U.S. patent number RE42,544 [Application Number 11/998,435] was granted by the patent office on 2011-07-12 for golf club head.
This patent grant is currently assigned to Taylor Made Golf Company, Inc.. Invention is credited to Bing-Ling Chao, Peter Larsen, Benoit Vincent, Brian Weed, Gery Zimmerman.
United States Patent |
RE42,544 |
Chao , et al. |
July 12, 2011 |
**Please see images for:
( Certificate of Correction ) ** |
Golf club head
Abstract
A golf club head has a body having a top, a sole, a toe end, a
heel end, and a forward wall. The forward wall defines a front
opening about which a face support is disposed. The face support
receives a face plate, thereby enclosing the front opening of the
body. The face support includes portions proximate to the top, the
toe end, and the heel end, each portion having a peripheral member
extending rearward from the forward wall and a rear member
extending inward from the peripheral member, with respect to the
front opening. The face support can be combined with a preferred
face construction and weight elements to optimize club head
performance to help a golfer achieve greater distance and
control.
Inventors: |
Chao; Bing-Ling (San Diego,
CA), Weed; Brian (Gloucester, MA), Larsen; Peter (San
Marcos, CA), Zimmerman; Gery (Fallbrook, CA), Vincent;
Benoit (Encinitas, CA) |
Assignee: |
Taylor Made Golf Company, Inc.
(Carlsbad, CA)
|
Family
ID: |
35137175 |
Appl.
No.: |
11/998,435 |
Filed: |
November 28, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
10831496 |
Apr 22, 2004 |
7140974 |
Nov 28, 2006 |
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Current U.S.
Class: |
473/329; 473/342;
473/346; 473/345 |
Current CPC
Class: |
A63B
53/0466 (20130101); A63B 53/047 (20130101); A63B
60/00 (20151001); A63B 53/06 (20130101); A63B
53/0416 (20200801); A63B 53/0412 (20200801); A63B
53/042 (20200801); A63B 53/0433 (20200801); A63B
2209/023 (20130101); A63B 2053/0491 (20130101); A63B
53/0408 (20200801); A63B 53/0425 (20200801) |
Current International
Class: |
A63B
53/04 (20060101); A63B 53/08 (20060101) |
Field of
Search: |
;473/324-350 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2 338 903 |
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Jan 2000 |
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GB |
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2338903 |
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Jan 2000 |
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GB |
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U-H05-068564 |
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Sep 1993 |
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JP |
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09-299519 |
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Nov 1997 |
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JP |
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10-155943 |
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Jun 1998 |
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JP |
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2002315854 |
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Oct 2002 |
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JP |
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T-2003-518993 |
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Jun 2003 |
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JP |
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Other References
Japanese Office action (English translation), Japanese App. No.
2005-123040, filed Apr. 21, 2005, 3pp. (Aug. 3, 2010). cited by
other.
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Primary Examiner: Passaniti; Sebastiano
Attorney, Agent or Firm: Klarquist Sparkman, LLP
Claims
We claim:
1. A golf club head, comprising: a body having a top, a sole, a toe
end, a heel end, and a forward wall, the forward wall defining a
front opening, the body further having a face support disposed
about the front opening, the face support having portions proximate
to .Iadd.at least one of .Iaddend.the top, the toe end, and the
heel end, the face support including a peripheral member extending
rearward from the forward wall for a length between about 3 mm and
30 mm, measured from a forward surface of the forward wall, the
peripheral member having a thickness between about 0.5 mm and 2.5
mm, and a rear member extending inward from the peripheral member,
with respect to the front opening, for a length of at least about 2
mm and no more than about 25 mm, the rear member having a thickness
between about 0.5 mm and 2.5 mm; and a face plate received by the
face support.
2. A golf club head as defined in claim 1, wherein the face support
further includes a portion proximate to the sole of the body, the
portion proximate to the sole having a rear member extending inward
with respect to the front opening and configured to support a lower
edge of the face plate.
3. A golf club head as defined in claim 1, wherein the face support
further includes a portion proximate to the sole of the body, the
portion proximate to the sole having a peripheral member extending
rearward from the forward wall for a length between about 3 mm and
30 mm, measured from a forward surface of the forward wall, the
peripheral member having a thickness between about 0.5 mm and 2.5
mm, and a rear member extending inward from the peripheral member,
with respect to the front opening, for a length of at least about 2
mm and no more than about 25 mm, the rear member having a thickness
between about 0.5 mm and 2.5 mm.
4. A golf club head as defined in claim 1, wherein the rear member
of the face support is continuous about the front opening, the rear
member extending inward from the peripheral member of each of the
portions of the face support.
5. A golf club head as defined in claim 1, wherein the peripheral
member has a thickness of about 1 mm and a length between about 4
mm and 6 mm, and the rear member has a thickness between about 0.6
mm and 1.5 mm and a length between about 2 mm and 7 mm.
6. A golf club head as defined in claim 1, wherein a junction of
the peripheral and rear members of the face support has a maximum
thickness of between about 1.5 and 2 mm.
7. A golf club head as defined in claim 1, wherein the rear member
tapers from a junction of the peripheral and rear members to an
inward end, the inward end having a thickness of between about 0.6
and 0.9 mm.
8. A golf club head as defined in claim 1, wherein the peripheral
member is spaced from a skirt of the body at one or both of the toe
and heel ends a horizontal distance of at least 1.5 mm measured
about 2 mm inward from a side forward surface of the body at the
front opening.
9. A golf club head as defined in claim 1, wherein the face support
further includes a portion proximate to the sole, the portion
proximate to sole having a rear member extending inward with
respect to the front opening the portion proximate to sole face
disposed such that the front surface of the face plate is
substantially flush with the forward wall of the body.
10. A golf club head as defined in claim 9, wherein the portion
proximate to the sole further having a peripheral member, the
peripheral member extending rearward from the forward wall
proximate to the sole for a length between about 3 mm and 30 mm,
the peripheral member having a thickness between about 0.5 mm and
2.5 mm, the rear member extending inward from the peripheral
member, with respect to the front opening, for a length of at least
about 2 mm and no more than about 25 mm, the rear member having a
thickness between about 0.5 mm and 2.5 mm.
11. A golf club head as defined in claim 1, wherein the peripheral
member is spaced from the top a vertical distance of at least 1 mm
measured about 2 mm rearward of an upper forward surface of the
body at the front opening.
12. A golf club head as defined in claim 11, wherein the peripheral
member is spaced from the sole a vertical distance of at least 1 mm
measured about 2 mm rearward of a lower forward surface of the body
at the front opening.
.[.13. A golf club head comprising: a crown; a sole; a skirt
disposed between the crown and the sole, the skirt having a toe end
and a heel end; a forward wall coupled to the crown, the sole, and
the skirt, the forward wall defining a front opening; a peripheral
member coupled to at least a portion of a periphery of the front
opening and extending rearwardly therefrom; a rear member directly
coupled to the peripheral member and extending inwardly therefrom,
partially towards a center of the front opening; and a face plate
coupled to the rear member..].
.[.14. The golf club head of claim 13, wherein at least a portion
of each of the peripheral member and the rear member is disposed
proximate to the crown, the sole, the toe end, or the heel end, or
combinations thereof..].
.[.15. The golf club head of claim 13, wherein the peripheral
member extends between about 3 mm and 30 mm from a forward surface
of the forward wall..].
.[.16. The golf club head of claim 15, wherein the peripheral
member extends between about 4 mm and 6 mm from a forward surface
of the forward wall..].
.[.17. The golf club head of claim 13, wherein the peripheral
member has a thickness between about 0.5 mm and 2.5 mm..].
.[.18. The golf club head of claim 13, wherein the peripheral
member is spaced a first distance of at least 1.5 mm measured in a
horizontal direction from the skirt, and wherein the first distance
is measured about 2 mm rearward from a side forward surface
proximate the front opening..].
.[.19. The golf club head of claim 13, wherein the peripheral
member is spaced a first distance of at least 1 mm measured in a
vertical direction from the crown, and wherein the first distance
is measured about 2 mm rearward from an upper forward surface
proximate the front opening..].
.[.20. The golf club head of claim 13, wherein the peripheral
member is spaced a first distance of at least 1 mm measured in a
vertical direction from the sole, and wherein the first distance is
measured about 2 mm rearward of a lower forward surface proximate
the front opening..].
.[.21. The golf club head of claim 13, wherein the rear member is
continuous about the periphery of the front opening..].
.[.22. The golf club head of claim 13, wherein the rear member
extends between about 2 mm and 25 mm from an inner surface of the
peripheral member, relative to the center of the front
opening..].
.[.23. The golf club head of claim 22, wherein the rear member
extends between about 2 mm and 7 mm from an inner surface of the
peripheral member, relative to the center of the front
opening..].
.[.24. The golf club head of claim 13, wherein the rear member has
a thickness between about 0.5 mm and 2.5 mm..].
.[.25. The golf club head of claim 24, wherein the rear member has
a thickness between about 0.6 mm and 1.5 mm..].
.Iadd.26. The golf club head of claim 1, the face support having
portions proximate to the top, the toe end, and the heel
end..Iaddend.
.Iadd.27. A golf club head comprising: a body; a forward wall
defining a front opening; a peripheral member coupled to at least a
portion of a periphery of the front opening and extending
rearwardly therefrom, the peripheral member being spaced from the
body; a rear member directly coupled to the peripheral member and
extending inwardly therefrom, partially towards a center of the
front opening; a face plate coupled to the rear member; a crown; a
sole; and a skirt disposed between the crown and the sole, the
skirt having a toe end and a heel end; wherein the forward wall is
coupled to the crown, the sole, and the skirt..Iaddend.
.Iadd.28. The golf club head of claim 27, wherein at least a
portion of each of the peripheral member and the rear member is
disposed proximate to the crown, the sole, the toe end, or the heel
end, or combinations thereof..Iaddend.
.Iadd.29. A golf club head comprising: a body; a forward wall
defining a front opening; a peripheral member coupled to at least a
portion of a periphery of the front opening and extending
rearwardly therefrom, the peripheral member being spaced from the
body; a rear member directly coupled to the peripheral member and
extending inwardly therefrom, partially towards a center of the
front opening; a face plate coupled to the rear member; the rear
member having a thickness between about 0.5 mm and 2.5 mm; and
wherein the thickness of the rear member tapers inwardly toward a
center of the front opening..Iaddend.
.Iadd.30. The golf club head of claim 29, wherein an inner end of
the rear member has a thickness between about 0.6 mm and 0.9
mm..Iaddend.
.Iadd.31. A golf club head comprising: a crown; a sole; a skirt
disposed between the crown and the sole, the skirt having a toe end
and a heel end; a forward wall coupled to the crown, the sole, and
the skirt, the forward wall defining a front opening; a peripheral
member coupled to at least a portion of a periphery of the front
opening and extending rearwardly therefrom, between about 4 mm and
6 mm from a forward surface of the forward wall, wherein the
peripheral member has a thickness between about 0.8 mm and 1.2 mm;
a rear member directly coupled to the peripheral member and
extending inwardly between about 2 mm and 15 mm from an inner
surface of the peripheral member, partially towards a center of the
front opening, wherein the rear member has a thickness between
about 0.6 mm and 1.5 mm; and a face plate coupled to the rear
member..Iaddend.
.Iadd.32. The golf club head of claim 31, wherein at least a
portion of each of the peripheral member and the rear member is
disposed proximate to the crown, the sole, the toe end, or the heel
end, or combinations thereof..Iaddend.
.Iadd.33. The golf club head of claim 31, wherein the peripheral
member is spaced a first distance of at least 1.5 mm measured in a
horizontal direction from the skirt, a second distance of at least
1 mm measured in a vertical direction from the crown, and a third
distance of at least 1 mm measured in a vertical direction from the
sole, and wherein the first distance is measured about 2 mm
rearward from a side forward surface proximate the front opening,
the second distance is measured about 2 mm rearward from an upper
forward surface proximate the front opening, and the third distance
is measured about 2 mm rearward of a lower forward surface
proximate the front opening..Iaddend.
.Iadd.34. The golf club head of claim 31, wherein the rear member
is continuous about the periphery of the front
opening..Iaddend.
.Iadd.35. The golf club head of claim 31, wherein the crown has a
thickness between about 0.7 mm and 1 mm..Iaddend.
.Iadd.36. The golf club head of claim 31, wherein the skirt has a
thickness between about 0.8 mm and 1.2 mm..Iaddend.
.Iadd.37. The golf club head of claim 31, wherein the sole has a
thickness between about 0.8 mm and 1.2 mm..Iaddend.
.Iadd.38. The golf club head of claim 31, wherein the forward wall
has a thickness between about 0.8 mm and 1.0 mm..Iaddend.
.Iadd.39. The golf club head of claim 31, wherein the crown has a
thickness between about 0.7 mm and 1 mm, the skirt has a thickness
between about 0.8 mm and 1.2 mm, and the sole has a thickness
between about 0.8 mm and 1.2 mm, and the forward wall has a
thickness between about 0.8 mm and 1.0 mm..Iaddend.
.Iadd.40. The golf club head of claim 31, wherein the face plate is
comprised of a composite material..Iaddend.
.Iadd.41. The golf club head of claim 40, further comprising a
metallic cap covering at least a portion of a striking surface of
the face plate..Iaddend.
.Iadd.42. The golf club head of claim 40, further comprising a
plurality of removable weights coupled to the club
head..Iaddend.
.Iadd.43. The golf club head of claim 42, wherein first and second
removable weights are disposed in a rear region of the club head, a
third removable weight is disposed in a toe region of the club
head, and a fourth removable weight is disposed in a heel region of
the club head..Iaddend.
.Iadd.44. The golf club head of claim 40, wherein the golf club
head displaces a volume between about 130 cm.sup.3 and 460
cm.sup.3..Iaddend.
.Iadd.45. The golf club head of claim 44, wherein the golf club
head displaces a volume of at least about 400
cm.sup.3..Iaddend.
.Iadd.46. The golf club head of claim 40, wherein the golf club
head has a moment of inertia I.sub.ZZ of at least 300
kg-mm.sup.2..Iaddend.
.Iadd.47. The golf club head of claim 46, wherein the golf club
head has a moment of inertia I.sub.ZZ of at least 350
kg-mm.sup.2..Iaddend.
.Iadd.48. The golf club head of claim 31, wherein at least a
portion of each of the peripheral member and the rear member is
disposed proximate to the crown, the sole, the toe end, or the heel
end, or combinations thereof; the crown has a thickness between
about 0.7 mm and 1 mm, the skirt has a thickness between about 0.8
mm and 1.2 mm, and the sole has a thickness between about 0.8 mm
and 1.2 mm, and the forward wall has a thickness between about 0.8
mm and 1.0 mm; the face plate is comprised of a composite material;
the golf club head displaces a volume of at least about 400
cm.sup.3; and the golf club head has a moment of inertia I.sub.ZZ
of at least 350 kg-mm.sup.2..Iaddend.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to golf clubs and, more
particularly, to an golf club head having an improved face plate
support.
Many factors must be considered when designing a golf club head.
One factor is the distribution of mass about the club head, which
is typically quantified by parameters such as moments of inertia
(MOI) magnitude and center of gravity (CG) location. Rotational
moments of inertia of a club head about the club head CG are
measures of a club head's resistance to rotation about the CG and
are related to the distribution of mass within the club head about
the CG. It is desirable for a club head to have high moments of
inertia about the CG, particularly to promote forgiveness for
off-center hits. To achieve high moments of inertia about the CG,
designers typically position mass to the periphery of the golf club
head and backwards from the face plate. In addition, a club head's
CG is spaced from the face plate at a prescribed location to
achieve a desired launch angle upon impact with a golf ball. As a
result, for wood-type club heads (i.e., fairway woods and drivers),
large internal volumes are typically desirable.
Another factor in club head design is the face plate of the club
head. Upon impact with a golf ball, the face plate of a club head
deflects and rebounds, thereby imparting energy to the struck golf
ball. The club head's coefficient of restitution (COR) is the ratio
of the difference between the ball speed after impact and the club
speed after impact and the club speed before impact. A thin face
plate generally will deflect more than a thick face plate. Thus, a
properly constructed club with a thin, flexible face plate can
impart a higher initial velocity to a golf ball than a club with a
thick, rigid face plate. In order to maximize the MOI about the CG
and achieve a high COR, it typically is desirable to incorporate
thin walls and a thin face plate into the design of the club head.
Thin walls afford the designers additional leeway in distributing
club head mass to achieve desired mass distribution, and a thin
face plate may provide for a high COR.
Thus, thin walls are important to a club's performance. However,
overly thin walls can adversely affect the club head's durability.
Problems also arise from stresses distributed across the club head
upon impact with the golf ball, particularly at junctions of club
head components, such as the junction of the face plate with other
club head components (e.g., the sole, skirt, and crown). One prior
solution has been to provide a reinforced periphery about the face
plate, such as welding, in order to withstand the repeated impacts.
Another approach to combat stresses at impact is to use one or more
ribs extending substantially from the crown to the sole vertically,
and in some instances extending from the toe to the heel
horizontally, across an inner surface of the face plate. These
approaches tend to adversely affect club performance
characteristics, e.g., diminishing the size of the sweet sport,
and/or inhibiting design flexibility in both mass distribution and
the face structure of the club head. Thus, these club heads fail to
provide optimal MOI, CG, and/or COR parameters, and as a result,
fail to provide much forgiveness for off-center hits for all but
the most expert golfers.
It should, therefore, be appreciated that there exists a need for a
golf club head having a face plate support that facilitates
performance and durability. The present invention fulfills this
need and others.
SUMMARY OF THE INVENTION
Briefly, and in general terms, the present invention provides a
golf club head having enhanced durability and performance
characteristics. The club head includes a face plate and a body
having a face plate support for receiving the face plate. The body
includes a top, a toe end and a heel end, a sole, and a forward
wall. The forward wall defines a front opening about which the face
plate support is disposed. The face plate support receives the face
plate, thereby enclosing the front opening of the body.
More specifically, and by way of example, the face plate support is
configured to enhance the durability and performance of the club
head. The face plate support includes portions proximate to the
crown, the toe end, and the heel end. Each of these face plate
support portions includes a peripheral member extending rearward
from the forward wall and a rear member extending inward from the
peripheral member, with respect to the front opening. The face
plate support can also include a portion proximate to the sole of
the body. The face plate support contributes to increased COR even
about the periphery of the face plate while providing durable
support. Thus, the face plate can be designed with an emphasis or
performance. For example, the face plate can be configured with a
face thickness variation that provides a maximum COR over a larger
face area than otherwise possible. Preferably, the face plate is
formed from composite material; however, a lightweight metal face
plate may alternatively be attached to a metal body of the club
head. In addition, in an exemplary embodiment, a junction of the
peripheral and tear members of the face plate support has a maximum
thickness of between about 1.5 and 2 mm.
For purposes of summarizing the invention and the advantages
achieved over the prior art, certain advantages of the invention
have been described herein above. Of course, it is to be understood
that not necessarily all such advantages may be achieved in
accordance with any particular embodiment of the invention. Thus,
for example, those skilled in the art will recognize that the
invention may be embodied or carried out in a manner that achieves
or optimizes one advantage or group of advantages as taught herein
without necessarily achieving other advantages as may be taught or
suggested herein.
All of these embodiments are intended to be within the scope of the
invention herein disclosed. These and other embodiments of the
present invention will become readily apparent to those skilled in
the art from the following detailed description of the preferred
embodiments having reference to the attached figures, the invention
not being limited to any particular preferred embodiment
disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way
of example only, with reference to the following drawings in
which:
FIG. 1 is a bottom perspective view of a first embodiment of a golf
club head in accordance with the present invention, depicting a
body and a face plate.
FIG. 2 is a toe-side elevational view of the golf club head of FIG.
1.
FIG. 3 is a cross-sectional view, taken along line I-I of FIG. 2,
depicting the club head with the face plate removed.
FIG. 4 is a front elevational view of the body of the club head of
FIG. 1, depicting a recessed face plate support about a front
opening of the body.
FIG. 5 is a partial cross-sectional view, taken along line II-II of
FIG. 4.
FIG. 5A is a detailed view at section A of FIG. 5, depicting a
portion of the face plate support adjacent to the crown of the club
head.
FIG. 5B is a detailed view at section B of FIG. 5, depicting a
portion of the face plate support adjacent to the sole of the club
head.
FIG. 6 is a partial cross-sectional view, taken viewed along line
III-III of FIG. 4.
FIG. 6A is a detailed view at section A of FIG. 6, depicting a
portion of the face plate support adjacent to the toe end of the
club head.
FIG. 6B is a cross-sectional view at section B of FIG. 6, depicting
a portion of the face plate support adjacent to the heel end of the
club head.
FIG. 7 is a front elevational view of a second embodiment of a body
for a golf club head in accordance with the present invention,
depicting a face plate support having a plurality of tabs about a
front opening of the body.
FIG. 8 is a cross-sectional view taken along line IV-IV of FIG.
7.
FIG. 9 is a toe-side elevational view of a third embodiment of a
club head in accordance with the present invention.
FIG. 10 is a partial cross-sectional view of the body of the club
head of FIG. 9, depicting a recessed face plate support about a
front opening of the body.
FIG. 10A is a cross-sectional view at section A of FIG. 10,
depicting a portion of the face plate support adjacent to the sole
of the club head.
FIG. 11 is a cross-sectional view similar to FIG. 5A, depicting a
composite face plate secured to the face plate support of the
body.
FIG. 12 is a cross-sectional view similar to FIG. 11, depicting a
composite face plate having a metal cap at an outer surface.
FIG. 13 is a cross-sectional view of a fourth embodiment of a body
for a wood-type golf club head in accordance with the present
invention, depicting a face plate support of the body having a
portion, including a rear member, adjacent to the sole.
FIG. 14 is a cross-sectional view of a fifth embodiment of a body
for an iron golf club head in accordance with the present
invention, depicting a face plate support of the body disposed
about a front opening.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings include preferred embodiments of golf club heads in
accordance with the present invention. With reference to FIGS. 1-4,
a wood-type club head 20 is shown having a separate face plate 22
and a body 24. The body 24 and the face plate 22 are relatively
light, thereby facilitating the use of four removable weights 26
disposed about the periphery of the club head 20, including two
weights in a rear region 28 of the body 24, one weight in a toe
region 30 of the body, and one weight in a heel region 32 of the
body. The body 24 includes a face plate support 34 disposed about a
front opening 36 of the body for receiving the face plate 22. The
face plate support 34 provides durable support for the face plate
22 while contributing to enhanced club performance, such as a high
COR even about the periphery of the face plate. More particularly,
upon impact with a golf ball, the face plate support 34 promotes
accommodates deflection of the face plate 22 even about the
periphery thereof.
The body 24 includes a sole 38, a top (i.e., crown 40), a skirt 42,
and a forward wall 44. The face plate support 34 includes a
peripheral member 46 extending rearward from the forward wall 44
and a rear member 48 extending inward with reference to the front
opening 36. The face plate support 34 includes portions proximate
to the crown 40, the toe 30, the heel 32 and the sole 38. More
particularly, in the exemplary embodiment, the face plate support
34 is continuous about the front opening 36. In other embodiments,
portions of the face plate support 34 can be configured as a
plurality of tabs spaced apart about the front opening 36. One such
example is depicted in FIGS. 7 and 8 and is discussed in further
detail below. Also, in other embodiments (e.g., FIGS. 13 and 14),
the portion of the face plate support 34 proximate to the sole 38
may not include a thin peripheral member 46.
With reference to FIGS. 1-4, the face plate support 34 is recessed
relative to the forward wall 44 allowing the face plate 22 to sit
flush with the forward wall 44 of the body 24. In the portions of
the face plate support 34 proximate to the crown 40 and sole 38,
the peripheral member 46 is generally perpendicular to a face plane
(V) (i.e., a plane tangent to a point at the geometric center of
the face plate striking surface), and the rear member 48 is
generally parallel to the face plane (V). As best seen in FIG. 2, a
loft plane (LP) of the club head is normal to the face plane (V)
and forms an acute angle with a horizontal ground plane (P) when
the club head 20 is at address position. Adjacent the toe and heel
ends 30, 32, of the skirt 42 the peripheral member 46 is generally
parallel to the face plane (V).
With reference now to FIG. 5 through FIG. 6B, the face plate
support 34 is configured to provide durable support while
facilitating club performance. More particularly, the face plate
support 34 is sufficiently thin to promote a high COR, even about
the periphery of the face plate 22, and is structured to provide
ample surface area for receiving the face plate, thereby enhancing
club head durability. The rear member 48 of the face plate support
34 has a thickness T.sub.R between about 0.5 mm and 2.5 mm and a
length L.sub.R between about 2 mm and 25 mm. The dimensions of the
face plate support 34 can vary in other embodiments of the
invention. For example, the dimensions of the face plate support 34
can vary depending upon the materials used to form the club head
20, head volume, and face plate dimensions. Preferably, the
thickness T.sub.R is between about 0.6 mm and 1.5 mm and the length
L.sub.R is between about 2 mm and 15 mm, and most preferably the
length L.sub.R is between about 2 mm and 7 mm. The peripheral
member 46 of the face plate support 34 has a thickness T.sub.P
between about 0.5 mm and 2.5 mm and a length L.sub.P between about
3 mm and 30 mm. Preferably, the thickness T.sub.P is between about
0.8 mm and 1.2 mm, and more preferably, the thickness T.sub.P is
about 1 mm. The peripheral member 46 preferably has a length
L.sub.P between about 4 mm and 6 mm. While the peripheral member 46
most preferably is substantially constant in thickness, the rear
member 48 preferably tapers inwardly toward a center of the front
opening 36. At an inner end of the rear member 48, the thickness
T.sub.E is between about 0.6 mm and 0.9 mm.
At a junction 50 of the peripheral and rear members 46, 48 of the
face plate support 34, there is preferably a maximum thickness
T.sub.J between about 1.5 mm and 2 mm. In the preferred embodiment
of FIGS. 1-6, the peripheral member 46 is spaced from an inner
surface 52 of the crown 40 by a distance S.sub.1 measured in a
vertical direction at a distance d.sub.1 rearward from an upper
forward wall 54 of the body 24 proximal the front opening 36; this
is more clearly shown in FIG. 11. Distance S.sub.1 is at least 1 mm
and distance d.sub.1 is about 2 mm. Similarly, the peripheral
member 46 is spaced from an inner surface 56 of the sole 38 a
vertical distance S.sub.2 measured at a distance d.sub.2 rearward
from a lower forward wall 58 of the body 24 proximal the front
opening 36. Distance S.sub.2 is at least 1 mm and distance d.sub.2
is about 2 mm. Preferably, the peripheral member 46 is spaced from
the crown 40 and sole 38 at least 1.5 mm measured in a vertical
direction.
Referencing FIG. 6, at the toe and heel ends 30, 32 the skirt 42,
the peripheral member 46 is spaced from an inner surface of the
body 24 by a distance S.sub.3 measured in a horizontal direction at
a distance d.sub.3 rearward from a side forward wall 60 of the body
24 proximal the front opening 36. Distance S.sub.3 is at least 1.5
mm and distance d.sub.3 is about 2 mm. Preferably, distance S.sub.3
is at least 2 mm.
Preferred dimensions for the body 24 of the golf club head 20 of
FIG. 1 are in the range of 0.7 mm to 1 mm for the crown thickness
T.sub.C and in the range of 0.8 mm to 1.2 mm for the sole and the
skirt thickness T.sub.S. Referencing FIG. 5B, the wall thickness T
of the wall that transitions from the crown 40, sole 38, toe 30,
and heel 32 to the forward wall 44 and the front opening 36 is
preferably about 1 mm. This results in a smoother transition to the
thickness T.sub.P of the peripheral member 46 of the face plate
support 34. Of course, for golf club heads having smaller volumes
the desirable dimensions for the club head may vary. For example,
fairway wood club heads 10' having a club head volume in the range
of about 130 cc to 190 cc may have substantially thicker soles 38',
as shown in FIGS. 9, 10 and 10A.
With reference now to FIG. 13, a body 70 is depicted for use in a
wood-type golf club head. For convenience of reference, like
components are given like reference numerals. The body 70 includes
a face plate support 34' continuous about a front opening 36'. In
the present embodiment, the face plate support 34' includes a lower
portion 72 adjacent to a sole 38 of the body 70. The lower portion
72 includes a rear member 48' extending from a lower lip 74 of the
body 70 and having dimensions similar to those discussed above. The
rear member 48' extends inward with respect to the front opening
36' and is recessed to allow a face plate (not shown) to sit flush
with the body 70. In the present embodiment, the entirety of the
lower portion 72 of the face plate support 34' excludes a thin
peripheral member. However, in other embodiments, the lower portion
72 can include a thin peripheral member only at prescribed
locations along the lower portion. Although the present embodiment
is for use in a wood-type club head, similar face plate support
configurations in which the face plate support does not include a
thin peripheral member at prescribed locations, can also be used
for other club heads, such as in iron-type club heads (e.g.,
one-irons through wedges). Moreover, other embodiments of club
heads can incorporate a face plate support comprising a plurality
of tabs in which selected tabs adjacent to the sole 38 do not
include a thin peripheral member, as discussed above.
With reference now to FIG. 14, a body 80 is depicted for use in an
iron-type golf club head. The body 80 includes a top 82, sole 84, a
toe end, a heel end, and a face plate support 34'' similar to face
plate supports 34 and 34' described in the previous exemplary
embodiments. The face plate support 34'' includes a peripheral
member 46'' extending rearward from a forward wall 44'' and a rear
member 48'' extending inward with reference to the front opening
36''. The face plate support 34 is sufficiently thin to promote
performance (i.e., higher COR about a peripheral portion of the
face plate), and is structured to facilitate club durability. The
dimensions for the peripheral and rear members 46'', 48'' (e.g.,
thickness and length) are similar to those discussed above. In the
exemplary embodiment, the face plate support 34 is continuous about
the front opening 36. In other embodiments, the face plate support
34 can be configured as a plurality of tabs spaced apart about the
front opening 36.
With reference again to FIGS. 1-4, the club head 20 has four
removable weights 26. Two weights are located in the rear region 28
of the club head 20. A third weight is located in the toe region 30
of the club head 20, and a fourth weight is located in the heel
region 32 of the club head. The weights 26 are accessible from the
exterior of the club head 20 and securely received into recesses
90. In the exemplary embodiment, each weight 26 is oriented such
that a longitudinal axis defined by each weight is directed toward
the face plate 22. Fewer, such as two or three weights, or more
than four weights may be provided as desired.
Various weight configurations may be used, such as those disclosed
in co-pending U.S. patent applications Ser. Nos. 10/290,817 and
10/785,692, which are incorporated herein by reference. In the
exemplary embodiment, the weights 26 are attached by screws, such
as those available from Textron, Inc., under the brand names
TORX.RTM. or TORX PLUS.RTM.. Screws, such as those available from
Textron, Inc., under the brand name CAMCAR.RTM., can be used as one
or more of the weights. In the exemplary embodiment, four weights
26 having a combined mass of about 23 g are provided as shown in
FIG. 3, wherein the volume of the club head is about 460 cc. A
total mass of the club head 20, including a face plate mass of
about 24 g, is about 199 g. With this arrangement, the magnitude of
a moment of inertia about a vertical axis at a center of gravity of
the club head, I.sub.ZZ, is about 405 kg-mm.sup.2.
With continued reference to FIGS. 1-4, the body 24 for the club
head 20 comprises cast titanium alloy. In other embodiments, other
metal or non-metallic materials may be used, for example, the body
can be formed of materials such as squeeze-cast magnesium alloy,
steel, and combination of magnesium and titanium alloys. Also, a
multi-piece body may be used including one or more different
materials. For example, a body may be provided with a sole, skirt,
partial crown and face opening formed by metal casting methods
known to those skilled in the art. A stamped metal or composite
crown may be included to complete the crown of the body and a
forged metal or composite face plate may be attached to form the
club head 20. Alternatively, a composite body may be provided.
A hollow club head having features of the present invention can
range in volume from about 130 cc to about 460 cc. Preferably, the
head has a volume of at least 360 cc and more preferably at least
400 cc. The removable weights preferably comprise a mass of between
about 20 g and 30 g., for a total head weight between about 180 g
to 205 g. The moment of inertia I.sub.ZZ is preferably at least 300
kg-mm.sup.2 for the present invention and more preferably is at
least 350 kg-mm.sup.2.
The club head may be formed by casting techniques known to those
skilled in the art, preferably by investment casting a titanium
alloy such as Ti-6Al-4V. Alternatively, a soluble wax core may be
used to create the specific internal structures (e.g., face plate
support, weight recess) to achieve the desired club head MOI and CG
location parameters. In particular, a separate wax mold may be
created for the recesses for the weights 26 that is then attached
to a main wax mold for the club head body 24, such as by gluing the
two wax molds. In the exemplary embodiment, the forward, heel and
toe recesses 90 are formed as part of a unitary head body 24.
Alternatively, the weight recesses 90 may be separately formed and
welded to an internal location of the club head body 24. Of course,
alternative embodiments of the present invention may include
integral, thickened wall portions 92, such as shown in FIGS. 7 and
8, in lieu of removable weights 26. Alternative embodiments may
omit distinct weight elements completely.
In several exemplary embodiments, the face plate 22 is formed of
composite material; nonetheless, a lightweight metal face plate 22
can also be used. Referring now to FIG. 11, the plies (layers) of
composite material (prepreg) comprising the composite face plate 22
can be defined according to the combination of fiber, resin system,
fiber area weight (FAW) and resin content (R/C) used. One example
of a preferred prepreg is 70 g FAW 34/700 material which comprises
34/700 fiber, Newport 301 resin, 70 g/m.sup.2 FAW and 40% R/C.
Various embodiments of suitable composite face plates, and methods
of manufacture, are disclosed in co-pending U.S. patent application
Ser. No. 10/442,348 filed May 21, 2003 and titled GOLF CLUB HEAD
AND METHOD OF MANUFACTURE, which is incorporated herein by
reference.
The composite face plate 22 can be manufactured by stacking and
cutting the plies in predetermined orientations. This may be done
in smaller groups of plies that are eventually stacked to form the
final thickness of the face plate 22. More particularly, the plies
of prepreg can be arranged in specific groups in which each ply has
a predetermined orientation with reference to a horizontal axis.
For example, a first or outermost ply may comprise 1080 glass
fabric oriented at 0 degrees, followed by 48 plies of 34/700
prepreg oriented such that 12 plies each are at 0, +45, 90 and -45
degrees. Another ply of 34/700 at 90 degrees precedes the final or
innermost ply of 1080 glass fabric oriented at 0 degrees.
The face plate 22 preferably achieves its final desired shape or
dimensions by die cutting. The final desired bulge and roll of the
face plate 22 may be achieved during the last of two or more
"debulking" or compaction steps of two minutes each to reduce air
trapped between plies. Preferably a third debulking step includes
forming a panel having the final desired bulge and roll, and more
preferably an additional fourth debulking step is provided to form
the panel to a final face thickness, where the duration of the
fourth debulking step is about three minutes. The weight and
thickness of the resulting panel are preferably measured prior to
the curing step.
Preferably, the composite golf club face comprises low fiber area
weight (FAW) materials, and has a thickness less than about 4 mm.
The weight savings from the use of the composite face is about 20 g
to 25 g compared to a 2.7 mm thick face plate formed from a
titanium alloy such as Ti-6Al-4V, for example. For fairway wood
golf club heads, the face plate is preferably at least 60 mm wide
and 25 mm high. For driver-type golf club heads, the face plate is
preferably at least 80 mm wide and 50 mm high.
Attaching a composite material face plate 22 to a metallic club
head body 24 may be accomplished with adhesives. In order to
prevent peel and delamination failure at the face-body junction,
the composite face plate 22 should be recessed from or
substantially flush with the plane of the forward surface of the
metal body 24 at the junction, as shown in FIG. 11. Preferably, the
composite face plate 22 is sufficiently recessed so that the ends
of the fibers are not exposed. The junction of the composite face
plate 22 and the metal body 24 preferably includes an annular ledge
as the face support 34. Alternatively, the face plate support 34
may comprise two or more sections 94 (FIGS. 7-8) or a plurality of
tabs, to support and attach the face plate.
In a preferred embodiment shown in FIG. 12, the face plate
comprises a titanium cap 96 placed over a composite portion 22' to
form the striking surface of the face plate. Preferably, the
titanium cap includes a peripheral rim 98 to cover the periphery of
the composite portion 22', wherein the rim may be continuous or
comprise a plurality of segments. The titanium cap thickness is
less than about 1 mm, and preferably, the titanium cap thickness is
less than 0.2 mm. The cap in one test sample was formed from
Ti-6Al-4V titanium alloy; however, other materials or titanium
alloys may be employed as desired. The thickness of the composite
portion 22' of the face plate is about 3.65 mm and the titanium cap
thickness is about 0.3 mm. Also preferably, a bond gap of about
0.05 mm to 0.2 mm, and more preferably about 0.1 mm, is provided
between the titanium cap 96 and the composite portion 22' for
adhesive attachment of the titanium cap over the composite portion.
In other embodiments, a composite portion 22' can be provided
without a titanium cap, in which case a front surface of the
composite portion 22' may comprise the striking surface of the face
plate.
A surface roughness can be provided to the composite face plate 22
to facilitate adhesive bonding. In a first approach, a layer of
textured film may be placed on the composite material before
curing, thereby forming a given surface roughness on the cured
composite material. An example of such a textured film is ordinary
nylon fabric. Curing conditions do not degrade the fabric, and an
imprint of the fabric texture is transferred to a surface of the
composite material. Tests have shown that adhesion of urethane and
epoxy, such as 3M.RTM. DP460, to the textured composite surface was
greatly improved and superior to adhesion to a metallic surface,
such as cast titanium alloy. In a second approach, the texture can
be incorporated into a mold surface, allowing the textured area to
be controlled precisely. For example, in an embodiment having a
composite face plate joined to a cast body, the texture can be
located on surfaces of the composite face plate where shear and
peel are dominant failure modes.
It should be appreciated from the foregoing that the present
invention provides a golf club head that includes a face plate and
a body having a top, a sole, a toe end, a heel end, and a forward
wall. The forward wall defines a front opening about which a face
support is disposed. The face support receives the face plate,
thereby enclosing the front opening of the body. A face plate is
received in a face support provided at the front opening. The face
support includes portions proximate to the top, the toe end, and
the heel end. Each portion of the face support includes a
peripheral member extending rearward from the forward wall and a
rear member extending inward from the peripheral member, with
respect to the front opening. The face support can be combined with
a preferred face construction and weight elements to optimize club
head performance to help a golfer achieve greater distance and
control.
Although the invention has been disclosed in detail with reference
only to the preferred embodiments, those skilled in the art will
appreciate that additional golf club heads can be included without
departing from the scope of the invention. Accordingly, the
invention is defined only by the claims set forth below.
* * * * *