MULTI-MATERIAL GOLF CLUBHEAD

Abstract

A golf club head in accordance with various aspects of the present invention, may have a higher volume and/or higher strength. The golf club head may also comprise a variously configured and/or detachable face, allowing various faces of differing materials to be attached to the body. A detachable face further allows the head to be tuned via placement/rearrangement of weights within the head to change the center of gravity and moment of inertia.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation-In-Part application which claims priority to U.S. Continuation patent application Ser. No. 11/969,693 entitled “Multi-Material Golf Club Head,” filed Jan. 4, 2008, which claims priority to U.S. Non-Provisional patent application Ser. No. 10/712,401 entitled “Multi-Material Golf Club Head,” filed Nov. 12, 2003, which claims priority to U.S. Provisional Patent Application Ser. No. 60/425,244 entitled “Multi-Material Hybrid Golf Club Head Design/Construction,” filed Nov. 12, 2002, which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to golf club heads having faces of various configurations and various mechanisms for changing golf club head characteristics.

BACKGROUND OF THE INVENTION

Current high-performance golf club heads are often manufactured from various metal and/or graphite structures and combinations of these and other materials. In attempts to maintain low weight, while having large volumes, in the case of drivers (commonly referred to as “woods”), the heads are often made of materials such titanium, steel or graphite composites.

Many performance characteristics are desirable in the case of driver heads, including size, strength, mass distribution/inertia properties and the sounds they make. For example, generally, as the size of the heads increases (many approaching 500 cc), the heads tend to be more “forgiving” for off-center hits.

Further still, more and more, golfers seek club heads with specific centers of gravity locations and moments of inertia to control drive characteristics. Further yet, golfers increasingly seek to change certain objective and subjective characteristics such as contact time between the face of the club and the ball and the sound and/or acoustic profile made upon impact between the club head and the ball. For example, some golfers prefer the hollow “ping” sound of a titanium driver, while others prefer the “dead” or solid sound of a composite head (more like a traditional wood driver).

Club designers attempt to use these various performance attributes to tune or enhance certain characteristics of club performance. However, conventional metal design/construction methods are limited by basic properties (e.g., stiffness, strength and density) of the materials used as well as by manufacturing limitations (e.g., casting, welding and forming).

Thus, while the above-mentioned attributes are sought, many remain unrealized. Improved heads which can vary stiffness and strength areas redistribute total weight allowing control of the location of center of gravity and moment of inertia and/or are made of lighter and stronger materials, allowing bigger club heads with correspondingly larger “sweet” spots. Further still, clubs which provide “tunable” centers of gravity and moments of inertia are also desirable. Additionally, faces may be made more flexible (“hotter”) or less flexible (“colder”) to increase or decrease contact time. Such clubs may be further capable of producing varying impact sounds, and are therefore desirable.

SUMMARY OF THE INVENTION

While the way that the present invention addresses the disadvantages of the prior art is discussed in greater detail below, in general, the present invention provides an improved golf club head. For example, a golf club head in accordance with various aspects of the present invention, may be manufactured with an ability to add additional weight to specific locations on the clubs, thereby allowing the weight, center of gravity, and moment of inertia to be controlled/adjusted.

In some embodiments, the golf club head also may have a detachable face, allowing various faces of differing materials and configurations to be attached to one body and/or providing access to an interior of the golf club head. A detachable face further allows the head to be tuned via addition/placement/rearrangement of weights within the head to change the center of gravity and moment of inertia as well as sound. In various embodiments, weights within the golf club head may also be positioned via mechanisms on internal and/or external surfaces of the golf club head at least partially eliminating the need to “open” the golf club head (e.g., via the detachable face). Further yet, by tuning the weight and the face, the sound and/or acoustic profile of the golf club head (e.g., when striking a golf ball) may likewise be changed.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the Figures, where like reference numbers refer to similar elements throughout the Figures, and:

FIG. 1 is a perspective view of a body structure of a golf club head in accordance with the present invention;

FIG. 2 is a perspective view of a faceplate in accordance with the present invention;

FIG. 3 is a perspective view of another faceplate in accordance with the present invention;

FIG. 4 is a perspective view of another faceplate in accordance with the present invention;

FIG. 5 is a perspective view of another faceplate in accordance with the present invention;

FIG. 6 is a cross-sectional view of a faceplate attached to a club structure in accordance with an embodiment of the present invention;

FIG. 7 is a cross-sectional view of a faceplate attached to a club structure in accordance with another embodiment of the present invention;

FIG. 8 is a cross-sectional view of a faceplate attached to a club structure in accordance with another embodiment of the present invention;

FIG. 9 is a plan view of a club structure with a damping material in accordance with an embodiment of the present invention; and

FIG. 10 is a plan view of a club structure with a damping material in accordance with another embodiment of the present invention.

DETAILED DESCRIPTION

The following description is of exemplary embodiments of the invention only, and is not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments of the invention. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the invention as set forth herein. For example, though various portions of the specification refer to particular materials used in connection with golf club heads, numerous other materials, now known or as yet unknown, having desirable properties should be considered within the scope of the present invention.

Additionally, briefly, each and every process for manufacturing hollow items from various materials is not explained herein, however, one skilled in the relevant art will appreciate that various conventional golf club forming techniques may be used in accordance with the present invention.

That being said, in accordance with various aspects of the present invention and with reference to the exemplary embodiment illustrated in FIG. 1, the present invention comprises a golf club head 100 having a body structure and a faceplate 140. As described in more detail below with respect to various exemplary embodiments, faceplate 140 may be configured from a variety of materials and may have a number of configurations for changing the properties of club head 100. Additionally, as described further below, club head 100 may be hollow, allowing the variable positioning of tuning weights 200 within club head 100 to suitably adjust performance characteristics (such as the location of the center of gravity and moment of inertia) of club 100 as well as change the sound of club 100 via damping the structural elements of club 100.

In accordance the present invention with to FIG. 1, faceplate 140 is a surface which is intended to make contact with the golf ball during use, transferring energy of the swing to the ball. Faceplate 140 comprises any of numerous materials, such as steel or titanium, but may comprise many other materials, now known or as yet unknown, depending on desirable properties, such as the desired weight and flexure properties.

As noted above, faceplate 140 may also have a various shapes and configurations. For example, with reference to FIG. 2, faceplate 140 may have a generally uniform thickness. Alternatively, faceplate 140 may be thinner on an inside, center portion of faceplate 140. For example, as illustrated in FIG. 3, faceplate 140 may have a “depressed” area 142 on the inside surface of faceplate 140. The depressed areas 142 leaves faceplate 140 having a gradually thinner cross section towards the bottom of the depression. Because faceplate 140 becomes thinner, it is possible to design faceplate 140 to have more flexure, and thereby increase contact time with a golf ball. Similarly, spring characteristics of faceplate 140 may be changed based on the thickness(es) used.

Additionally, in various embodiments, the depressed area may contain a filler material 144 which is added to the inside surface to fill out faceplate 140. Filler material 144 may generally be any material such as composites, epoxies, elastomers, or the like, and are generally dictated by desired properties, such as to change the acoustic profile of club head 100 or to reduce or otherwise change flexure properties.

Various other configurations of faceplate 140 may have varying cross-sections on an inside, center portion. For example, as illustrated in FIG. 4, faceplate 140 comprises an “undulating” cross-section. Stated otherwise, faceplate 140 has one or more depressed areas 142 on the inside surface of faceplate 140, but also has at least one higher area 146, for example, generally centrally located within depressed area 142. Again, as described above, this embodiment may also have filler material 144 in depressed area 142, and may also cover higher area 146.

In another embodiment, faceplate 140 comprises a progressively stepped down depressed area. For example, with reference to FIG. 5, depressed area comprises a series of steps 142a, 142b, 142c, etc. culminating in a thinnest thickness of faceplate 140 at a bottom of the depression. As with the embodiments described above, a filler material may be added to the depression. Likewise, stepped depression 142a, 142b, 142c, etc. may undulate, that is, they may step down and then up again, similar to the embodiment illustrated in FIG. 4.

In general, one skilled in the art will appreciate that, in accordance with the present invention, faceplate 140 may be configured in many ways from many materials and thus, particularly in embodiments where faceplate 140 is releasably attachable, allow for “tuning” the properties of club head 100 by virtue of selecting different faceplates 140.

In this regard, in accordance with various non-limiting embodiments of the present invention, faceplate 140 may be suitably detachable from body structure 110. For example, referring back to FIG. 1, in one embodiment, body frame structure 122 comprises a faceplate aperture 128 having a perimeter 142 substantially contiguous with the perimeter of faceplate 140. Thus, when faceplate 140 is attached to body structure 110, faceplate 140 and body structure 110 integrate substantially seamlessly.

Additionally, in accordance with various alternative aspects of the present invention, body structure 110 may be permanently bonded with faceplate 140 through a now known or as yet unknown welding processes, and preferably, using a coolant system and/or heat sinks such as a thermal putty (e.g., Bloc-It® available from LA-CO Industries, Inc./Markal Company) or other coolant system such as welding in a liquid bath (e.g., oil, water or the like).

As mentioned above, in various embodiments of the present invention, body structure 110 further comprises mechanisms for facilitating releasable attachment of faceplate 140 to body structure 110. For example, with reference back to FIG. 1, body structure 110 may comprise a faceplate receiving ridge 144 upon which faceplate 140 is retained. In such embodiments, receiving ridge suitably comprises a recessed “lip” or series of “tabs” (not shown) which prevents faceplate 140 from passing completely within body structure 110, and, moreover may suitably assist in maintaining a striking surface 146 of faceplate 140 contiguous with an outer surface of body structure 110. Moreover, in embodiments using a releasably attachable faceplate 140, no thermal protection is needed as no welding is required.

In still further embodiments, receiving ridge 144 further facilitates attachment of faceplate 140 to body structure 110. For example, receiving ridge 144 may further comprise mounting mechanisms for attaching and detaching faceplate 140. For example, mounting mechanisms may comprise body holes 148 in body structure 110, faceplate holes 150 in faceplate 140, and screw 149 combinations or other similar fastening devices connect faceplate 140 to body structure 110 via corresponding faceplate holes 150.

In accordance with various alternative embodiments, any number of other configurations for facilitating releasable attachment of faceplate 140 to body structure 110 may be used. For example, with reference now to FIG. 6, body structure 110 again comprises faceplate receiving ridge 144 upon which faceplate 140 is retained by one or more body holes 148, faceplate holes 150 and screw 149 combinations. Optionally, various washers (not shown) may likewise be employed. In various embodiments body holes 148 and faceplate holes 150 may be configured in club head 100 (e.g., body structure 110 and/or faceplate holes 150) by any conventional or unconventional means, such as during casting and/or subsequent machining or EDM.

In still another embodiment, faceplate 140 may be attached by a laterally extending screw 151. In this regard, a screw 151 extends from one side of club structure 110, into the inner volume of club head 100, and attaches to faceplate 140. In various embodiments, screw 151 may enter from various sides of club structure 110, though in an exemplary embodiment such as illustrated in FIG. 7, screw 151 enters through the back of club head 100. Optionally, a built-up area 152 on club structure 110, which may or may not be threaded, may likewise included for purposes of reinforcement, screw/fastener guidance and/or to adjust the center of gravity of club head 100. In this embodiment, screw 151 attaches to a rear side of faceplate 140, for example, by threads, press fit, adhesive, or other attachment mechanism. Similar to built-up area 152, faceplate 140 may optionally comprise another built-up area 153, for similar purposes of reinforcement, screw/fastener guidance and/or to adjust the center of gravity of club head 100.

In yet another embodiment such as illustrated in FIG. 8, faceplate 140 may be attached to club structure 110 via a key mechanism 160. Key mechanism 160 suitably allows a tool to interact with an engagement portion 161, for example, through a key hole 162, allowing one more engagement bolts 163 to be retracted or extended into body structure 110, for securing faceplate 140 to body structure 110. For example, in the illustrated embodiment, faceplate 140 is located in faceplate aperture 128, and by inserting the noted tool (e.g., a key), and rotating, engagement bolts 163 extend into engagement slots 164 in club structure 110, securing or releasing faceplate 140 from club head 100.

Though not illustrated, one skilled in the art will appreciate that any number of screw combinations similar to that illustrated in FIGS. 6, 7, 8 and others may be used in accordance with the present invention. Likewise, the various embodiments described herein may be used in various combinations.

In various exemplary embodiments, tuning, damping or “intermittent” materials may be located on various portions of club head 100 to impart or change various characteristics of club head 100. Damping materials may be any material which changes the damping properties of club head 100. For example, various elastomers, rubbers, plastics, and the like may be used. Such materials absorb energy and damp vibration, which can effect club feel, sound, and performance. Alternatively, more rigid materials may be used as the “intermittent” material. For example, metals or ceramics may be used to effect club feel, sound, and performance.

Still further, various visco-elastic materials may be used as tuning inserts in connection with the present invention such as damping or “intermittent” materials. Visco-elastic materials are generally those materials characterized by having both elastic and viscous behaviors. For example, elastic materials store and release all or nearly all of the energy during loading, while a viscous material is opposite of elastic materials and returns little or no energy from the loading.

Tuning inserts in the form of damping materials discussed herein may be situated between club structure 110 and faceplate 140. In one embodiment, for example as illustrated in FIG. 9, damping materials are a series of individual damping pieces 145, for example, located on receiving ridge 144. Alternatively, damping material may be a single unitary washer-like structure 145 such as illustrated in FIG. 10.

Additionally, as noted above, club heads 100 in accordance with the present invention, allow inertia properties can be improved, positively impacting performance by repositioning weight inside the head body to alter the location of center of gravity and/or inertia values to help improve trajectory (CG) or forgiveness on off-center hits (inertia properties) or it can be allocated to an adjustable secondary center of gravity/sound type tuning insert(s)/mechanism(s).

For example, tuning inserts in the form of tuning weights 200 can be positioned within club 100 to change such characteristics. For example, experienced golfers may wish to move the center of gravity of club 100 higher up the club, and more toward the crown of the club to reduce backspin, while less experienced golfers may prefer the opposite. Tuning weights may be positioned within club head 200 in any number of manners now known or as yet unknown, preferably using access through faceplate aperture 128.

For example, with reference to FIG. 1, a weight retaining stud 132 is illustrated. It should be appreciated that numerous weight retaining studs may be placed in various locations in club head 100, providing the ability to not only adjust gross weight, bust also center of gravity location and moment of inertia. For purposes of illustration, however, only one stud 132 is shown. Weight retaining stud 132 is configured to allow a weight 134 to be attached. For example, in the presently described embodiment, weight 134 is a rubber, “washer-like” piece weighing approximately 30 g which is attached to stud 132 with a typical machine screw, bringing the total weight of club head 100 to the “ideal” weight of about 200 g, with a center of gravity in a desired location and/or a desired moment of inertia.

Further still the use of weights and/or damping materials attached to club head 100 suitably provides sound changing effects. For example, a weight attached to club head 100 may suitably provided a more “solid” sound when club head 100 strikes the ball, giving the impression club head 100 is not substantially hollow. Additionally, other materials may be added to the interior of club head 100 to achieve similar sound changing results. For example, club head 100 may contain some filler material such as fiberglass, silicone, rubber or other materials.

Thus, in addition to the tangible “objective” benefits of this new design/construction golf head (such as improved inertia/CG properties/magnification capabilities), several more “subjective” benefits exist as well. In addition to the ability to tune the sound characteristics by changing the type/location of materials and/or dampers, the aesthetic elements can also now be optimized.

Finally, it should be appreciated that the present invention has been described above with reference to various exemplary embodiments. However, many changes, combinations and modifications may be made to the exemplary embodiments without departing from the scope of the present invention. For example, the various components may be implemented in alternate ways. These alternatives can be suitably selected depending upon the particular application or in consideration of any number of factors associated with the operation of the system. In addition, the techniques described herein may be extended or modified for use with other types of devices. These and other changes or modifications are intended to be included within the scope of the present invention.

Claims

1. A golf club head, comprising:

a body structure; and

a faceplate; and wherein

said body structure having a faceplate aperture further comprising a perimeter substantially coincident with said faceplate, said faceplate aperture further comprising a faceplate receiving ridge upon which said faceplate is retained on said body frame structure and a tuning insert therebetween.

2. A golf club head in accordance with claim 1, further comprising a fastening mechanism for fastening said faceplate to said body structure.

3. A golf club head in accordance with claim 2, wherein said fastening mechanism comprises removable and re-attachable fasteners.

4. A golf club head in accordance with claim 2, wherein said fastening mechanism is a laterally extending screw.

5. A golf club head in accordance with claim 2, wherein said fastening mechanism is a key mechanism.

6. A golf club head in accordance with claim 1, wherein said tuning insert comprises a damping mechanism.

7. A golf club head in accordance with claim 1, further comprising a tuning weight attached to an interior surface of said body structure.

8. A golf club head in accordance with claim 7, wherein said tuning weight provides for an adjustable center of gravity.

9. A golf club head in accordance with claim 7, wherein said tuning weight provides for an adjustable moment of inertia.

10. A golf club head in accordance with claim 1, wherein said faceplate has a centrally located depression.

11. A golf club head in accordance with claim 1, wherein said faceplate has an undulating depression.

12. A golf club head in accordance with claim 1, wherein said faceplate has a stepped depression.

13. A golf club head in accordance with claim 1, wherein said faceplate has a predetermined acoustic profile.

14. A golf club head, comprising:

a body structure having a faceplate aperture;

a faceplate with a varying thickness;

a fastening mechanism for fastening said faceplate to said body structure; and

wherein said faceplate aperture further comprising a faceplate receiving area upon which said faceplate is retained on said body frame structure and a tuning insert between said body structure and said faceplate.

15. A golf club head in accordance with claim 14, wherein said fastening mechanism comprises removable and re-attachable fasteners.

16. A golf club head in accordance with claim 14, wherein said fastening mechanism is a laterally extending screw.

17. A golf club head in accordance with claim 14, wherein said fastening mechanism is a key mechanism.

18. A golf club head in accordance with claim 14, further comprising a tuning weight attached to an interior surface of said body structure.

19. A golf club head in accordance with claim 14, wherein said tuning insert comprises a damping mechanism.

20. A golf club head in accordance with claim 14, wherein said faceplate has at least one of a centrally located depression, an undulating depression, and a stepped depression.

21. A golf club head in accordance with claim 14, wherein said faceplate has a predetermined acoustic profile.

22. A golf club head, comprising:

a body structure having a faceplate aperture;

a tuning weight inside the golf club head;

a faceplate with at least one of a centrally located depression, an undulating depression, and a stepped depression; and

removable and re-attachable fasteners for fastening said faceplate to said body structure; and wherein said faceplate aperture further comprising a faceplate receiving area upon which said faceplate is retained on said body frame structure and a tuning insert between said body structure and said faceplate.