the initial
cure state temperature Temp.sub.i and less than the final cure
state temperature Temp.sub.f to change the bonding agent from an
uncured state to an initial cure state (i.e., an initial cure state
temperature range) (block 2520). Accordingly, the bonding agent may
form an initial bond with the back surface 166 of the face portion
162. After bonding the bonding agent to the back surface 166, the
golf club head 100 may be cooled for a period of time at ambient or
room temperature (not shown). Accordingly, the bonding agent may be
in an initial cured state and bonded to the back surface 166 of the
face portion 162 so that the bonding agent may be bonded to the
back surface 166 during the injection molding of a polymer material
in the interior cavity 700. Ambient or room temperature may be
defined as a room temperature ranging between 5.degree. C.
(32.degree. F.) and 31.degree. C. (104.degree. F.). The first
temperature Temp.sub.1 and duration by which the golf club head 100
and/or the bonding agent heated to the first temperature Temp.sub.1
may depend on the curing or bonding properties of the bonding
agent. The apparatus, methods, and articles of manufacture are not
limited in this regard.
[0154] After the bonding agent is bonded to the back surface 166 of
the face portion 162, the golf club head 100 may be heated (i.e.,
pre-heating the golf club head 100) prior to receiving a polymer
material (not shown). The golf club head 100 may be heated so that
when the polymer material is injected in the golf club head 100,
the polymer material is not cooled by contact with the golf club
head and remains in a flowing liquid form to fill the internal
cavity 700. The temperature at which the golf club head is heated,
which may be referred to herein as a third temperature, may be
similar to the temperature of the polymer material when being
injected into the internal cavity 700. However, the temperature at
which the golf club head is heated may be less than the final cure
temperature Temp.sub.f of the bonding agent. Accordingly, the
bonding agent may not transition from the initial cure state to the
final cured state during the injection molding process. Further,
the pre-heating temperature of the golf club head 100 may be
determined so that excessive cooling of the golf club head 100 may
not be necessary after injection molding the polymer material in
the internal cavity 700. Prior to being injected into the internal
cavity 700, the polymer material may also be heated to a liquid
state (not shown). The temperature at which the polymer material
may be heated may depend on the type of polymer material used to
partially or fully fill the interior cavity 700. Further, the
temperature at which the polymer material is heated may be
determined so that shrinkage of the polymer material is reduced
during the injection molding process. However, as described herein,
the polymer material may be heated to a temperature that is less
than the final cure temperature Temp.sub.f of the bonding agent.
The apparatus, methods, and articles of manufacture are not limited
in this regard.
[0155] As described herein, the cavity 700 may be partially or
fully filled with a polymer material by injecting the polymer
material in the cavity 700 (block 2530). The injection speed of the
polymer material may be determined so that the interior cavity 700
may be slowly filled to provide a better fill while allowing air to
escape the interior cavity 700 and allowing the injected polymer
material to rapidly cool. For example, the polymer material may be
a non-foaming and injection-moldable thermoplastic elastomer (TPE)
material. The polymer material may be injected into the interior
cavity 700 from one or more of the ports described herein (e.g.,
one or more ports of the first and second sets of ports 1420 and
1430, respectively, shown in FIG. 14). One or more other ports may
allow the air inside the interior cavity 700 displaced by the
polymer material to vent from the interior cavity 700. In one
example, the golf club head 100 may be oriented horizontally as
shown in FIG. 14 during the injection molding process. The polymer
material may be injected into the interior cavity 700 from ports
1431 and 1432. The ports 1421, 1422 and/or 1423 may serve as air
ports for venting the displaced air from the interior cavity 700.
Thus, regardless of the orientation of the golf club head 100
during the injection molding process, the polymer material may be
injected into the interior cavity 700 from one or more lower
positioned ports while one or more upper positioned ports may serve
as air vents.
[0156] According to one example, any one of the ports or any air
vent of the golf club head 100 used as air port(s) for venting the
displaced air may be connected to a vacuum source (not shown)
during the injection molding process. Accordingly, air inside the
interior cavity 700 and displaced by the polymer material may be
removed from the interior cavity 700 by the vacuum source.
Accordingly, trapped air pocket(s) in the interior cavity 700
and/or a non-uniform filling of the interior cavity 700 with the
polymer material may be reduced. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0157] After injecting the polymer material into the interior
cavity 700, the golf club head 100 may be heated to a second
temperature Temp.sub.2 that is greater than or equal to the final
cure temperature Temp.sub.f of the bonding agent to reactivate the
bonding agent to bond the polymer material to the bonding agent
(i.e., a final cure state temperature range) (block 2540). The
second temperature Temp.sub.2 and the duration by which the golf
club head 100 is heated to the second temperature Temp.sub.2 may
depend on the properties of the bonding agent as shown in FIG. 26
to form a permanent bond between the golf club head 100 and the
bonding agent and between the polymer material and the bonding
agent. The golf club head 100 may be then cooled at ambient or room
temperature (not shown). According to one example, the
characteristic time (CT) of the golf club head 100 may be measured
(not shown) after manufacturing the golf club head 100 as described
herein. CT measurements may determine if the golf club head 100
conforms to CT rules established by one or more golf governing
bodies.
[0158] In one example, for any of the golf club heads described
herein, the thickness of the face portion (T.sub.f) may be related
to a thickness of the bonding agent (T.sub.b) by the following
expression:
Tb=d*Tf
[0159] Where: [0160] 1.ltoreq.d.ltoreq.6 [0161] Tf is the thickness
of the face portion in units of inch, and [0162] Tb is the
thickness of the bonding agent in units of inch.
[0163] In one example, according to the above expression, the
thickness of the bonding agent may be similar to the thickness of
the face portion. For example, the thickness of the face portion
and the thickness of the bonding agent may be 0.050 inch (1.25 mm).
In another example, the thickness of the bonding agent may be twice
the thickness of the face portion. For example, the thickness of
the face portion may be 0.05 inch (1.25 mm) and the thickness of
the bonding agent may be 0.1 inch (2.54 mm). In another example,
the thickness of the bonding agent may be four times greater than
the thickness of the face portion. For example, the thickness of
the face portion may be 0.05 inch (1.25 mm) and the thickness of
the bonding agent may be 0.2 inch (5.08 mm). In yet another
example, the thickness of the bonding agent may be five times
greater than to the thickness of the face portion. For example, the
thickness of the face portion may be 0.05 inch (1.25 mm) and the
thickness of the bonding agent may be 0.3 inch (7.62 mm). The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0164] In one example, for any of the golf club heads described
herein, the hardness of the face portion may be greater than the
hardness of the bonding agent, and the hardness of the bonding
agent may be greater than the hardness of the polymer material or
polymer material that at least partially fills the golf club head
as described herein. The relationship between the hardness of the
face portion, the hardness of the bonding agent, and the hardness
of the polymer material may be expressed as:
Df>Db>De
[0165] Where: [0166] Df is the hardness of the face portion, [0167]
Db is the hardness of the bonding agent, and [0168] De is the
hardness of the polymer material.
[0169] In one example, the hardness of the face portion may be
greater than or equal to 35 HRC (Rockwell Hardness C) and less than
or equal to 55 HRC. In another example, the hardness of the face
portion may be greater than or equal to 45 HRC and less than or
equal to 65 HRC. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0170] In one example, the hardness of the bonding agent may be
greater than or equal to 20 Shore D (Shore durometer hardness type
D) and less than or equal to 90 Shore D. In another example, the
hardness of the bonding agent may be greater than or equal to 30
Shore D and less than or equal to 60 Shore D. In yet another
example, the hardness of the bonding agent may be greater than or
equal to 40 Shore D and less than or equal to 50 Shore D. In yet
another example, the hardness of the bonding agent may be greater
than or equal to 55 Shore D and less than or equal to 70 Shore D.
In yet another example, the hardness of the bonding agent may be
greater than or equal to 60 Shore D to less than or equal to 75
Shore D. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0171] In one example, the hardness of the polymer material at
least partially or entirely filling the interior cavity and bonded
to the face portion with the bonding agent may be greater than or
equal to 5 Shore D (Shore durometer hardness type D) and less than
or equal to 25 Shore D. In another example, the hardness of the
polymer material at least partially or entirely filling the
interior cavity and bonded to the face portion with the bonding
agent may be greater than or equal to 10 Shore D and less than or
equal to 20 Shore D. In yet another example, the hardness of the
polymer material at least partially or entirely filling the
interior cavity and bonded to the face portion with the bonding
agent may be greater than or equal to 45 Shore D and less than or
equal to 65 Shore D. In yet another example, the hardness of the
polymer material at least partially or entirely filling the
interior cavity and bonded to the face portion with the bonding
agent may be greater than or equal to 40 Shore D and less than 80
Shore D. In yet another example, the bonding agent and the polymer
material may be selected to have similar or substantially similar
hardness characteristics. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0172] The thickness of the face portion relative to the thickness
of the bonding agent may be related to the relative hardnesses of
the face portion material, the bonding agent and/or the polymer
material. A relatively thin face portion may be constructed from a
relatively harder material to limit the flexure of the face portion
and prevent structural damage to the face portion. A relatively
thicker face portion may be constructed from a relatively soft
material to increase flexure of the face portion to provide
improved golf ball trajectory characteristics. The bonding agent
may provide structural support to the face portion and further
provide dampening and/or reduce vibration and noise. Accordingly,
the thickness and/or the hardness of the bonding agent may be
related to the thickness and/or hardness of the face portion to
provide structural support, vibration and noise reduction and/or
dampening to the face portion and or the golf club head and/or to
provide improved golf ball trajectory characteristics when the face
portion strikes a golf ball. The polymer material may provide
structural support to the face portion and further provide
dampening and/or reduce vibration and noise. Accordingly, the
volume and/or the hardness of the polymer material may be related
to the thickness of the face portion, the hardness of the face
portion, the thickness of the bonding agent, and/or the hardness of
the bonding agent to provide structural support, vibration and
noise reduction and/or dampening to the face portion and or the
golf club head and/or to provide improved golf ball trajectory
characteristics when the face portion strikes a golf ball. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0173] In one example, the relative thicknesses of the face portion
and the bonding agent may be related to the hardnesses of the face
portion, the bonding agent and/or the polymer material. The
relative thicknesses of the face portion and the bonding agent may
be expressed by the following expressions:
d=f(Df,Db,De)
or
d=f(Df,Db)
or
d=f(Db,De)
[0174] Where: [0175] d=Tb/Tf [0176] Df>Db>De [0177] Df is the
hardness of the face portion, [0178] Db is the hardness of the
bonding agent, and [0179] De is the hardness of the polymer
material.
[0180] According to the above expression, a ratio of the thickness
of the bonding agent and the thickness of the face portion may be a
function of the hardness of the material of the face portion, the
hardness of the bonding agent, and/or the hardness of the polymer
material. In one example, function f may be based on the following
expression:
d.apprxeq.Df/Db
[0181] According to the above expression, a ratio of the thickness
of the bonding agent and the thickness of the face portion (i.e., d
in the above expression) may be equivalent to a ratio of the
hardness of the material of the face portion and the hardness of
the bonding agent. In another example, function f may be based on
the following expression:
d.apprxeq.Df/De
[0182] According to the above expression, a ratio of the thickness
of the bonding agent and the thickness of the face portion (i.e., d
in the above expression) may be equivalent to a ratio of the
hardness of the material of the face portion and the hardness of
the polymer material. In another example, the function f may be
based on the following expression:
d.apprxeq.2Df/(Db+De)
[0183] According to the above expression, a ratio of the thickness
of the bonding agent and the thickness of the face portion (i.e., d
in the above expression) may be equivalent to a ratio of the
hardness of the material of the face portion and an average of the
hardness of the bonding agent and the hardness of the polymer
material. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0184] The bonding agent may be any type of bonding agent such as
the bonding agents described herein. In one example, the bonding
agent may be DP100 Plus Clear epoxy adhesive, DP100 epoxy adhesive,
DP420 epoxy adhesive or DP810 epoxy adhesive manufactured by 3M
Company of St. Paul, Minn. In another example, the bonding agent
may be any type of adhesive material such as epoxy having a
hardness within any of the hardness ranges described herein and/or
having any of the characteristics described herein. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0185] In one example, as described herein, the polymer material
may be injection molded in the body portion of any of the golf club
heads described herein. In other examples. The polymer material may
be made or formed by any useful forming means for forming polymers.
This include, molding including compression molding, injection
molding, blow molding, and transfer molding; film blowing or
casting; extrusion, and thermoforming; as well as by lamination,
pultrusion, protrusion, draw reduction, rotational molding, spin
bonding, melt spinning, melt blowing; or combinations thereof. In
another example, any one or more of the polymer materials described
herein may be in pellet or solid pieces that may be placed in the
interior cavity and expanded and/or cured with heat. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0186] The interior cavity of any of the golf club heads described
herein may be partially or entirely filled with one or more
thermoset materials (e.g., one or more epoxy materials), such as
any one or more of the epoxy materials described herein or any
other suitable epoxy material(s). For example, the interior cavity
of any of the golf club heads described herein may be substantially
filled with one or more thermoset materials (e.g., one or more
epoxy materials), such as any of the epoxy materials described
herein or any other suitable epoxy material(s). In one example, the
interior cavity of any of the golf club heads described herein may
be at least 90% filled with a thermoset material. In another
example, the interior cavity of any of the golf club heads
described herein may be at least 80% filled with a thermoset
material. In yet another example, the interior cavity of any of the
golf club heads described herein may be at least 70% filled with a
thermoset material. In yet another example, the interior cavity of
any of the golf club heads described herein may be at least 60%
filled with a thermoset material. In yet another example, the
interior cavity of any of the golf club heads described herein may
be at least 50% filled with a thermoset material. In yet another
example, the interior cavity of any of the golf club heads
described herein may be partially, substantially, or entirely
filled with one or more thermoset materials (i.e., at least two
thermoset materials). A thermoset material partially,
substantially, or entirely filling the interior cavity may affect
vibration and noise dampening, structural support for a relatively
thin face portion, ball travel distance, ball speed, ball launch
angle, ball spin rate, ball peak height, ball landing angle and/or
ball dispersion. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0187] As illustrated in FIG. 27, for example, the interior cavity
2712 of a body portion 2710 of the golf club head 2700, which may
be similar to any of the golf club heads described herein, may be
filled with a thermoset material 2714 (e.g., epoxy material) below
the horizontal midplane 2770 of the golf club head 2700. In another
example, the interior cavity 2712 of the golf club head 2700 or any
of the golf club heads described herein may be filled with a
thermoset material (e.g., epoxy material) above the horizontal
midplane 2770 (not shown). In yet another example, the interior
cavity 2712 of the golf club head 2700 or any of the golf club
heads described herein may be filled with a thermoset material
(e.g., epoxy material) above and below the horizontal midplane 2770
and yet have regions in the interior cavity 2712 that may not
include any thermoset materials or include other materials (not
shown). The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0188] As shown in FIG. 28, for example, a golf club head 2800,
which may be similar to any of the golf club heads described
herein, may include a body portion 2810 with an interior cavity
2812 having a width 2816 of a thermoset material 2814. The width
2814 may be related to face portion thickness 2819 of the face
portion 2818 by the following expression:
W.sub.th=aT.sub.f
Where:
[0189] 0.5.ltoreq.a.ltoreq.5.0 [0190] W.sub.th is the width of the
thermoset material in inches, and [0191] T.sub.f is the thickness
of the face portion in inches.
[0192] In one example, the width 2816 of the thermoset material
2814 may be greater than or equal to half the face portion
thickness 2819. In another example, the width 2816 of the thermoset
material 2814 may be greater than or equal to the face portion
thickness 2819 (e.g., W.sub.th.gtoreq.T.sub.f). In yet another
example, the width 2816 of the thermoset material 2814 may be
greater than or equal to twice the face portion thickness 2819
(e.g., W.sub.th.gtoreq.2*T.sub.f). In another example, the width
2816 of the thermoset material 2814 may be greater than or equal to
three times the face portion thickness 2819 (e.g.,
W.sub.th.gtoreq.3*T.sub.f). In yet another example, the width 2816
of the thermoset material 2814 may be greater than five times the
face portion thickness 2819 (e.g., W.sub.th.gtoreq.5*T.sub.f). In
yet another example, the width 2816 of the thermoset material 2814
may be greater than or equal to the face portion thickness 2819 and
less than or equal to three times the face portion thickness 2819
(e.g., T.sub.f.ltoreq.W.sub.th.ltoreq.3*T.sub.f). The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0193] In one example, the mass of the thermoset material (e.g.,
epoxy) partially, substantially (e.g., filling at least 50% of the
interior cavity), or entirely filling the interior cavity of any of
the golf club heads described herein may be greater than or equal
to 6.0 grams and less than or equal to 32.0 grams. In another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
6.0 grams and less than or equal to 24.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
12.0 grams and less than or equal to 18.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
16.0 grams and less than or equal to 27.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
20.0 grams and less than or equal to 31.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
21.0 grams and less than or equal to 28.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially or entirely filling the interior cavity of any of the
golf club heads described herein may be greater than or equal to
10.0 grams and less than or equal to 20.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially, or entirely filling the interior cavity of any of
the golf club heads described herein may be greater than or equal
to 15.0 grams and less than or equal to 30.0 grams. In yet another
example, the mass of the thermoset material partially,
substantially, or entirely filling the interior cavity of any of
the golf club heads described herein may be greater than or equal
to 20.0 grams and less than or equal to 30.0 grams. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0194] In one example, for any of the golf club heads described
herein, the mass of a thermoset material partially, substantially,
or entirely filling the interior cavity may be related to the mass
of the golf club head by the following expression:
0.03 .ltoreq. m T m H .ltoreq. 0.2 ##EQU00005##
[0195] Where: [0196] m.sub.T is the mass of the thermoset material
in grams, and [0197] m.sub.H is the mass of the golf club head in
grams.
[0198] In one example, a ratio of the mass of the thermoset
material and the mass of the golf club head may be greater than or
equal to 0.04 and less than or equal to 0.08. In another example, a
ratio of the mass of the thermoset material and the mass of the
golf club head may be greater than or equal to 0.05 and less than
or equal to 0.09. In another example, a ratio of the mass of the
thermoset material and the mass of the golf club head may be
greater than or equal to 0.05 and less than or equal to 0.11. In
another example, a ratio of the mass of the thermoset material and
the mass of the golf club head may be greater than or equal to 0.09
and less than or equal to 0.12. In another example, a ratio of the
mass of the thermoset material and the mass of the golf club head
may be greater than or equal to 0.08 and less than or equal to
0.17. In yet another example, a ratio of the mass of the thermoset
material and the mass of the golf club head may be greater than or
equal to 0.01. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0199] A thermoset material partially, substantially, or entirely
filling the interior cavity may have a certain Shore D hardness to
provide vibration and noise dampening and/or structurally support a
relatively thin face portion of a golf club head. In one example, a
thermoset material partially, substantially, or entirely filling
the interior cavity may have a Shore D hardness of at least 20. In
another example, a thermoset material partially, substantially, or
entirely filling the interior cavity may have a Shore D hardness of
greater than or equal to 20 and less than or equal to 80. In
another example, a thermoset material partially, substantially, or
entirely filling the interior cavity may have a Shore D hardness of
greater than or equal to 25 and less than or equal to 45. In yet
another example, a thermoset material partially, substantially, or
entirely filling the interior cavity may have a Shore D hardness of
greater than or equal to 35 and less than or equal to 65. In yet
another example, a thermoset material partially, substantially, or
entirely filling the interior cavity may have a Shore D hardness of
greater than or equal to 45 and less than or equal to 75. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0200] A thermoset material partially, substantially, or entirely
filling the interior cavity may have a certain density to provide
vibration and noise dampening and/or structurally support a
relatively thin face portion of a golf club head. In one example, a
thermoset material partially, substantially, or entirely filling
the interior cavity may have a density of greater than or equal to
1.0 grams per cubic centimeter (g/cm.sup.3) and less than or equal
to 2.0 g/cm.sup.3. In another example, a thermoset material
partially, substantially, or entirely filling the interior cavity
may have a density of greater than or equal to 1.1 g/cm.sup.3 and
less than or equal to 1.5 g/cm.sup.3. In yet another example, a
thermoset material partially, substantially, or entirely filling
the interior cavity may have a density of greater than or equal to
1.0 g/cm.sup.3 and less than or equal to 1.4 g/cm.sup.3. In yet
another example, a thermoset material partially, substantially, or
entirely filling the interior cavity may have a density of greater
than or equal to 1.1 g/cm.sup.3 and less than or equal to 1.2
g/cm.sup.3. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0201] The polymer material (e.g., the thermoset material 2814 as
shown in FIG. 28) may be located adjacent to the back surface 2821
of the face portion 2818. For example, the thermoset material 2814
may be attached and/or bonded directly to the back surface 2821 of
the face portion 2818. Alternatively, the thermoset material 2814
may be located away from the face portion 2818. In one example, the
thermoset material 2814 be attached and/or bonded to the back wall
portion 2875 of the back portion 2874. As a result, the thermoset
material 2814 may not be in contact with the back surface 2821 of
the face portion 2818. In yet another example, the thermoset
material 2814 may be attached and/or bonded to the back surface
2821 and the back wall portion 2875 but not to the side wall
portion 2876 at or proximate to the top portion 2880 and/or the
sole portion 2890. In addition as another example, the thermoset
material 2814 may not be attached and/or bonded to the side wall
portion 2876 at or proximate to the toe portion and/or the heel
portion of the golf club head 2800. That is, the thermoset material
2814 may be suspended in the interior cavity 2812 without contact
with the side wall portion 2876 (e.g., 360-degree space around the
thermoset material 2814). In yet another example, the thermoset
material 2814 may be attached and/or bonded to the back surface
2821, the back wall portion 2875, and the side wall portion 2876 at
or proximate the top portion 2880 and the sole portion 2890 but not
the toe portion and the heel portion of the golf club head 2800.
While the above examples may describe the thermoset material 2814
being attached and/or bonded to various surfaces and/or wall
portions of the golf club head 2800, the thermoset material 2814
may be attached and/or bonded to more or less surfaces and/or wall
portions. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0202] As shown in FIG. 29, for example, a golf club head 2900,
which may be similar to any of the golf club heads described
herein, may have a body portion 2910 include an internal cavity
2912 having an internal cavity width that may vary between the top
portion 2980 and the sole portion 2990. In particular, the internal
cavity 2912 may include a first width 2920 (W.sub.1) above a
horizontal midplane 2970 of the golf club head 2900, a second width
2930 (W.sub.2) below the horizontal midplane 2970, and a third
width 2940 (W.sub.3) between the first width 2920 and the second
width 2930. The third width 2940 may be at or below the horizontal
midplane 2970. In one example, the third width 2940 may be above
one or more weight ports (e.g., one generally shown as 2922).
Accordingly, the third width 2940 may be located above one or more
mass portions (not shown in FIG. 29 but for example, a mass portion
disposed in the weight port 2922) and/or be closer to the
horizontal midplane 2970 than one or more mass portions. In another
example, the third width 2940 may be above one or more weight ports
of the golf club head 2800 and below the horizontal midplane 2970.
The third width 2940 may be greater than the first width 2920
(e.g., W.sub.3>W.sub.1) and greater than the second width 2930
(e.g., W.sub.3>W.sub.2). In one example, the first width 2920
may be greater than or equal to the second width 2930 (e.g.,
W.sub.2.gtoreq.W.sub.1). In another example, the second width 2930
may be greater than or equal to the first width 2920 (e.g.,
W.sub.1.gtoreq.W.sub.2). In yet another example, the third width
2940 may be no more than three times the second width 2930. In yet
another example, the third width 2940 may be no more than twice the
second width 2930. In yet another example, the third width 2940 may
be no more than 1.5 times the second width 2930. In yet another
example, the third width 2940 may be no more than 1.25 times the
second width 2930. The apparatus, methods, and articles of
manufacture described herein are not limited in this regard.
[0203] The third width 2940 may be at a certain vertical location
of the body portion 2910. The face portion 2918 of the golf club
head 2900 may include a plurality of grooves. The face portion 2918
of the golf club head 2900 may include a similar number of grooves
as the golf club head 100 of FIG. 1. Accordingly, the face portion
2918 may include a plurality of grooves (e.g., eleven grooves are
generally shown as grooves 2951, 2952, 2953, 2954, 2955, 2956,
2957, 2957, 2959, 2960, and 2961 in FIG. 29). In one example, the
third width 2940 may be located between the third groove 2953 and
the eleventh groove 2961 from the sole portion 2990. In another
example, the third width 2940 may be located between the fourth
groove 2954 and the eighth groove 2958 from the sole portion 2990.
In yet another example, the third width 2940 may be located between
the fifth groove 2955 and the seventh groove 2957 from the sole
portion 2990. The apparatus, methods, and articles of manufacture
described herein are not limited in this regard.
[0204] In one example, the process of filling the interior cavity
of the golf club head may not include applying a bonding portion to
the back surface of the face portion. For example, as shown in FIG.
30, the process 3000 of filling the interior cavity of the golf
club head may include partially, substantially, or entirely filling
the interior cavity with an epoxy material (block 3010), and then
curing the epoxy material (block 3020). The epoxy material may be
injected into the interior cavity from one or more ports on the
body portion of a golf club head as described herein. In one
example, the process of curing the epoxy material may include using
heat, radiation, and/or pressure for a certain period of time. In
another example, the process of curing the epoxy material may only
include allowing the epoxy material to cure at ambient or room
temperature for a certain period of time. In another example, the
process of filling the interior cavity of the golf club head may
include applying a first epoxy material to the back surface of the
face portion, curing the first epoxy material to a first cure state
as described herein, filling the interior cavity with a second
epoxy material that may be the same as or different from the first
epoxy material, and curing the first epoxy material to the second
cure state and curing the second epoxy material as described
herein. In another example, more than two epoxy materials can be
used to substantially or fully fill the interior cavity with single
or multiple curing processes used for each epoxy material. The
apparatus, methods, and articles of manufacture described herein
are not limited in this regard.
[0205] The heating and cooling processes described herein may be
performed by conduction, convention, and/or radiation. For example,
all of the heating and cooling processes may be performed by using
heating or cooling systems that employ conveyor belts that move the
golf club head 100 through a heating or cooling environment for a
period of time as described herein. The apparatus, methods, and
articles of manufacture described herein are not limited in this
regard.
[0206] Although a particular order of actions may be described
herein with respect to one or more processes, these actions may be
performed in other temporal sequences. Further, two or more actions
in any of the processes described herein may be performed
sequentially, concurrently, or simultaneously.
[0207] While the above examples may described an iron-type or a
wedge-type golf club head, the apparatus, methods, and articles of
manufacture described herein may be applicable to other types of
golf club heads.
[0208] A numerical range defined using the word "between" includes
numerical values at both end points of the numerical range. A
spatial range defined using the word "between" includes any point
within the spatial range and the boundaries of the spatial range. A
location expressed relative to two spaced apart or overlapping
elements using the word "between" includes (i) any space between
the elements, (ii) a portion of each element, and/or (iii) the
boundaries of each element.
[0209] The terms "and" and "or" may have both conjunctive and
disjunctive meanings. The terms "a" and "an" are defined as one or
more unless this disclosure indicates otherwise. The term "coupled"
and any variation thereof refer to directly or indirectly
connecting two or more elements chemically, mechanically, and/or
otherwise. The phrase "removably connected" is defined such that
two elements that are "removably connected" may be separated from
each other without breaking or destroying the utility of either
element.
[0210] The term "substantially" when used to describe a
characteristic, parameter, property, or value of an element may
represent deviations or variations that do not diminish the
characteristic, parameter, property, or value that the element may
be intended to provide. Deviations or variations in a
characteristic, parameter, property, or value of an element may be
based on, for example, tolerances, measurement errors, measurement
accuracy limitations and other factors. The term "proximate" is
synonymous with terms such as "adjacent," "close," "immediate,"
"nearby", "neighboring", etc., and such terms may be used
interchangeably as appearing in this disclosure.
[0211] The apparatus, methods, and articles of manufacture
described herein may be implemented in a variety of embodiments,
and the foregoing description of some of these embodiments does not
necessarily represent a complete description of all possible
embodiments. Instead, the description of the drawings, and the
drawings themselves, disclose at least one embodiment, and may
disclosure alternative embodiments.
[0212] As the rules of golf may change from time to time (e.g., new
regulations may be adopted or old rules may be eliminated or
modified by golf standard organizations and/or governing bodies
such as the United States Golf Association (USGA), the Royal and
Ancient Golf Club of St. Andrews (R&A), etc.), golf equipment
related to the apparatus, methods, and articles of manufacture
described herein may be conforming or non-conforming to the rules
of golf at any particular time. Accordingly, golf equipment related
to the apparatus, methods, and articles of manufacture described
herein may be advertised, offered for sale, and/or sold as
conforming or non-conforming golf equipment. The apparatus,
methods, and articles of manufacture described herein are not
limited in this regard.
[0213] Although certain example apparatus, methods, and articles of
manufacture have been described herein, the scope of coverage of
this disclosure is not limited thereto. On the contrary, this
disclosure covers all apparatus, methods, and articles of articles
of manufacture fairly falling within the scope of the appended
claims either literally or under the doctrine of equivalents.
* * * * *