Golf Club Face Including Voids

The present disclosure generally relates to golf club faces, and more specifically to a golf club face including voids.

Embodiments of the presently disclosed technology may include golf club faces. In accordance with some aspects of the presently disclosed technology, a golf club face may include a front surface to impact a golf ball, a rear surface, and a plurality of two or more voids between the front surface and the rear surface distributed in a pattern.

In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mmto about 8.5 mm.

In embodiments, each of the plurality of two or more voids may be spherical.

In embodiments, the plurality of two or more voids may be distributed radially around a center of the golf club face.

In embodiments, each of the plurality of two or more voids may be cylindrical.

In embodiments, each of the plurality of two or more voids may extend across the golf club face horizontally.

In embodiments, each of the plurality of two or more voids may extend across the golf club face vertically.

In embodiments, each of the plurality of two or more voids may be separated by at least 1 diameter length from a center of adjacent ones of the plurality of two or more voids.

In embodiments, at least some of the plurality of two or more voids may have different volumes.

In embodiments, each of the plurality of two or more voids may extend radially outward from a center of the golf club face.

In embodiments, the golf club face may further include a fill material to fill each of the plurality of two or more voids.

In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane.

In embodiments, the golf club face has a diameter-to-thickness ratio between about 0.5 to about 1.0, wherein the diameter-to-thickness ratio is defined as

In accordance with some aspects of the presently disclosed technology, a golf club head may include a face. The face may include a front surface to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include a plurality of two or more voids distributed in a pattern.

In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mmto about 25.0 mm.

In embodiments, each of the plurality of two or more voids may be spherical.

In embodiments, at least some of the plurality of two or more voids may have different volumes.

In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane between about 0.025 mm to about 2.00 mm.

In accordance with some aspects of the presently disclosed technology, a method of forming voids in a golf club face is disclosed. The method may include a number of steps. One step may include forming an initial face insert. The initial face insert may include an initial front surface. The initial front surface may include a first set of ribs. The initial face insert may include an initial rear surface opposite the initial front surface. The initial rear surface may include a second set of ribs opposite the first set of ribs. The initial face insert may include an initial body extending between the initial front surface and the initial rear surface. Another step may include cooling the initial face insert to form an intermediate face insert. This may form a plurality of two or more voids in an intermediate body between the first set of ribs and the second set of ribs.

In embodiments, another step may include removing the first set of ribs and the second set of ribs to form a final face insert. The final face insert may include a front surface intended to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include the plurality of two or more voids.

These and other features of the presently disclosed technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts, may be clearer upon consideration of the following detailed description and the claims with reference to these drawings, all of which form a part of this specification, with like reference numerals designating corresponding parts in the various figures. It is to be expressly understood that these drawings are for illustration purposes and description and are not intended to be limiting. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” may include plural referents unless the context clearly dictates otherwise.

Existing ways to form golf club faces are generally cast or forged to form a solid face. However, the shape, volume, and/or other characteristics of many golf club faces are very limited to maintain golf club head characteristics. These existing golf club faces However, these existing methods fail to improve structural integrity and/or durability while improving CG, MOI, and/or other characteristics.

The presently disclosed technology described herein contemplates a golf club head, such as an iron, a fairway wood, a driver, or another type of golf club head, that includes a face with voids. The voids may provide mass redistribution benefits, durability benefits, structural integrity benefits, and/or other golf club performance benefits. The voids may allow for further adjustment of CG and/or MOI of the golf club head. The voids may provide for increased ball speed. The voids may also improve sound and feel. The voids may be filled with fill material, as will be discussed herein. The voids may allow for thicker or otherwise larger faces because of the mass savings created by the voids allows for additional material to have a mass of the face reach the intended weight.

Establishing a reference coordinate system for the presently disclosed technology, an x-axis may refer to the axis that is horizontal to the face from a heel-to-toe direction, a y-axis may refer to the vertical axis through the club in a crown to sole direction, a z-axis may refer to the horizontal axis that is horizontal front to back in a forward and rear direction. Alternatively speaking, the x-axis may be defined as a horizontal axis tangent to a geometric center of the face with the positive direction towards a heel of the golf club head, a y-axis is a vertical axis orthogonal to the x-axis with a positive direction towards a top of the golf club head, and a z-axis being orthogonal to both the x-axis and the y-axis with a positive direction towards a front of the golf club head. The x-y-z coordinate system described above shall be the same for all subsequent discussions. For example, the x-y-z coordinate system may be used to describe the CG of the golf club head. The golf club head may have a CG-x, a CG-y, and a CG-z component corresponding to the x-, y-, and z-coordinates discussed herein.

is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Golf club headmay include a face. The facemay include front surface (at least shown as front surfacein), voids, body, and rear surface (at least shown as rear surfacein). Front surface (at least shown as front surfacein) may refer to a frontal surface of face. Front surface (at least shown as front surfacein) may be the striking surface intended to impact a golf ball and may be substantially planar. In some embodiments, front surface (at least shown as front surfacein) may have a bulge and roll. The bulge may refer to a curvature between a heel-to-toe direction of face, or a horizontal curvature. The roll may refer to a curvature between a bottom-to-top direction of face, or a vertical curvature.

Rear surface (at least shown as rear surfacein) may be the back surface of face. Rear surface (at least shown as rear surfacein) may be the opposite surface of front surface (at least shown as front surfacein). Rear surface (at least shown as rear surfacein) may face an interior of golf club head.

Between front surface (at least shown as front surfacein) and rear surface (at least shown as rear surfacein) may be body. Bodymay be the material between these two opposing surfaces. Front surface (at least shown as front surfacein), rear surface (at least shown as rear surfacein), and bodymay include, or be, the same material. For example, the material may include metal, plastic, composite, and/or other materials. The metal may include tungsten, steel, titanium, aluminum, scandium, zinc, nickel, copper, iron, alloys, and/or other metals without departing from the spirit and scope of the presently disclosed technology. The plastic may include thermosets, thermoplastics, and/or other plastics. Composites may include a variety of materials known to those skilled in the art, including for example, graphite, carbon fiber, resins, ceramics, boron fiber, polymers, foams, and so on. In some embodiments, each of front surface (at least shown as front surfacein), rear surface (at least shown as rear surfacein), and bodymay include, or be, different materials.

Bodymay include voids. Voidsmay be between front surface (at least shown as front surfacein) and rear surface (at least shown as rear surfacein). Voidsmay be empty regions or chambers in body. Voidsmay be channels. Voidsmay be substantially cylindrical. In some embodiments, voidsmay be substantially spherical, though it should be appreciated that voidsmay be differently shaped, sized, and/or dimensioned without departing from the spirit and scope of the presently disclosed technology. Voidsmay extend out radially from a point on face. For example, voidsmay extend out radially from a geometric center, a sweet spot, and/or another point on face. Voidsmay be fully contained by face. For example, no portion of void may extend beyond front surface (at least shown as front surfacein), rear surface (at least shown as rear surfacein), and/or sides of face. In some embodiments, these voidsmay be referred to as internal voids. The presently disclosed technology may include a diameter-to-thickness ratio. A diameter-to-thickness ratio may be defined as

In some embodiments, the diameter used or the diameter-to-thickness ratio may be based on a smallest void, a largest void, or another void. In embodiments, void may be selected in a cross-section along a thickest portion of face, a thinnest portion of face, and/or another portion of face. In some embodiments, the thickness of facefor the diameter-to-thickness ratio may be based on a thickest portion of face, a thinnest portion of face, and/or another portion of face. In some embodiments, the diameter-to-thickness ratio between about 0.5 and about 1.0. In some embodiments, a total void volume may be less than about 50% of the face volume. For example, it may be less than about 15% of the total face volume, which may include the void volume and the rest of the face volume. In an example, voidsmay be between about 700 mmand about 1500 mm, and the total face volume may be between about 5500 mmand about 8500 mm. This ratio may provide a lighter face which may be more responsive for users. Each individual void may have a volume between about 0.025 mmand about 25.0 mm. In some embodiments, each individual void may have a volume between about 0.05 mmand about 8.5 mm. For example, cylindrical voids, as discussed herein, may be about 0.5 mm to about 5.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. Spherical voids may have diameters of about 0.25 mm to about 2.5 mm.

is a cross-sectional view of golf club facein accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially spherical. Voidsmay be distributed in a symmetrical pattern around a geometric center or another point on face. While nine voidsare illustrated, it should be appreciated that there may be more or fewer without departing from the spirit and scope of the presently disclosed technology. A total void volume may be less than about 10% of the face volume.

is a cross-sectional view of golf club facein accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially spherical. Voidsmay be distributed in an elliptical-like pattern around a point on face. In some embodiments, some or each of the voidsmay be differently shaped, sized, and/or dimensioned. For example, voidscloser to the center of the pattern may be larger while voidson the edge of the distribution pattern may be smaller. Voidsmay be spaced apart such that they are each at least one diameter length away from adjacent voids. In some embodiments, voidsmay be spaced apart from each other at least one diameter length of the smallest void. In embodiments, voidsmay be spaced apart from each other at least one diameter length of the largest void. In embodiments, voidsmay be spaced apart from each other less than one diameter length away from adjacent voids. It should be appreciated that voidsmay be differently spaced without departing from the spirit and scope of the presently disclosed technology.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially cylindrical. Voidsmay extend across a toeward surface of face. For example, toeward portions of voidsmay be exposed to outside of golf club head. Voidsmay loop around at heelward portions of voids. For voidsthat loop back around, an individual voidmay have a volume between about 125.0 mmand about 1000.0 mm. For example, cylindrical voids, as discussed herein, may be about 10.0 mm to about 200.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. In some embodiments, the cylindrical voidsmay be between about 50.0 mm and about 100 mm across faceand then loop back across facebetween about 50.0 mm and about 100 mm.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially cylindrical. Voidsmay extend across an entire heel-to-toe direction of face. For example, toeward portions of voidsmay be exposed to outside of golf club head. Heelward portions of voidsmay be exposed to other internal portions of golf club head(e.g., toeward portion of a hosel). Facemay be solid from a central portion downward.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially cylindrical. Voidsmay extend across a toeward surface of face. For example, toeward portions of voidsmay be exposed to outside of golf club head. A portion of voidsmay extend across a top of face. For example, the top-most voidon the heel side may be exposed to outside of golf club head. Voidson the toe-end of facemay loop around at heelward portions of voids. Voidson the heel-end of facemay loop around at toeward portions of voids. A central region of facemay be voidless or otherwise free from voids. In other words, a central region of facemay be solid.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Facemay be the same as, or substantially similar to, face, except facehas more of a central region of facethat is solid. For example, a solid portion of facemay extend further heelward and toeward than the solid portion of face.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially cylindrical. A first set of voidsalong the top of facemay extend across a toeward surface of faceand a heelward surface of face. A second set of voidsalong a bottom heelward section of facemay loop around at heelward portions of the second set of voids. A third set of voidsalong a bottom toeward section of facemay loop around at toeward portions of the second set of voids. A small lower region of facemay be solid.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Facemay be the same as, or substantially similar to, face, except facehas less of a central region of facethat is solid. For example, a solid portion of facemay extend less downward than the solid portion of face. The set of voidsextending heel-to-toe direction across facemay be on an upper and lower section of face.

is a perspective view of golf club headin accordance with one or more embodiments of the presently disclosed technology. Golf club headmay include face, which may include front surfaceand voids. Voidsmay be exposed on a toeward side as discussed herein. In some embodiments, these exposed portions of voidsmay be plugged, sealed, injected, and/or covered with a material. The material may be metal, plastic, or a composite as discussed herein.

is a partial cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surfacein). Facemay include voidsand body. Voidsmay be a different pattern than other voids discussed herein. Voidsmay be substantially cylindrical. Voidsmay extend across the entire top-to-bottom direction of face. For example, topward portions of voidsmay be exposed to outside of golf club head. Bottomward portions of voidsmay be exposed to outside of golf club head. It should be appreciated that based on the varied examples described herein, that the patterns, locations, shapes, number, offset, distribution, and/or other characteristics of the presently disclosed voids may vary without departing from the spirit and scope of the presently disclosed technology.

is a cross-sectional view of golf club headin accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of. Golf club headmay include face, front surface, voids, body, and rear surface. Voidsmay be between front surfaceand rear surface. In some embodiments, voidsmay be filled with a fill material (not shown). The fill material (not shown) may include metal, plastic, glass, polymer, or a composite as discussed herein. The fill material may be an artifact of the manufacturing process to form voids. In some embodiments, the fill material may cause performance benefits by having different densities than the rest of faceand/or golf club head. Facemay be similar to face.

is a set of cross-sectional views of golf club faces,, andin accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of. Facemay include front surface, voids, body, rear surface, and axis. In some embodiments, voidsmay be centered along axis. Axismay represent a midplane of face, that is a geometric middle or center plane of face.

Facemay include front surface, fill material, body, and/or rear surface. Facemay be the same as, or substantially similar to, face. Fill materialmay include metal, plastic, glass, polymer, or a composite as discussed herein. Each of fill materialmay be a different material than other fill material. In some embodiments, a set of fill materialmay be different from a second set of fill material.

Facemay include front surface, voids, body, rear surface, and axis. Facemay be the same as, or substantially similar to, faceexcept voidsare offset from axis. In some embodiments, voidsmay be offset faceward. In embodiments, voidsmay be offset backward. The offset may be up to about 1.0 mm. In some embodiments, the offset may be up to about 0.1 mm. In embodiments, the offset may be about 0.05 mm. In some embodiments, In embodiments, the offset may be between about 0.025 mm to about 2.00 mm.

is a rear view of golf club facein accordance with one or more embodiments of the presently disclosed technology. Facemay be an initial face insert. Facemay be just, or immediately, formed, casted, forged, formed, molded, additive manufactured. Facemay include front surface, body, and/or rear surface. Front surfacemay include first set of ribs. First set of ribsmay be distributed in a radial pattern extending away from a point on face. As described herein, the initial face insert may include composite faces, metal faces, forged faces, cast faces, L cup face, C cup faces, and/or other types of faces without departing from the spirit and scope of the presently disclosed technology.

is a cross-sectional view of golf club facein accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of. Facemay be an initial face insert. Facemay be the same as, or substantially similar to, face. Facemay include front surface, body, and rear surface. Rear surfacemay include second set of ribs. Bodymay extend between front surfaceand rear surface.

is a cross-sectional view of golf club facein accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of. Facemay be an intermediate face insert. The intermediate face insert may be cooled. For example, the intermediate face insert may be formed by cooling, chilling, and/or resting the initial face insert. Facemay include front surface, voids, body, rear surface, and ribs. Facemay be formed from faceand/or face. Cooling faceor facemay form voidsin body. Voidsmay be between the first set of ribsand the second set of ribs. A height of ribs, a dimension measuring perpendicularly away from face, may determine a size, shape, and/or position of voidsin body. For example, taller ribson front surfacethan ribson rear surfacemay offset the position of voidsmore toward front surface. For example, ribsmay dissipate heat from bodyforming voids. After the initial face insert is cast, ribsmay act as cooling fins and cause voidsin face. In some embodiments, ribsmay be made of a first material and rest of facemay be made of a second material to change the dissipation rate of the heat from body. For example, more thermally conductive materials may increase the dissipation rate while less thermally conductive materials may decrease the dissipation rate. Along this cross-section, voidsmay appear rectangular.

is a cross-sectional view of golf club facein accordance with one or more embodiments of the presently disclosed technology taken substantially along line C-C′ of. Facemay be an intermediate face insert. Face, including front surface, voids, body, rear surface, and ribsmay be the same as, or substantially similar to, face, including front surface, voids, body, rear surface, and ribs. Along this cross-section, voidsmay appear circular.