GOLF CLUB HEAD WITH COMPOSITE FACEPLATE
Golf club heads have a composite faceplate having an Impact Response Modulator disposed in the sole to improve ball flight characteristics. The Impact Response Modulator (IRM) includes a casing with a plurality of casing walls that form an aperture therebetween. The faceplate structurally reinforces the IRM by forming the casing walls out of high-strength material, thereby improving faceplate deflection while maintaining sufficient durability.
Latest KARSTEN MANUFACTURING CORPORATION Patents:
This claims the benefit of U.S. Provisional Application No. 63/699,398, filed on Sep. 26, 2024, U.S. Provisional Application No. 63/784,868, filed on Apr. 7, 2025, and U.S. Provisional Application No. 63/874,540, filed on Sep. 2, 2025, all of which are incorporated in their entirety.
FIELD OF INVENTIONThis invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.
BACKGROUNDThe strike face of a golf club head deflects upon impact with a golf ball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. More deflection will increase energy transfer between the club head and the golf ball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted to the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air increasing carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and/or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. To counter those stresses, conventional golf club heads employ build-ups, increased thicknesses, or other structural features adjacent the flexure to improve durability, at the sacrifice of performance. Consequently, conventional golf club heads fail to increase strike face deflection without compromising club head durability.
Conventional flexure features are typically formed of the same material as the body. Consequently, conventional clubs employ build-ups, increased thicknesses, or other structural features adjacent the flexure to improve durability, at the sacrifice of performance.
Wood-type golf club heads (i.e., drivers, fairway woods, or hybrids) having an impact response modulator (hereafter “IRM”) monolithically formed with a strike face, are described herein that improve performance and durability. The IRM is positioned in the sole proximate the strike face to strategically weaken the sole, increasing strike face deflection, and improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material. The casing may be provided in a composite faceplate that has one or more buffer zones that facilitate the assembly process. As used herein, the phrase “composite faceplate” does not suggest a particular material used to form the faceplate, as further defined below.
The composite faceplate is formed of a high-strength material that improves performance and durability. More specifically, the composite faceplate has a strike face intended to impact a ball. The high-strength material allows the strike face and IRM to have a reduced thickness, improving performance while maintaining sufficient durability. The composite faceplate is a monolithic component that forms at least a portion of the strike face and comprises a sole return that forms both the casing and a forward portion of the sole. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Stress in the casing walls is reduced by forming the casing with a high-strength faceplate material. Accordingly, the casing walls can have a reduced thickness, be placed closer to the strike face without exceeding the yield strength of the high-strength material, or a combination thereof. The selected use of a high-strength material increases strike face deflection and durability, facilitates fabrication, and maintain discretionary weight over a clubhead without this monolithic construction.
The composite faceplate comprises a face region and a sole return, wherein the entire casing and the entire aperture reside within the sole return. A peripheral wall of the composite faceplate entirely surrounds the face and sole return regions. In some embodiments, the peripheral wall is continuously joined or attached to the body, such that there are no portions of the periphery that are unattached to the body. Accordingly, the body forms no portion of the casing. In other embodiments, the peripheral wall is partially or intermittently joined or attached to the body. The periphery of the composite faceplate is spaced away from the casing walls so that no joints or connections are proximate the casing walls. Furthermore, by having a monolithic, composite faceplate that forms the entire casing, joints or connections between the composite faceplate and the body are spaced from the slot and therefore minimally impact slot performance while reducing areas of potential failure increasing durability of the casing walls.
I. DefinitionsThe golf club heads disclosed herein include a composite faceplate that improves durability and performance. The phrase “composite faceplate” is defined herein as a unitary, complex structure having multiple, integrally formed and interconnected portions, and does not limit, describe, or suggest a particular material used to form the faceplate. More specifically, the composite faceplates disclosed herein include at least a face region, forming a strike surface of the golf club head, and a sole return region that can include a casing, extending rearwardly of the face region. As such, each of the composite faceplates disclosed herein forms different, distinct regions of the golf club head and is attached to the body as a unit or module.
The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.
The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golf ball. The term “strike face” can be used interchangeably with the term “face.”
The strike face 102 is bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club head 100 deviates from a bulge curvature and/or roll curvature of the strike face 102 (defined below). The strike face perimeter includes at least an upper edge 118 that defines a transition between the strike face 102 and the crown 110 and a leading edge 103 that defines a transition from the strike face 102 to the sole 112. The upper edge 118 defines a face apex (FA), located at the intersection between the upper edge 118 and the YZ plane (described below). The leading edge 103 defines a face nadir (FN) located at the intersection between the leading edge 103 and the YZ plane. The strike face 102 further defines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in
The strike face 102 comprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike face 102 in the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and/or the roll curvature can comprise one or more radii.
The golf club head 100 defines a ground plane (GP) as a reference plane associated with the surface on which a golf ball is placed. The ground plane GP is a horizontal plane tangent to the sole 112 in the address position. The ground plane GP is illustrated in
The golf club head 100 defines a loft plane 15 as a plane that is tangent to the strike face 102 at the face center (FC). The loft plane 15 is illustrated in
The golf club head 100 defines a loft angle 20 as the angle measured between the loft plane 15 and the XY plane (defined below). The loft angle 20 is illustrated in
The golf club head 100 defines a lie angle 25 as the angle between a hosel axis 30, extending longitudinally through the hosel 105, and the ground plane GP. The lie angle 25 is measured from a front view of the golf club head 100, as illustrated in
The golf club head 100 can define an address position, wherein the golf club head 100 is oriented such that the golf club head 100 forms its intended loft angle 20 and lie angle 25. For example, in the address position, the loft plane 15 and the XY plane form the intended loft angle 20 between one another. Likewise, in the address position, the hosel axis 30 and the ground plane GP form the intended lie angle 25 between one another.
As illustrated in
The primary coordinate system, as described herein, defines an XY plane as a vertical plane extending along the X-axis 40 and the Y-axis 50. The primary coordinate system defines an XZ plane as a horizontal plane extending along the X-axis 40 and the Z-axis 60. The primary coordinate system further defines a YZ plane as a vertical plane extending along the Y-axis 50 and the Z-axis 60. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the primary coordinate system origin located at the face center (FC). In these or other embodiments, the golf club head 100 can be viewed from a front view when the strike face 102 is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head 100 can be viewed from a side view when the heel 104 or the toe 106 is viewed from a direction perpendicular to the YZ plane.
The golf club head 100 comprises a club head center of gravity (hereafter “CG” or “club head CG”), referring to the point at which the mass is centered within the golf club head 100. The club head CG is illustrated in
The “body depth,” or “depth” DB of the club head 100, as used herein, refers to a front-to-rear dimension measured across the body. Referring to
The “body height,” or “height” HB of the club head 100, as described herein, can refer to a crown-to-sole dimension measured across the body 101. Referring to
The “body width,” or “width” WB of the club head 100, as described herein, can refer to a heel-to-toe dimension measured across the body. Referring to
The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golf ball.
The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head.
“Driver” golf club heads as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the volume of the driver can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc-650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.
Driver embodiments can comprise a body height HB between 2.0 and 3.0 inches. In some driver embodiments, the body height HB can be between 2.0 and 2.2 inches, between 2.2 and 2.4 inches, between 2.4 and 2.6 inches, between 2.6 and 2.8 inches, or between 2.8 and 3.0 inches. In some driver embodiments, the body height HB can be greater than 2.0 inches, greater than 2.2 inches, greater than 2.4 inches, greater than 2.6 inches, greater than 2.8 inches, or greater than 3.0 inches.
Driver embodiments can comprise a body width WB between 4.4 and 5.0 inches. In some driver embodiments, the body width WB can be between 4.4 and 4.6 inches, between 4.6 and 4.8 inches, or between 4.8 and 5.0 inches. In some driver embodiments, the body width WB can be greater than 4.4 inches, greater than 4.6 inches, greater than 4.8 inches, or greater than 5.0 inches.
Driver embodiments can comprise a body depth DB between 4.3 and 4.9 inches. In some driver embodiments, the body depth DB can be between 4.3 and 4.5 inches, between 4.5 and 4.7 inches, or between 4.7 and 4.9 inches. In some driver embodiments, the body depth DB can be greater than 4.3 inches, greater than 4.5 inches, greater than 4.7 inches, or greater than 4.9 inches.
“Fairway wood” golf club heads as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.
Further, “fairway wood” golf club heads as used herein comprises a volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the volume of the fairway wood can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.
Fairway wood embodiments can comprise a body height HB between 1.25 and 1.75 inches. In some fairway wood embodiments, the body height HB can be between 1.25 and 1.40 inches, between 1.40 and 1.55 inches, or between 1.55 and 1.75 inches.
Fairway wood embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some fairway wood embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches.
Fairway wood embodiments can comprise a body depth DB between 3.0 and 4.0 inches. In some fairway wood embodiments, the body depth DB can be between 3.0 and 3.3 inches, between 3.3 and 3.6 inches, between 3.6 and 3.8 inches, or between 3.8 and 4.0 inches.
“Hybrid” golf club heads as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.
Further, “hybrid” golf club heads as used herein comprise a volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the volume of the hybrid can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.
Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
II. General Description of a Golf Club HeadVarious embodiments of a golf club comprising a composite faceplate, having both a face region and a sole return region that integrally forms the entire casing and aperture, are illustrated in the figures. More specifically, the composite faceplate is monolithically formed from a high-strength material so that the sole return encompasses the entirety of the casing and the aperture it defines. The composite faceplate is joined with the body to form a club head. The golf club is generally understood to comprise the club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.
Referring to
The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club head 100 comprises a crown 110 and a sole 112, whereas club head 200 comprises a crown 210 and a sole 212). Any one or more of the features below can be used in combination with one another.
The composite faceplate comprises a high-strength material having sufficient strength to withstand repeated impacts with a golf ball. In some embodiments, the composite faceplate material can be a high-strength steel alloy such as, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.
In other embodiments, the composite faceplate material can be a high-strength titanium alloy, for example, but not limited to HST 220, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fe (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).
The body 101 can comprise one or more body materials. In some embodiments, at least a portion of the body 101 comprises a metal material, such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the metal material can comprise a Ti-8Al-1Mo-1V alloy, Ti-8Al-2V (Ti-8-1-1-plus), or a 17-4 stainless steel. In some embodiments, the metal material can comprise Ni (Nickel)-Co (Cobalt)-Cr (Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6Al-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3Al-2.5V, Ti-6Al-1Zr-1Nb-1Mo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals.
In some embodiments, at least portions of the body 101 comprises one or more lightweight materials, such as a carbon-composite material. The phrase “carbon-composite material” is defined herein as the type of material, such as a carbon reinforced fiber material or any other carbon organic based material. This is in contrast to the phrase “composite faceplate,” which as noted above is defined as a multi-faced component having integrally provided, interconnected structures that form distinct regions of the golf club head. In some embodiments, portions of the crown 110, the sole 112, the heel 104, the toe 106, or a combination thereof can be formed by a carbon-composite material. In some embodiments, the club head 100 can comprise one or more carbon-composite panels. In some embodiments, referring to
In some embodiments, the carbon-composite material can comprise a polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic resin. In some embodiments, the carbon-composite material can comprise a carbon fiber composite material having multiple layers of unidirectional carbon fibers formed as a single, continuous piece. In some embodiments, the carbon-composite material can comprise a bi-directional woven carbon fiber composite material having a single layer formed as a single, continuous piece. In some embodiments, the carbon-composite material can comprise a fiber reinforced thermo-plastic material. The carbon-composite material can be extruded, compression molded, injection molded, blow molded or bladder molded, 3-D printed, or otherwise formed by any other appropriate forming means.
According to certain aspects of the present invention, the composite faceplate material comprises a high-yield strength. In some embodiments, the composite faceplate material comprises a yield strength greater than 130 ksi, greater than 145 ksi, greater than 155 ksi, greater than 165 ksi, greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater than 230 ksi, greater than 240 ksi, greater than 250 ksi, greater than 260 ksi, greater than 270 ksi, greater than 280 ksi, greater than 290 ksi, greater than 300 ksi, greater than 310 ksi, greater than 320 ksi, greater than 330 ksi, greater than 340 ksi, or greater than 350 ksi.
When the composite faceplate is joined to a portion of the body formed of a metal material, the yield strength of the composite faceplate material is greater than the yield strength of that metal material. For example, when the frame of the body comprises a metal material, the yield strength of the frame material is less than that of the composite faceplate material. In some embodiments, the frame material has yield strength from 100 ksi to 165 ksi. In some embodiments, frame material has a yield strength of less than 165 ksi, less than 155 ksi, less than 145 ksi, less than 135 ksi, less than 125 ksi, less than 115 ksi, or less than 105 ksi. Regardless of the specific yield strength of the frame material, the yield strength of the composite faceplate will be greater.
In some embodiments, the club head 100 comprises a composite faceplate strength ratio comparing the yield strength of the composite faceplate material to the yield strength of the body material. In some embodiments, the composite faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.
III. Impact Response ModulatorAs previously mentioned, the golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”), having increased face deflection at impact with a golf ball. The IRM 120 is provided in the composite faceplate, which is formed of a high-strength material that reinforces the IRM 120 to improve durability of the golf club head. Referring to
The casing 130 includes walls that form and surround the aperture 140. As illustrated in
To improve durability, the front wall 132 is separated from the strike face 102 by a sole transition region 166 formed from the high-strength material. The sole transition region 166 forms an integral part of the composite faceplate. The sole transition region 166 separates the front wall 132 from the strike face 102 by an offset distance OD, which is described in further detail below. As such, the casing 130 comprises a front wall 132 that partially forms the aperture 140 and is distinct from the strike face 102. Spacing the front wall of the casing away from the strike face increases durability while maintaining performance. The sole transition region dissipates stress and evenly transfers the flow of stress from the face to the front wall of the casing.
Further, as best illustrated in
The forward sole region 166 balances durability and strike face deflection by spacing the casing 130 and the aperture 140 rearward of the strike face 102. If not for the forward sole region 166, the casing 130 and/or the aperture 140 would directly abut the strike face 102. In such cases, the impact stress and in the casing 130 and the strike face 102 would lend to lead to failure, and the strike face 102 and/or the casing walls would need to be significantly thickened to preserve durability. Doing so would hinder strike face deflection such that any performance gains achieved by the inclusion of the IRM 120 would be lost or greatly diminished. Spacing the casing 130 and the aperture 140 rearward of the strike face 102 by the forward sole region 166 allows the strike face 102 and casing walls to be thinned, therefore increasing strike face deflection.
The casing 130 can comprise a front wall height FWH, as best illustrated in
As mentioned above, the casing 130 also comprises an offset distance OD, as best illustrated in
The front wall 132 comprises a front wall thickness FWT, as best illustrated in
In some embodiments, the casing can comprise reliefs having relief angles, defined below. The relief angles can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, increasing the relief angle (i.e., angling the relief more rearwardly), decreases strike face deflection but increases durability. Similarly, decreasing the relief angle (i.e., angling the relief more flat or parallel to the length of the casing), increases strike face deflection but decreases durability. The use of a fixed shaft-receiving mechanism or an adjustable shaft-receiving mechanism can affect whether or not the casing includes a heel relief. An adjustable shaft-receiving structure comprises a heel recess or indentation for a mechanical fastener. The heel recess prevents the casing from extending into the heel thereby preventing the casing from including a heel relief.
In some embodiments, the casing can comprise a heel relief, a toe relief, or both. In some embodiments, the heel relief angle can be the same as the toe relief angle. In other embodiments, the heel relief angle can be different than the toe relief angle. For example, in some embodiments, the club head can comprise only a toe relief angle when used in conjunction with a lower hosel socket. In other embodiments, the casing can include both a heel relief angle and toe relief angle. The heel relief angle and toe relief angle relieve stress buildup at the heel end and toe end, respectively, thereby improving durability of the casing.
The casing comprises a heel relief angle measured as the angle between a line that extends between the intersection of the heel plane and the front wall bottom rear edge to the absolute heel point and the leading edge plane. The heel relief angle can range between 2 and 75 degrees. The heel relief angle can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the heel relief angle is 53 degrees.
The casing comprises a toe relief angle measured as the angle between a line that extends between the intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and the leading edge plane. The toe relief angle can range between 2 and 75 degrees. The toe relief angle TRA can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the toe relief angle is 53.38 degrees.
The above IRM geometries, as well as additional geometries are described in U.S. patent application Ser. No. 19/212,636, filed on May 19, 2025, of which the contents of which are fully incorporated herein.
In some embodiments, the IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170, as best illustrated in
In some embodiments, the insert 170 can be retained within the casing walls 132, 142, 152, 154 by at least one tab 145, as illustrated in
As described above, the composite faceplate forms the entire casing and aperture, as well as a part of the strike face. The composite faceplate is formed of a high-strength material that reinforces the casing to increase strike face deflection without compromising durability. The composite faceplate also positions joints and connections away from the aperture/casing walls to facilitate fabrication and assembly while reducing the number of failure points on the walls of the casing that experience high stress.
Various embodiments of composite faceplates formed of a high-strength material forming the entire casing are described in further detail below. Specifically, embodiments of fairway wood-type club heads and driver-type club heads are shown with different hosel configurations and other features. The different hosel configurations affect the total length of the casing, and therefore performance. For example, in some embodiments, the club head comprises a bottom-adjustable hosel having a lower hosel socket in the sole. In these embodiments, the casing and aperture are relatively shorter to provide space on the sole to accommodate the lower hosel socket. In other embodiments, the lower hosel socket is omitted, thereby increasing available space on the sole to accommodate a longer casing and aperture.
In one embodiment, a fairway wood-type club head comprises a bottom-adjustable hosel and a composite faceplate formed a high-strength material. In another embodiment, a fairway wood type club head comprises a fixed or top-adjustable hosel configuration and an composite faceplate formed of a high-strength material. In another embodiment, a driver-type club head comprises a bottom-adjustable hosel and a composite faceplate formed of a high-strength material. In another embodiment, a driver-type club head comprises a fixed or top-adjustable hosel configuration and a composite faceplate formed of a high-strength material. Aspects of the present invention may be utilized in other club head types such as irons or hybrid-type club heads.
A bottom-adjustable hosel, as described above, is an adjustable hosel configuration comprising a bottom opening, or a lower hosel socket, located on the sole of the club head that receives a fastener to secure the shaft to the club head. Bottom-adjustable hosels allow the club head to be fixed at an angle relative to the shaft, thereby setting the club head to a particular loft and/or lie angle. The lower hosel socket limit available space for, and/or otherwise, may interfere with, the IRM and the composite faceplate. In some embodiments, the lower hosel socket is formed in the body and does not form part of the composite faceplate. In other embodiments, the lower hosel socket is incorporated into the composite faceplate.
A top-adjustable hosel or fixed hosel configuration, as described above, is a hosel configuration that lacks a bottom opening to increase the length of the slot thereby increasing performance. The lack of a lower hosel socket further improves manufacturability of joining the composite faceplate to the body by simplifying the weld line. In these embodiments, the hosel configuration may be top-adjustable or fixed. A top-adjustable hosel refers to a hosel configuration in which does not have a bottom opening but can still be adjusted into different loft/lie configurations in the top hosel portion. Alternatively, the hosel configuration may be fixed in which the shaft in permanently and non-adjustably secured to the hosel, removing the need for a lower hosel socket on the sole. Both the top-adjustable configuration and fixed configuration removes the need for a bottom opening, thereby allowing the length of the casing to increase, thereby increasing flexure and performance. Details of composite faceplate embodiments which utilize top-adjustable or fixed hosel configurations are described in further detail below.
A fairway wood-type club head 1000 comprises a composite faceplate 1050 having a face region and a sole return region that forms the entire casing to increase performance while maintaining durability, as illustrated in
The interface at which the composite faceplate is joined to the body may be located to facilitate fabrication and assembly. For example, a heel section of the peripheral wall may be spaced from both the casing and the lower hosel socket to permit welding without impacting those structures. In this embodiment, the body has a sole opening to harbor and secure a bottom-adjustable hosel. The sole opening is formed within the body material and not the composite faceplate, as illustrated in
The body 1001 of the golf club head 1000 may be formed of one or more materials having a yield strength less than that of the composite faceplate 1050. More specifically, the body 1001 may have a crown 1010, a sole 1012, a toe end 1006, and heel end 1004, a rear end 1011, a front 1008, a hosel 1005, and a frame 1013 forming a front 1008 of the body 1001. The frame 1013 may be formed of the same material as some or all of the rest of the body 1001, or may be formed of a different material. In either event, the frame 1013 may be formed of a frame material having a first yield strength, as illustrated in
The composite faceplate 1050 is coupled to the body 1001 to form an interior cavity 1007 of the golf club head 1000. The composite faceplate 1050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate having a yield strength that is greater than the frame yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.
The composite faceplate 1050 comprises a face region 1051 which forms a portion of the strike face 1002 at the front 1008 of the body 1001. The face region 1051 comprises a strike surface 1052 configured to impact a golf ball, a face region toe side 1053 located toe-ward of the strike surface 1052 and bordering the frame toe end 1017, a face region heel side 1054 located heel-ward of the strike surface 1052 and bordering the frame heel end 1016, a face region crown side 1055 located crown-ward of the strike surface 1052 and bordering the frame crown 1014, and a face region sole side 1056 located sole-ward of the strike surface 1052 and defining a sole leading edge 1057.
The composite faceplate further comprises a sole return region 1058, formed integral with the face region 1051 having a casing 1030 with an aperture 1040 within a sole return sole wall 1059 to improve ball speed and spin characteristics. The high-strength material of the composite faceplate 1050 and thus the casing, improves performance and durability. The casing 1030 includes a front wall 1032, a rear wall 1038, a toe wall 1036, and a heel wall 1034, wherein the front wall 1032, the rear wall 1038, the toe wall 1036, and the heel wall 1034 define an aperture 1040. Advantageously, the body 1001 does not form any portion of the aperture 1040.
The composite faceplate further comprises a sole transition region 1060, formed integral with the face region 1051 and the sole return region 1058 that spaces the aperture from the leading edge to improve bending and durability. More specifically, the sole transition region extends from the sole leading edge 1057 of the face region 1051 to the casing front wall 1032. The sole transition region 1060 can further define aperture offset distance (OD) as defined above, and measured between the sole leading edge 1057 and the casing front wall 1032. The sole transition region 1060 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 1052 and face region 1051.
A peripheral wall 1061 of the composite faceplate 1050 is joined to the body 1001, to form the golf club head. More specifically, the peripheral wall 1061 extends around entireties of the face region 1051, the sole return region 1058, and the sole transition region 1060, and is joined to the frame 1013 of the body 1001, such as by welding. The peripheral wall comprises a peripheral wall heel section 1062, disposed between the casing heel wall 1034 and the lower hosel socket of the frame, that is spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance. The peripheral wall 1061 further comprises a peripheral wall sole section 1063, disposed between the casing rear wall 1038 and the frame sole 1015, that is spaced from the casing rear wall 1038 by a sole buffer distance. Both the heel buffer distance and sole buffer distance are between 0.05 and 0.25 inch to sufficient space the joint of the frame and composite faceplate away from the walls of the casing to improve durability. In some embodiments, the peripheral wall 1061 is continuously joined to the frame 1013. In other embodiments, the peripheral wall is partially or intermittently joined to the frame 1013.
A golf club head 1100, as illustrated in
The composite faceplate 1150 further comprises a crown transition region 1167, formed integral with the face region 1151, the sole return region 1158, the sole transition region 1160, and the crown return region 1165. The crown transition region 1167 extends from a crown leading edge 1168 of the face region 1151 to the crown return crown wall 1166 of the crown return region 1165.
In this embodiment, the peripheral wall 1161 extends entirely around the face region 1151, the sole return region 1158, the sole transition region 1160, the crown return region 1165, and the crown transition region 1167, and is joined to the frame 1113 of the body 1101. The crown transition region 1167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.
In some embodiments, the high-strength crown return region 1165 further comprises an indent 1141, as shown in
The crown return region 1165 extends rearwardly away from the crown leading edge 1168 by at least a distance of 0.10 inch to provide sufficient coverage of high-strength material in the forward portion of the crown. In some embodiments, the crown return region 1165 extends between 0.10 and 1.25 inches rearwardly from the crown leading edge. For example, the crown return region 1165 can extend between 0.10 and 0.25, 0.25 and 0.50 inch, 0.50 and 0.75 inch, 0.75 and 1.00 inch, or between 1.00 and 1.25 inches.
The indent 1141 comprises an indent thickness TI that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indent thickness TI can be between 0.005 and 0.020 inch, whereas the crown return thickness TCR can be between 0.020 and 0.050 inch. In some embodiments, the indent thickness TI can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return region 1165 can comprise an indent thickness ratio TI/TCR defined as the indent thickness TI divided by the crown return thickness TCR. In some embodiments, the indent thickness ratio TI/TCR can be less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1.
In the illustrated embodiment, the indent 1141 is located approximately in the center of the crown return region 1165 and extends in a generally heel-to-toe direction. In other embodiments, the indent 1141 can be offset towards to the toe 1106 or towards the heel 1104. In the illustrated embodiment, the indent 1141 has an approximately rectangular shape. In other embodiments, the indent 1141 can have other shapes such as an elongated oval or an arcuate shape. Altering the position and shape of the indent can target specific portions of the strike face and change flexure response, as desired. The indent # can be applied to club heads (# of crown returns) described below.
The club head 1100 having a composite faceplate 1150 formed of a high-strength material, and comprising a crown return region 1165 and a sole return region 1158, further increases durability and performance of the club head by reinforcing areas of high-stress with a high yield strength material. In other embodiments, the composite faceplate 1150 can further form other areas of the club head body 1001 with high-strength materials, such as the hosel.
A golf club head 1200, as illustrated in
Specifically, the composite faceplate 1250 comprises a lower hosel region 1269, formed integrally with the face region 1251, the sole return region 1258, and the sole transition region 1260, and extends between the face region heel side 1254 and the sole return sole wall 1259 of the sole return region 1258. The lower hosel region 1269 includes a lower hosel socket 1218 defining a socket perimeter 1222 having a socket perimeter outboard section 1224 and a socket perimeter inboard section 1223. The lower hosel socket 1218 is monolithically and entirely formed with the composite faceplate 1250 to increase the amount of high-strength material coverage in the club head, particularly in areas that experience high-stress.
The peripheral wall heel section 1262 of the composite faceplate 1250 is disposed between the frame heel end 1216 and the lower hosel socket 1218 of the lower hosel region 1269 and is spaced from the socket perimeter outboard section 1224 by a heel buffer distance. The heel buffer distance is least 0.05 inch to allow for sufficient clearance for welding the peripheral wall 1261 to the frame 1213. In other embodiments, the heel buffer distance can be less than 0.049 inches if improved welding or other techniques are used.
Furthermore, by forming the lower hosel socket 1218 integrally with the composite faceplate 1250, the casing 1230 can be positioned closer to lower hosel socket 1218, thereby extending the effective length of the casing 1230 to increase bending and deflection. Because the peripheral wall heel section 1262 does not lie between the socket perimeter inboard section 1223 and the casing heel wall 1234, additional buffer spacing is not required between the hosel and the casing. As such, the length of the casing, and therefore the aperture, can be increased to improve performance.
A golf club head 1300 and a body 1301, as shown in
Specifically, the composite faceplate 1350 comprises a toe wrap region 1370 that is formed integrally with the face region 1351, the sole return region 1358, the sole transition region 1360, and the lower hosel region 1369. The toe wrap region 1370 extends rearward of the face region toe side 1353. The toe wrap region 1370 extends rearward of the face region toe side 1353 such that the peripheral wall 1361 extends entirely around the toe wrap region 1370. The toe wrap region 1370 includes a toe lateral wall 1371. In some embodiments, the toe lateral wall 1371 can be approximately horizontal with the ground plane. In other embodiments, the toe lateral wall 1371 can formed at an angle relative to the ground plane.
The composite faceplate 1350 further comprises a heel wrap region 1372 formed integrally with the face region 1351, the sole return region 1358, the sole transition region 1360, and the lower hosel region 1369. The heel wrap region 1372 extends rearward of the face region heel side 1354 such that the peripheral wall 1361 extends entirely around the heel wrap region 1372. The heel wrap region 1372 includes a heel lateral wall 1373. In some embodiments, the heel lateral wall 1373 can be approximately horizontal with the ground plane. In other embodiments, the heel lateral wall 1373 can formed at an angle relative to the ground plane.
In some embodiments, the composite faceplate 1450 is coupled to a mass pad 1479 of the body 1401 having an increased thickness than a surrounding wall thickness of the sole 1412, as illustrated in
In some embodiments, a club head 1500 comprising a body and a composite faceplate can further comprise a sole trough located at the joint or junction between the body and the composite faceplate for ease of manufacture and weldability, as illustrated in
By incorporating a sole trough 1578 between the composite faceplate 1550 and the club head body 1501, the golf club head 1500 may comprise a variety of sole mass pads 1579 for shifting the CG faceward and soleward. When combined with the composite faceplate 1550, these features synergistically improve launch efficiency, spin rates, and carry distance, while maintaining durability in the golf club head 1500. Each of the sole mass pad 1579 embodiments can be integrally formed or co-casted with an interior surface 1580 of the sole 1512. More specifically, the sole mass pad 1579 can be configured as increased sole thickness at the interior surface 1580 of the sole 1512 and define a front wall 1582, a rear wall 1583, a heel wall 1584, and a toe wall 1585. In preferred embodiments, the sole mass pad 1579 is positioned centrally on the sole 1512 to control spin and increase ball speed. However, the sole mass pad 1579 may also be shifted closer to the heel end 1504 or the toe end 1506, and/or extend only partially along the width of the sole 1512 for influencing the club head MOI properties, forgiveness, and shot shape tendencies.
The composite faceplate 1550 may be coupled to club head bodies 1501 comprising differently shaped sole mass pads 1579 for reducing spin rates, improving vertical launch performance, and increasing distance. As described above, each of the various sole mass pad 1579 embodiments distribute mass forward and soleward in the club head 1500 without interfering with the increased strike face deflection and durability characteristics of the composite faceplate 1550. In some embodiments, for example, the sole mass pad 1579 may comprise a substantially rectangular shape when viewing the golf club head 1500 from a cross-sectional toe- or heel-side view. As shown in
In additional embodiments, the composite faceplate 1550 may be coupled to a body 1501 comprising a substantially triangular sole mass pad 1579 when viewing the golf club head 1500 from a cross-sectional toe- or heel-side view. As shown in
In even further embodiments, the composite faceplate 1550 may be coupled to a body 1501 comprising a sole mass pad 1579 that forms a mass pad extension 1590. As shown in
In some embodiments, the casing 330 can comprise one or more end reinforcements 326 that dissipate stress within the casing 330. The end reinforcements 326 can be regions of the sole 312 having increased thickness that surround one or more of the casing walls. The end reinforcements 326 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. In addition to integrally forming the casing walls, the faceplate 314 can also form the end reinforcement(s) 326, as illustrated in
The end reinforcement(s) can each comprise a thickness (i.e., a heel end reinforcement thickness or a toe end reinforcement thickness) measured from the aperture 340 to the opposing surface of the end reinforcement. As discussed above, the end reinforcement(s) can have substantially larger thicknesses than the remainder of the casing walls. Specifically, in some embodiments, the heel end reinforcement thickness and/or the toe end reinforcement thickness can be at least 50% greater, 75% greater, 100% greater, 150% greater, 200% greater, or 300% greater than the front wall thickness FWT.
In another embodiment, a fairway wood golf club head 2000 comprises a composite faceplate and a top-adjustable or fixed hosel configuration so that the casing/aperture can be longer to increase bending and performance of the casing. As described above, the top-adjustable and fixed hosel configurations remove the need for a lower hosel socket, thereby allowing the lengths of the casing and aperture to increase. A longer aperture increases bending and deflection of the casing experiences, thereby returning more energy back to the strike face to increase ball speed. The golf club head 2000 may comprise either a fixed hosel or a top-adjustable hosel, as desired.
The golf club head 2000 comprises a body 2001 having a crown 2010, a sole 2012, a toe end 2006, a heel end 2004, a rear end 2011, a front 2008, a hosel 2005 defining a hosel axis 2009, and a frame 2013 forming a front 2008 of the body 2001 and formed of a frame material having a first yield strength, as illustrated in
The composite faceplate 2050 is coupled to the body 2001 to form an interior cavity 2007 of the golf club head 2000. The composite faceplate 2050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate 2050 having a yield strength that is greater than the body 2001 and frame 2013 yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.
The composite faceplate 2050 comprises a face region 2051 which forms a portion of the strike face 2002 of the front 2008 of the body 2001. The face region 2051 comprises a strike surface 2052 configured to impact a golf ball, a face region toe side 2053 located toe-ward of the strike surface 2052 and bordering the frame toe end 2017, a face region heel side 2054 located heel-ward of the strike surface 2052 and bordering the frame heel end 2016, a face region crown side 2055 located crown-ward of the strike surface 2052 and bordering the frame crown 2014, and a face region sole side 2056 located sole-ward of the strike surface 2052 and defining a sole leading edge 2057.
The composite faceplate further comprises a sole return region 2058, formed integral with the face region 2051. The sole return region has a casing 2030 to improve ball speed and spin characteristics. Forming the casing within the sole wall 2059 of the sole return region 2058 and thereby of the high-strength material of the composite faceplate, the casing performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 2030 includes a front wall 2032, a rear wall 2039, a toe wall 2036, and a heel wall 2034, wherein the front wall 2032, the rear wall 2039, the toe wall 2036, and the heel wall 2034 define an aperture 2040. The body 2001 does not form any portion of the aperture 2040. Furthermore, the casing heel wall 2034 is heelward of the hosel axis 2009 to increase the effective length of the casing 2030 and aperture 2040.
In this embodiment, the casing comprises a Total Length (TL), measured from the absolute toe point to the absolute heel point, parallel to the x-axis 40, that can be between 2.60 to 4.0 inches. For example, the total length TL can range from 2.60 to 3.0 inches, 3.0 to 3.5 inches, or 3.5 to 4.0 inches. In one embodiment, the total length TL is 2.681 inches.
The composite faceplate further comprises a sole transition region 2065, formed integral with the face region 2051 and the sole return region 2058, extending from the sole leading edge 2057 of the face region 2051 to the casing front wall 2032. The sole transition region 2065 can further define an aperture offset distance (OD) as defined above, and measured between the sole leading edge 2057 and the casing front wall 2032. The sole transition region 2065 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 2052 and face region 2051.
The composite faceplate 2050 further comprises a peripheral wall 2061, extending around the entirety of the face region 2051, the sole return region 2058, and the sole transition region 2060, and is joined to the frame 2013 of the body 2001. The peripheral wall 2061 comprises a peripheral wall heel section 2062 disposed heelward of casing heel wall 2034 and heelward of the hosel axis 2009. The peripheral wall 2061 further comprises a peripheral wall sole section 2063 disposed between the casing rear wall 2038 and the frame sole 2015, spaced from the casing rear wall 2038 by a sole buffer distance. The sole buffer distance is between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability.
In another embodiment, a golf club head 2100 comprises a composite faceplate 2150 that is similar to the composite faceplate 2050 described above, but further comprises a crown return region 2165, as shown in
The composite faceplate 2150 further comprises a crown transition region 2167, formed integral with the face region 2151, the sole return region 2158, the sole transition region 2160, and the crown return region 2165, extending from a crown leading edge 2168 of the face region 2151 to the crown return crown wall 2166 of the crown return region 2165. As such, the peripheral wall 2161 extends entirely around the face region 2151, the sole return region 2158, the sole transition region 2160, the crown return region 2165, and the crown transition region 2167, and is joined to the frame 2113 of the body 2101. The crown transition region 2167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.
In another embodiment, a golf club head comprises a crown return and a long casing formed in a high-strength composite faceplate to increase performance and durability of the golf club head. The golf club head 2200 is similar to club head 2100 described above but further comprises partial heel and toe wraps, similar to club head 1300 described above.
In all embodiments of golf club heads 1000, 1100, 1200, 1300, 1400, 1500, 2000, 2100 described above, the front wall of the casing is offset from the leading by a distance of at least 0.075 inch to further increase durability while maintaining performance of the casing. Offsetting the casing front wall away from the strike face allows stress to flow around the leading edge and onto the sole. Furthermore, the stress flows throw high-strength material of the composite faceplate.
In another embodiment, and according to aspects of the present invention, a driver type club head 3000 comprises a composite faceplate 3050 that comprises a sole return that forms the entire casing to increase performance while maintaining durability, as illustrated in
The golf club head 3000 comprises a body 3001 having a crown 3010, a sole 3012, a toe end 3006, and heel end 3004, a rear end 3011, a front 3008, a hosel 3005, and a frame 3013 forming a front 3008 of the body 3001 and formed of a frame material having a first yield strength, as illustrated in
The composite faceplate 3050 is coupled to the body 3001 to form an interior cavity 3007 of the golf club head 3000. The composite faceplate 3050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate having a yield strength that is greater than the body and frame yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.
The composite faceplate 3050 comprises a face region 3051 which forms a portion of the strike face 3002 and the front 3008 of the body 3001. The face region 3051 comprises a strike surface 3051 configured to impact a golf ball, a face region toe side 3053 located toe-ward of the strike surface 3051 and bordering the frame toe end 3017, a face region heel side 3054 located heel-ward of the strike surface 3051 and bordering the frame heel end 3016, a face region crown side 3055 located crown-ward of the strike surface 3051 and bordering the frame crown 3014, and a face region sole side 3056 located sole-ward of the strike surface 3051 and defining a sole leading edge 3057.
The composite faceplate 3050 further comprises a sole return region 3058, formed integral with the face region 3051. The sole return region has a casing 3030 to improve ball speed and spin characteristics. Forming the casing 3030 within the sole wall 3059 of the sole return region 3058 and thereby of the high-strength material of the composite faceplate 3050, the casing 2020 performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 3030 includes a front wall 3032, a rear wall 3039, a toc wall 3036, and a heel wall 3034, wherein the front wall 3032, the rear wall 3039, the toc wall 3036, and the heel wall 3034 define an aperture 3040. The body 3001 does not form any portion of the aperture 3040.
The composite faceplate further comprises a sole transition region 3060, formed integral with the face region 3051 and the sole return region 3058, extending from the sole leading edge 3057 of the face region 3051 to the casing front wall 3032. The sole transition region 3060 can further define aperture offset distance (OD) as defined above, and measured between the sole leading edge 3057 and the casing front wall 3032. The sole transition region 3060 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 3052 and face region 3051.
The composite faceplate 3050 further comprises a peripheral wall 3061, extending around the entirety of the face region 3051, the sole return region 3058, and the sole transition region 3060, joined to the frame 3013 of the body 3001. The peripheral wall comprises a peripheral wall heel section 3062 disposed between the casing heel wall 3034 and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance. The peripheral wall 3061 further comprises a peripheral wall sole section 3063 disposed between the casing rear wall 3038 and the frame sole 3015, spaced from the casing rear wall 3038 by a sole buffer distance. Both the heel buffer distance and sole buffer distance are between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability. In some embodiments, the peripheral wall 3061 is continuously joined to the frame 3013.
In another embodiment, a driver type golf club head 3100 comprises a composite faceplate 3150 that is similar to the composite faceplate 3050 described above, but further comprising a crown return region 3165, as shown in
The composite faceplate 3150 further comprises a crown transition region 3167, formed integral with the face region 3151, the sole return region 3158, the sole transition region 3160, and the crown return region 3165, extending from a crown leading edge 3168 of the face region 3151 to the crown return crown wall 3166 of the crown return region 3165. As such, the peripheral wall 3161 extends entirely around the face region 3151, the sole return region 3158, the sole transition region 3160, the crown return region 3165, and the crown transition region 3167, and is joined to the frame 3113 of the body 3101. The crown transition region 3167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.
The crown return region 3165 extends rearwardly away from the crown leading edge 3168 by at least a distance of 0.075 inch to provide sufficient coverage of high-strength material in the forward portion of the crown. In some embodiments, the crown return region 3165 extends a distance by at least 0.5 inches rearwardly of the crown leading edge 3168.
In another embodiment, a golf club head 3200 further comprises a composite faceplate 3250 that is similar to composite faceplate 3050 described above, but further comprises a lower hosel region 3269, as illustrated in
Specifically, the composite faceplate 3250 comprises a lower hosel region 3269, formed integrally with the face region 3251, the sole return region 3258, and the sole transition region 3260, and extends between the face region heel side 3254 and the sole return sole wall 3259 of the sole return region 3258. The lower hosel region 3269 includes a lower hosel socket 3218 defining a socket perimeter 3222 having a socket perimeter outboard section 3224 and a socket perimeter inboard section 3223. The lower hosel socket 3218 is monolithically and entirely formed with the composite faceplate 3250 to increase the amount of high-strength material coverage in the club head, particularly in areas that experience high-stress.
The peripheral wall heel section 3262 of the composite faceplate 3250 is disposed between the frame heel end 3216 and the lower hosel socket 3218 of the lower hosel region 3269 and is spaced from the socket perimeter outboard section 3224 by a heel buffer distance. In some embodiments, the heel buffer distance is least 0.025 inch to facilitate certain methods of joining the composite faceplate to the body, such as welding. In other embodiments, the heel buffer distance can be less than 0.025 inches.
Furthermore, by forming the lower hosel socket 3218 integrally with the composite faceplate 3250, the casing 3230 can positioned closer to lower hosel socket 3218, thereby extending the effective length of the casing 3230 to increase bending and deflection. Because the peripheral wall heel section 3262 does not lie between the socket perimeter inboard section 3223 and the casing heel wall 3234, the buffer distance does not exist within the region between the hosel and the casing. As such, the length of the casing can be longer to increase the performance of the casing.
In another embodiment, a driver type golf club head 4000 comprises a composite faceplate 4050 and a top-adjustable or fixed hosel configuration so that the casing/aperture can be longer to increase bending and performance of the casing. As described above, the top-adjustable and fixed hosel configurations remove the need for a lower hosel socket, thereby allowing the lengths of the casing and aperture to be increased. A longer aperture increases bending and deflection of the casing, thereby returning more energy back to the strike face to increase ball speed. The golf club head 4000 may comprise either a fixed hosel or a top-adjustable hosel, as desired.
The golf club head 4000 comprises a body 4001 having a crown 4010, a sole 4012, a toe end 4006, a heel end 4004, a rear end 4011, a front 4008, a hosel 4005 defining a hosel axis 4009, and a frame 4013 forming a front 4008 of the body 4001 and formed of a frame material having a first yield strength, as illustrated in
The composite faceplate 4050 is coupled to the body 4001 to form an interior cavity 4007 of the golf club head 4000. The composite faceplate 4050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate 4050 having a yield strength that is greater than the body 4001 and frame 4013 yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.
The composite faceplate 4050 comprises a face region 4051 which forms a portion of the strike face 4002 at the front 4008 of the body 4001. The face region 4051 comprises a strike surface 4052 configured to impact a golf ball, a face region toe side 4053 located toe-ward of the strike surface 4052 and bordering the frame toe end 4017, a face region heel side 4054 located heel-ward of the strike surface 4052 and bordering the frame heel end 4016, a face region crown side 4055 located crown-ward of the strike surface 4052 and bordering the frame crown 4014, and a face region sole side 4056 located sole-ward of the strike surface 4052 and defining a sole leading edge 4057.
The composite faceplate further comprises a sole return region 4058, formed integral with the face region 4051. The sole return region has a casing 4030 to improve ball speed and spin characteristics. Forming the casing within the sole wall 4059 or the sole return region 4058 and thereby of the high-strength material of the composite faceplate, the casing performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 4030 includes a front wall 4032, a rear wall 4039, a toe wall 4036, and a heel wall 4034, wherein the front wall 4032, the rear wall 4039, the toe wall 4036, and the heel wall 4034 define an aperture 4040. The body 4001 does not form any portion of the aperture 4040. Furthermore, the casing heel wall 4034 is heelward of the hosel axis 4009 to increase the effective length of the casing 4030 and aperture 4040.
The composite faceplate further comprises a sole transition region 4065, formed integral with the face region 4051 and the sole return region 4058, extending from the sole leading edge 4057 of the face region 4051 to the casing front wall 4032. The sole transition region 4065 can further define an aperture offset distance (OD) as defined above, and measured between the sole leading edge 4057 and the casing front wall 4032. The sole transition region 4065 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 4052 and face region 4051.
The composite faceplate 4050 further comprises a peripheral wall 4061, extending around the entirety of the face region 4051, the sole return region 4058, and the sole transition region 4060, and is joined to the frame 4013 of the body 4001. The peripheral wall 4061 comprises a peripheral wall heel section 4062 disposed heelward of casing heel wall 4034 and heelward of the hosel axis 4009. The peripheral wall 4061 further comprises a peripheral wall sole section 4063 disposed between the casing rear wall 4038 and the frame sole 4015, spaced from the casing rear wall 4038 by a sole buffer distance. The sole buffer distance is between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability.
In this embodiment, the casing comprises a Total Length (TL), measured from the absolute toe point to the absolute heel point, parallel to the x-axis 40, that can be between 2.60 to 4.0 inches. For example, the total length TL can range from 2.60 to 3.0 inches, 3.0 to 3.5 inches, or 3.5 to 4.0 inches. In one embodiment, the total length TL is 2.65 inches.
In another embodiment, a golf club head 4100 comprises a composite faceplate 4150 that is similar to the composite faceplate 4050 described above, but further comprises a crown return region 4165, as shown in
The composite faceplate 4150 further comprises a crown transition region 4167, formed integral with the face region 4151, the sole return region 4158, the sole transition region 4160, and the crown return region 4165, extending from a crown leading edge 4168 of the face region 4151 to the crown return crown wall 4166 of the crown return region 4165. As such, the peripheral wall 4161 extends entirely around the face region 4151, the sole return region 4158, the sole transition region 4160, the crown return region 4165, and the crown transition region 4167, and is joined to the frame 4113 of the body 4101. The crown transition region 4167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.
In some embodiments, the crown return region 4165 may comprise turbulators 4172 to decrease the drag of the driver-type golf club head. The turbulators 4172 are formed integral with the composite faceplate 4150 and therefore are formed in a forward portion of the crown. In some embodiments, there can be additional turbulators formed on the body. In some embodiments, the crown return region 4165 of the composite faceplate 4150 comprises at least 2 turbulators 4172.
V. Method of forming Impact Response Modulator with High-Strength MaterialAny of the above embodiments of the composite faceplate can be formed through one or more methods, such as forming. In other embodiments, the composite faceplate may be forged into a rough shape and then bent to a final geometry. Still further, the composite faceplate may be casted or formed through additive manufacturing.
In some embodiments, the faceplate that integrally forms the casing can be manufactured via a multi-stage forging process.
Referring to block 5200, the solid block billet is initially forged into an intermediate composite faceplate 519. The solid block billet can be heated to a desired forging temperature, and a forging pressure can be applied to shape the malleable billet into the intermediate composite faceplate 519. In some embodiments, the forging temperature can be between 700° C. and 1100° C. In some embodiments, the forging pressure can be between 500 tons and 800 tons. The intermediate composite faceplate 519, illustrated in
Next, referring to block 5300, the billet material between the front wall 532 and the rear wall 542 is machined away to form an aperture 540. In some embodiments, a one-step process can be used to form by fully machining the aperture 540 through the sole return region 558. In other embodiments, the aperture 540 can be formed through a two-step process comprising an aperture machining step followed by an aperture precision forging step. In such embodiments, the aperture machining step creates a pilot recess that extends only partially through the sole return region 558. The aperture precision forging step can thereafter press through the pilot recess, forming the final, desired aperture geometry by pressing all the way through the sole return region 558.
Referring to block 5400, the desired strike face geometry can be formed. In some embodiments, as illustrated in
Similarly, the geometry of the transition component can be formed by machining, precision forging, or a combination thereof. The sole transition region 560 can be formed to a specific desired thickness to balance strike face deflection with durability. In some embodiments, the transition component thickness can be substantially uniform. In other embodiments, the transition component thickness can vary such that a central portion of the sole transition region 560 comprises a greater thickness than the transition component thickness proximate the heel and toe. In such embodiments, the increased thickness near the center of the transition portion 503 can reinforce the casing front wall 532 and improve durability without sacrificing strike face deflection.
Referring to block 5500, the intermediate composite faceplate 519 is forged into its ultimate configuration via a bending precision forging step. In some embodiments, prior to the bending precision forging step, a die 547 can be placed into the aperture 540 to prevent the aperture 540 from collapsing during bending, as illustrated in
The multi-stage forging process described above can be especially useful in manufacturing faceplates with integral sole returns forming the casing, but without additional returns such as a crown return, a toe return, or a heel return. This configuration simplifies manufacturing, as only a single bending precision forging step is required to bend the strike surface 552 relative to the sole return region 558. In other embodiments, the multi-stage forging process can be used to manufacture a faceplate integrally forming the entire casing and also including a crown return, sole return, toe return, or any combination thereof. In such embodiments, the multi-stage forging process can include multiple bending precision forging steps to bend the various returns relative to the strike face component.
In alternative embodiments, the composite faceplate and casing can be manufactured via a multi-stage forming process 6000, as illustrated in the process flow diagram of
As referenced in block 6100, the sheet material is rough forged to redistribute material and selectively increase thickness in designated regions of the sheet. In particular, the sheet material can be heated to a desired rough forging temperature to allow the sheet material to become sufficiently malleable. In some embodiments, the rough forging temperature can be between 700° C. and 1100° C. Upon heating, a rough forging pressure can be applied to the sheet material to locally thicken or thin designated regions of the sheet to meet specific structural or functional requirements. In some embodiments, the rough forging pressure can be between 800 tons and 1200 tons.
Following rough forging, a detailed forging step, as shown in block 6200, is carried out to refine the geometry and surface features of the metal sheet. Similar to the rough forging step, the sheet material can be heated to a desired detailed forging temperature, and a detailed forging pressure can be applied to shape the malleable sheet material. In some embodiments, the rough forging temperature can be between 700° C. and 1100° C. and the rough forging pressure can be between 800 and 1200 tons. By refining the geometry and surface features, the detailed forging step ensures precise dimensional tolerances and localized thickness variations necessary to optimize the sheet for the subsequent forming process, described in greater detail below.
Once detail forging is complete, the sheet material is formed into a substantially flat intermediate composite faceplate 619 comprising specific strike face and sole geometries, as referenced in block 6300. For example, the sheet material can undergo any suitable forming process to define a strike surface 652 and a sole return region 658, as illustrated in
Similar to the previous forging steps, a forming pressure can be applied to shape the components of the intermediate composite faceplate 619. In some embodiments, the forming pressure can be between 100 and 500 tons. In some embodiments, the forming pressure can be applied by stamping, embossing, or otherwise forming the intermediate composite faceplate 619. In even further embodiments, the components are machined into the intermediate composite faceplate 619.
Thereafter, the intermediate composite faceplate 619 undergoes a controlled bending process along the sole transition region 660, as shown in block 6400, establishing the intended strike surface 652 and sole return region 658 configurations for final assembly. In particular, the strike surface 652 can be bent upwards relative to the sole return region 658 to match the desired loft angle for the finished faceplate. This controlled bending process creates a monolithic composite faceplate 650 that integrally forms the casing 630, as illustrated in
In the final step of the multi-step forming process, an aperture 640 is machined into the casing 630 of the sole return region 658. In some embodiments, the aperture 640 can be fully machined through the sole return region 658. In other embodiments, the aperture 640 can be formed through a two-step process comprising an aperture machining step followed by an aperture precision forging step. In some embodiments, the aperture machining step creates a pilot recess that extends only partially through the sole return component. The aperture precision forging step can thereafter press through the pilot recess and form the remainder of the aperture 640 all the way through the sole return region 658.
The composite faceplate created with any of the above methods of manufacturing can be attached, fused, or joined to the club head body through various means. In one example, the composite faceplate can be welded to the body. The body has a frame with complementary geometry to the composite faceplate so that the periphery of the composite faceplate is continuously or intermittently welded to the body. Accordingly, the casing remains completely surrounded by high-strength material without any joints/connections located near the walls of the casing. In other embodiments, the composite faceplate can be adhesively, mechanically, removably, or co-casted to club head body. Still further, multiple different joining methods may be used on different sections of the peripheral wall.
CLAUSESClause 1. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; a lower hosel socket, adjacent the frame sole and the frame heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club head, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; and a peripheral wall, extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body.
Clause 2. The golf club head of clause 1, wherein the first yield strength of the frame is less than 150 ksi.
Clause 3. The golf club head of clause 1, wherein the second yield strength of the composite faceplate is greater than 195 ksi.
Clause 4. The golf club head of clause 1, wherein the frame material is formed from 17-4 stainless steel.
Clause 5. The golf club head of clause 1, wherein the composite faceplate material is formed from c300 maraging steel.
Clause 6. The golf club head of clause 1, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.
Clause 7. The golf club head of clause 1, wherein the peripheral wall further comprises a peripheral wall sole section, disposed between the rear wall of the casing and the frame sole, spaced from the rear wall of the casing by a sole buffer distance of at least 0.10 inch.
Clause 8. The golf club head of clause 1, wherein an insert is disposed within the aperture.
Clause 9. The golf club head of clause 1, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.
Clause 10. The golf club head of clause 1, wherein the peripheral wall further comprises a peripheral heel section, disposed between the lower hosel socket and the heel wall of the casing.
Clause 11. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having an socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region and is continuously joined to the frame of the body.
Clause 12. The golf club head of clause 11, wherein the peripheral wall further comprises a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance of at least 0.075 inch.
Clause 13. The golf club head of clause 11, wherein the first yield strength of the frame is less than 150 ksi.
Clause 14. The golf club head of clause 11, wherein the second yield strength of the composite faceplate is greater than 195 ksi.
Clause 15. The golf club head of clause 11, wherein the frame material is formed from 17-4 stainless steel.
Clause 16. The golf club head of clause 11, wherein the composite faceplate material is formed from c300 maraging steel.
Clause 17. The golf club head of clause 11, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.
Clause 18. The golf club head of clause 11, wherein an insert is disposed within the aperture.
Clause 19. The golf club head of clause 11, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.
Clause 20. The golf club head of clause 11, wherein the composite faceplate further comprises: a toe wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region toe side; and a heel wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region heel side.
Clause 21. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; and a lower hosel socket, adjacent the frame sole and the frame heel end, defining a socket perimeter having a socket perimeter inboard section; and a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toc wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; and a peripheral wall, extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the sole return heel wall and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance; and a peripheral wall sole section disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.
Clause 22. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; and a lower hosel socket, adjacent the frame sole and the frame heel end, defining a socket perimeter having a socket perimeter inboard section; and a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and defining a crown leading edge; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toc wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toc wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toc wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; a crown return region, formed integral with the face region, the sole return region, and the sole transition region, including a crown return crown wall extending rearwardly of the face region; a crown transition region, formed integral with the face region, the sole region, the sole transition region, and the crown return region, extending from the crown leading edge of the face region to the crown return crown wall of the crown return region; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, the crown return region, and the crown transition region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the sole return heel wall and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.
Clause 23. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having a socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.
Clause 24. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toc wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toc wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, disposed between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having a socket perimeter outboard section; a toe wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region toe side; a heel wrap region, formed integral with the face region, the sole region, the sole transition region, the lower hosel region, and the toe wrap region, extending rearward of the face region heel side; a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, the lower hosel region, the toe wrap region, and the heel wrap region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.
EXAMPLES A. Example 1—Ball Flight Performance of Golf Club Head with IRMThe ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The control club head was substantially similar to the exemplary club head but was devoid of an Impact Response Modulator entirely.
The exemplary and control club heads were used by golfers and shots were studied for various ball flight characteristics, including ball speed, launch angle, and spin rate. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club head and the control club head. The ball flight results of the player test are displayed in Table 1 below.
As displayed in Table 1 above, the exemplary club head exhibited an increase in ball speed of 1.0 mph and a decrease in spin rate of 364 rpm in comparison to the control club head, with a similar launch angle. The decreased spin rate created a more piercing ball flight that cuts through the air and travels further. These improved ball flight characteristics increased carry distance by 3.4 yards on average.
In addition to the performance results obtained through player testing, robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested both club heads by hitting golf balls at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 3 displays the results of the robotic testing at each location, as well as the averages over all locations.
At the face center (FC), the exemplary club head exhibited an increase in ball speed of 1.4 mph and a decrease in spin of 511 rpm over the control club head. It was further observed that the ball impacts of the exemplary club head over the control club head created a more piercing ball flight that cut through the air and traveled further. These improvements resulted in an increase in carry distance of 9.0 yards. On average across all locations, the exemplary club head exhibited an increase in ball speed of 1.3 mph and a decrease in spin of 522 rpm in comparison to the control club head, resulting in an increase in carry distance of 5.1 yards. Overall, results of both the player test and the robotic test illustrate the benefits of the IRM. The comparative tests illustrate the general efficacy of the IRM in comparison to a club head without an IRM. In particular, the IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. As such, the exemplary club head exhibited improved ball speed, spin rate, and distance in comparison to the control club head devoid of the IRM. As discussed above, performance can be further improved through high-strength reinforcement of the casing.
B. Example 2—Ball Flight Performance of IRM with High-Strength Material ReinforcementThe example below explored an Impact Response Modulator with a casing reinforced by high-strength material. The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control fairway-wood type club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a high-strength faceplate and a separately formed high-strength component located on the sole and forming the Impact Response Modulator and entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. In particular, the high-strength faceplate and high-strength sole casing were formed of C300 steel, comprising a material yield strength of 255 ksi. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head body, Impact Response Modulator, and casing comprised a 17-4 steel material, comprising a lower material strength of 150 ksi. The control club head had a front wall height FWH of 0.274 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.192 inch due to the high-strength material reinforcement. The offset distance OD from the casing front wall to the strike face in the control club head was 0.24 inch, whereas the exemplary club head had a reduced offset distance OD of 0.177 inch. The reduced front wall height FWH and offset distance OD each increase the amount the casing bends at impact, thereby increasing strike face deflection.
The exemplary and control club heads were used by golfers and shots were studied for various ball flight characteristics, including ball speed, launch angle, and spin rate, via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 3 below.
As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength IRM component allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. Although the casing was not integrally formed with the faceplate, the example demonstrates that reinforcing the casing with a high-strength component results in measurable performance benefits, including an increased ball speed and reduced spin rate. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the embodiments described herein, which include forged and formed faceplates having sole returns that integrally form the entire casing. Similar ball speed and spin rate improvements are expected for the exemplary club head.
C. Example 3—Durability Performance of Golf Club Head Comprising IRM Spaced Rearwardly from Strike FaceThe durability performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator spaced rearwardly from the strike face were compared to those of a control fairway-wood type club head comprising an Impact Response Modulator positioned directly adjacent to the strike face of the club head. The exemplary club head, as shown in
Durability characteristics in the strike surface and club head body, including maximum structural stress values, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The material stress yield limits and results are displayed in Table 4 below.
As displayed in Table 4 above, both the exemplary and control club heads exhibited equivalent faceplate peak stress values approaching and surpassing the C300 stress yield limit of 255 ksi. However, as shown in
Additionally, Table 4 displays that the exemplary club head exhibited a decrease in club head body peak stress of 27 ksi compared to the control club head. Because the club head body peak stress is less than the body material stress yield, the exemplary club head does not comprise maximum stress regions within the club head body, as shown in
The durability performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material that was a lesser strength than the casing of the exemplary fairway-wood type club head. Both the exemplary and control club heads comprised casings with equivalent lengths and depths. The two club heads differed, however, because the exemplary club head comprised a forged C300 steel casing, having a tensile yield strength of 255 ksi, and the control club head comprised a casing formed by the casted 17-4 steel body material, having a tensile yield strength of 150 ksi. Because the exemplary club head casing was formed of the higher strength C300 steel material, the exemplary club head casing additionally incorporated a reduced casing front wall height (FWH) and a decreased offset distance (OD) between the casing front wall and the strike face. In particular, the control club head had a front wall height FWH of 0.300 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.211 inch due to the high-strength material reinforcement. Further, the offset distance OD from the casing front wall to the strike face in the control club head was 0.150 inch, whereas the exemplary club head had a reduced offset distance OD of 0.090 inch. A reduction in front wall and sole return region surface area limits the amount of material that can disperse impact stresses. As such, the reduced front wall height FWH and offset distance OD each allow for increased strike face deflection but also contribute to decreased Impact Response Modulator and golf club head durability.
Impact Response Modulator and club head body durability were determined via an air cannon test. For this test, golf balls repeatedly impacted the strike face until the golf club head exhibited signs of damage, such as cracks in the strike face, cracks in the sole, or other club head deformities. An increased impact speed was imparted onto the exemplary vs. control clubs. More specifically, the golf ball impacted the strike face at 115 miles per hour for the first 2000 shots, 125 miles per hour for shots 2001-2500, 135 miles per hour for shots 2501-3000, and 145 miles per hour for shots 3001-3500. Despite having a reduced front wall height (FWH) and offset distance (OD), the high-strength C300 steel casing (255 ksi) of the exemplary club head exhibited greater durability performance in comparison to the 17-4 steel body material casing (150 ksi) of the control club head. In particular, the control club head exhibited sole cracks after 2798 impacts. The exemplary club head, however, showed no sign of club head body damage until the 3377th impact. Because of the graduated increased of ball speed mph over a larger number of hits, the exemplary club strike face was impacted with 10 mph of greater speed than the control club strike face (at failure). As proven by the durability testing results, reinforcing the Impact Response Modulator casing with a high-strength material, such as C300 steel, provided the Impact Response Modulator and golf club head with greater structural integrity capable of withstanding repeated high-speed impacts. Although the casing of the exemplary club head featured an inherently less durable design with the reduced front wall height FWH and offset distance OD, the incorporation of the high-strength material allowed for a level of durability capable of resisting degradation and exceeding the performance of the control club head.
E. Example 5—Ball Flight Performance of Composite Faceplate with High-Strength Material ReinforcementThe ball flight performance characteristics of driver type golf club heads with various casing embodiments were tested via Finite Element Analysis (FEA) simulations. All the club heads were formed of the same body material and comprised similar back weighting. Each casing embodiment, however, either comprised different casing lengths or were formed of a different casing material. The analysis simulated face center (FC) and low center (LC) strikes at 105 mph club head speed. Ball speed, launch angle, and spin rate were collected as comparative results across the various casing embodiments. The following casing designs were studied: (1) a control golf club head comprising a lower hosel socket and an Impact Response Modulator with a casing formed by the 17-4 steel body material; (2) a golf club head comprising a lower hosel socket and a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing; and (3) a golf club head devoid of a lower hosel socket and comprising a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing. Due to the presence of the lower hosel socket, club heads (1) and (2) comprise casings extending only partially across the width of the club head. In particular, the casings of club heads (1) and (2) comprise a casing length, measured from the heel wall to the toe wall, of 2.33 in. Alternatively, club head (3), which lacks a lower hosel socket, comprises a casing extending across the entire width of the club head. In particular, the casing of club head (3) comprises a casing length, measured from the heel wall to the toe wall, of 2.84 in. The ball speed, launch angle, and spin rate results of the face center (FC) and lower center (LC) strikes are displayed in Tables 5 and 6 below, respectively.
As illustrated by Tables 5 and 6, golf club (1) exhibited the worst ball flight performance and golf club (3) exhibited the best combined ball and spin rate improvements, on average, for face center and low center strikes. In particular, golf club (1) exhibited the lowest ball speeds and greatest spin rates in comparison to golf clubs (2) and (3) for both the face center and low center strikes. Golf club (2) performed significantly better for face center and low center strikes with an average ball speed increase of 0.245 mph and an average spin rate decrease of 110 rpm in comparison to golf club (1). Lastly, golf club (3) also performed significantly better for face center and lower center strikes with an average ball speed increase of 0.17 mph and an average spin rate decrease of 276 mph in comparison to golf club (1). Despite golf club (3) exhibiting a lower ball speed increase than golf club (2) in comparison to the control golf club (1), golf club (3) exhibited the most significant improvements in spin rate, especially with low center strikes. Low spin is especially desirable for high swing speeds (over 100 mph) that result in greater compression and friction between the golf ball and strike surface. By reducing spin rates, golfers with high swing speeds can maximize distance and reduce shot curvature.
As proven by the ball flight performance testing results, incorporating the Ti-9s+ composite faceplate on a golf club head with a lower hosel socket contributed to an increased ball speed and a reduced spin rate. Further, removing the lower hosel socket and incorporating the C300 steel composite faceplate with a full-length casing collectively provided golf club (3) with greater ball speed and reduced spin rate for both face center (FC) and low center (LC) strikes. Such improvements, especially the reduced spin rate, result in golf club (3) maximizing distance, improving trajectory stability, and reducing the effects of drag during flight.
F. Example 6—Impact Behavior of Golf Club Head with Composite Faceplate and CasingThe impact behavior characteristics of driver type golf club heads with various casing embodiments were tested via Finite Element Analysis (FEA) simulations. All the club heads were formed of the same body material and comprised similar back weighting. Each casing embodiment, however, either comprised different casing lengths or were reinforced with a different casing material. The analysis simulated face center strikes at 105 mph club head speed. Ball speed, launch angle, and spin rate were collected results across the various casing embodiments. More specifically, an FEA dynamic solver computed a maximum displacement (in.) of the casing front wall over the duration of impact. A greater maximum displacement is a direct indicator of greater energy absorption and thus, greater energy transfer back to the golf ball for increased ball speed and reduced spin rate. The impact behavior comparison was made between clubs (1), (2), and (3), as described in Example 5. In particular, club (1) is a control club head comprising a lower hosel socket and Impact Response Modulator with a casing formed by the 17-4 steel body material; club (2) is a club head comprising a lower hosel socket and a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing; and club (3) is a club head devoid of a lower hosel socket and comprising a Ti-9s+ composite faceplate with an Impact Response Modulator and casing. The maximum front wall displacement values for club heads (1), (2), and (3) are displayed in Table 7 below.
As illustrated by Table 7, golf club (1) exhibited the worst impact behavior performance. Club (3) exhibited the most dynamic impact behavior. In particular, golf club (1) exhibited the lowest front wall displacement values in comparison to golf clubs (2) and (3). Golf club (2) performed significantly better with a displacement increase of 0.015 in. in comparison to golf club (1). Lastly, golf club (3) performed significantly better with a displacement increase of 0.032 in. in comparison to golf club (1).
As proven by the ball flight performance testing results and consistent with the ball flight performance results of Example 5, incorporating the Ti-9s+ composite faceplate on a golf club head with a lower hosel socket contributed to an increased casing front wall displacement. The combination of removing the lower hosel socket and incorporating the Ti-9s+ composite faceplate with a full-length casing collectively provided golf club (3) with a front wall displacement value capable of maximizing energy transfer into the golf ball, thereby increasing ball speed, improving trajectory stability, and reducing the effects of drag during flight.
G. Example 7—Modal AnalysisThe vibrational impact response characteristics of an exemplary fairway-wood type club head comprising a composite faceplate with a high-strength Impact Response Modulator and casing were compared to those of a control fairway-wood type club head comprising an Impact Response Modulator with a casing formed by the body material. The body material comprises a lower yield strength than the exemplary club's composite faceplate material. The exemplary club head, as shown in
The vibrational impact response characteristics of the club head were determined via Finite Element Analysis (FEA) simulations. The analysis evaluated the vibrational behavior of the club head in response to undamped, free vibrations in various directions and deformation patterns. More specifically, the analysis focused on peak excitation regions 9095, 10095 of the club head in the dominant vibrational frequency (hereafter referred to as “first mode”) observed at impact. A peak excitation region 9095, 10095 defines any region of the club head that experiences at least 70% peak vibrational excitation in the first mode at impact. The lower the club head volume of these peak excitation regions 9095, 10095, the easier it is to dampen summative modes in the club head that contribute to the increased resonance and duration of post-impact vibrations. Therefore, a smaller peak excitation region volume facilitates the ability to attenuate vibrations that contribute to undesired sound and impact feel. The peak excitation region volumes (in.3) for the exemplary and control club heads are displayed in Table 8 below.
As displayed in Table 8 above, the exemplary club head exhibited a much smaller peak excitation region volume in comparison to the control club head. In particular, the peak excitation region 9095 of the exemplary club head is only present in a small region of the sole 9012 rearward of the casing 9030, as shown in
A robot test was conducted to compare the performance of exemplary club head of the present invention to a control club head. The exemplary club head was similar to the golf club head 1200 above in that the exemplary club head had a composite faceplate formed of a higher strength material than the body. The composite faceplate included a sole return region having a casing forming an aperture. The composite faceplate further formed a lower hosel region including a lower hosel socket. The control club head lacked a composite faceplate, but still included a casing formed by the body that was a lower strength material over the high strength material of the composite faceplate of the exemplary club head.
The robot was programmed to deliver both clubs with the same club head speed and impact dynamics, and repeatedly striking the ball at the same location. The resulting ball speed for each club head was recorded and averaged, and displayed in Table 8 below.
As illustrated in Table 8 above, the exemplary club head having a high-strength casing exhibited an increase of 1.1 mph ball speed and a decrease in spin of 517 rpm over the control club head having a lower strength casing. The high-strength material allows for the casing to be thinner while maintaining sufficient durability so that the casing can flex more during impact with the golf ball. The increased flexure results in at least 1 mph increase in ball speed and a 517 rpm decrease in spin over a casing with lower yield strength found in the body of the club head. Low spin is especially desirable for high swing speeds (over 100 mph) that result in greater compression and friction between the golf ball and strike surface. By reducing spin rates, golfers with high swing speeds can maximize distance and reduce shot curvature.
Claims
1. A golf club head comprising:
- a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; and a lower hosel socket, adjacent the frame sole and the frame heel end;
- a composite faceplate coupled to the body to form an interior cavity of the golf club head, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; and a peripheral wall, extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body.
2. The golf club head of claim 1, wherein the first yield strength of the frame is less than 150 ksi.
3. The golf club head of claim 1, wherein the second yield strength of the composite faceplate is greater than 195 ksi.
4. The golf club head of claim 1, wherein the frame material is formed from 17-4 stainless steel.
5. The golf club head of claim 1, wherein the composite faceplate material is formed from c300 maraging steel.
6. The golf club head of claim 1, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.
7. The golf club head of claim 1, wherein the peripheral wall further comprises a peripheral wall sole section, disposed between the rear wall of the casing and the frame sole, spaced from the rear wall of the casing by a sole buffer distance of at least 0.10 inch.
8. The golf club head of claim 1, wherein an insert is disposed within the aperture.
9. The golf club head of claim 1, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.
10. The golf club head of claim 1, wherein the peripheral wall further comprises a peripheral heel section, disposed between the lower hosel socket and the heel wall of the casing.
11. A golf club head comprising:
- a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end;
- a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having an socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region and is continuously joined to the frame of the body.
12. The golf club head of claim 11, wherein the peripheral wall further comprises a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lowerhosel region, spaced from the socket perimeter outboard section by a heel buffer distance of at least 0.075 inch.
13. The golf club head of claim 11, wherein the first yield strength of the frame is less than 150 ksi.
14. The golf club head of claim 11, wherein the second yield strength of the composite faceplate is greater than 195 ksi.
15. The golf club head of claim 11, wherein the frame material is formed from 17-4 stainless steel.
16. The golf club head of claim 11, wherein the composite faceplate material is formed from c300 maraging steel.
17. The golf club head of claim 11, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.
18. The golf club head of claim 11, wherein an insert is disposed within the aperture.
19. The golf club head of claim 11, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.
20. The golf club head of claim 11, wherein the composite faceplate further comprises:
- a toe wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region toe side; and
- a heel wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region heel side.
Type: Application
Filed: Sep 24, 2025
Publication Date: Mar 26, 2026
Applicant: KARSTEN MANUFACTURING CORPORATION (Phoenix, AZ)
Inventors: Matthew T. Schier (Phoenix, AZ), Eric J. Morales (Laveen, AZ), Cory S. Bacon (Scottsdale, AZ), Cole D. Brubaker (Scottsdale, AZ), Taylor T. Morton (Phoenix, AZ), Mark C. Bloxham (Phoenix, AZ), Jesus D. Gamboa (Phoenix, AZ), Mitchell J. Simonet (Phoenix, AZ)
Application Number: 19/339,232
