Mixed Material Golf Club Head

This is a continuation of U.S. patent application Ser. No. 18/325,623, filed on May 30, 2023, which is a continuation of U.S. patent application Ser. No. 17/249,680, filed on Mar. 9, 2021 and is now U.S. Pat. No. 11,660,511, which is a continuation of U.S. patent application Ser. No. 16/723,065, filed on Dec. 20, 2019 and is now U.S. Pat. No. 10,940,374, which is a continuation-in-part of U.S. patent application Ser. No. 16/714,109, filed on Dec. 13, 2019 and is now U.S. Pat. No. 10,940,373, which claims the benefit of U.S. Provisional Appl. No. 62/779,335, filed on Dec. 13, 2018, and which is a continuation-in-part of U.S. patent application Ser. No. 16/380,873, filed on Apr. 10, 2019 and is now U.S. Pat. No. 10,765,922, which is a continuation of U.S. patent application Ser. No. 15/901,081, filed on Feb. 21, 2018 and is now U.S. Pat. No. 10,300,354, which is a continuation of U.S. patent application Ser. No. 15/607,166, filed on May 26, 2017 and now U.S. Pat. No. 9,925,432, which claims the benefit of U.S. Provisional Appl. No. 62/342,741, filed on May 27, 2016, the contents of all of which are incorporated fully herein by reference.

This disclosure relates generally to a golf club head with a mixed material construction.

In general, there are many important physical parameters (i.e., volume, mass, etc.) that effect the overall performance of a golf club head. One of the most important physical parameters, is the total mass of the golf club head. The total mass of the golf club head is the sum of the total structural mass and the total discretionary mass. Structural mass generally refers to the mass of the materials that are required to provide the club head with the structural resilience needed to withstand repeated impacts. Structural mass is highly design-dependent and provides a designer with a relatively low amount of control over specific mass distribution. Conversely, discretionary mass is any additional mass (beyond the minimum structural requirements of the golf club head) that may be added to the club head design for the sole purpose of customizing the performance and/or forgiveness of the club. There is a need in the art for alternative designs to all metal golf club heads to provide a means for maximizing discretionary weight to maximize club head moment of inertia (MOI) and lower/back center of gravity (CG).

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

Described herein is a golf club head that comprises a mixed material rear body in combination with a metallic front body, comprising a strike face and surrounding frame. The mixed material rear body is comprised of a fiber reinforced thermoplastic composite resilient layer, a molded thermoplastic structural layer, a metallic weight pad, and a metallic weight secured within the metallic weight pad. The mixed material rear body construction provides a significant reduction in structural mass, allowing for improved allocation of discretionary mass, thus improvements in the MOI and CG of the golf club head.

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.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

Described herein are various embodiments of a golf head having a mixed material construction. The mixed material construction comprises a metallic front body and a mixed material rear body. One embodiment of the club head includes a composite rear body with a metallic weight pad. In these or other embodiments, the rear body of the club head can include a fiber reinforced thermoplastic composite resilient layer, a molded thermoplastic structural layer, and a metallic weight secured within the metallic weight pad. In many embodiments, the golf club head can be wood-type golf club head (i.e. driver, fairway wood, hybrid).

In some embodiments, the club head can comprise a driver. In these embodiments, the loft angle of the club head can be 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 these embodiments, the volume of the club head can be greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 450 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 club head 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.

In some embodiments, the club head can comprise a fairway wood. In these embodiments, the loft angle of the club head can be 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 these embodiments, the loft angle of the club head 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 some embodiments, the loft angle of the club head 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.

In embodiments where the club head comprises a fairway wood, the volume of the club head is 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 these embodiments, the volume of the club head 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 cc-350 cc, or approximately 275 cc-375 cc.

In some embodiments, the club head can comprise a hybrid. In these embodiments, the loft angle of the club head can be 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 these embodiments, the loft angle of the club head 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.

In embodiments where the club head comprises a hybrid, the volume of the club head is 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 club head can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

illustrate an embodiment of a golf club headhaving a metallic front body, and a rear body. The front bodyand rear bodyare secured together to define a substantially closed/hollow interior volume. As is conventional with wood-style golf heads, the golf club headincludes a crown, a sole, and can be divided into a heel regionand a toe region.

In some embodiments, the golf club headcomprises a metallic front body, and a composite rear body, wherein the rear body comprises a woven fiber reinforced thermoplastic resilient layer, a molded thermoplastic structural layer, and a metallic weight pad. The combination of a woven fiber reinforced thermoplastic resilient layerand a molded thermoplastic structural layer, enables savings in structural mass, in comparison to a similar club head made entirely from metal.

The structural weight savings achieved by using a resilient layerand a structural layer, can be used to either reduce the entire weight of the club head(which may provide faster club head speed and/or long hitting distances) or to increase the amount of discretionary mass that is available for placement on the golf club head. In one embodiment, the additional discretionary mass, gained from using a composite resilient layerand a composite structural layer, can be reintroduced into the club headin the form of a metallic weight pad. The combination of a light composite rear bodyand metallic weight pad, allow the club head, to allocate a majority of the mass of the club head in a position to maximize the MOI and CG, leading to more forgiveness and longer shots.

Referring to, the front bodyof the club headcomprises a strike face, intended to impact a golf ball. The front bodycomprises a surrounding framethat extends rearward from a perimeterof the strike face, to provide the front bodywith a cup-shaped appearance. The surrounding framecomprises an internal surfaceand an external surface. Furthermore, the surrounding framecan comprise a flange, to provide an attachment surface to connect the front bodyand the rear body. When the front bodyis combined with the rear body, the external surfaceof the front bodyforms a portion of the crownand the soleof the club head. The front bodyfurther comprises a hoselfor receiving a golf club shaft or shaft adapter in the heel regionof the golf club head.

In some embodiments, the strike faceand surrounding framecan be integrally formed. In other embodiments, the strike faceand surrounding framecan be separately formed and joined together. In one embodiment, the strike faceis forged and the surrounding frameis cast, then the strike faceand surrounding frameare joined through welding, brazing, plasma welding, low-power laser welding, forging, or another suitable joining technique.

In many embodiments, the front bodyis made from a metallic material to withstand the repeated impact stress from striking a golf ball. In some embodiments, the front body, can be formed from stainless steel, titanium, aluminum, a steel alloy (e.g.steel,steel,steel, 17-4 stainless steel, maraging steel), a titanium alloy (e.g. Ti 7-4, Ti 6-4, T-9S), an aluminum alloy, or a composite material. In some embodiments, the strike faceof the golf club headcan comprise stainless steel, titanium, aluminum, a steel alloy (e.g.steel,steel,steel, 17-4 stainless steel, maraging steel), a titanium alloy (e.g. Ti 7-4, Ti 6-4, T-9S), an aluminum alloy, an amorphous metal alloy, or a composite material.

The front bodycomprises a mass. In some embodiments, wherein the strike faceand surrounding frameare separate, the mass of the front bodyis the sum of the mass of the strike faceand the mass of the surrounding frame. Depending on the material the front bodyis made of, the mass of the front bodycan range between 40 grams and 140 grams. In most embodiments, the mass of the front bodydoes not exceed 140 grams. In some embodiments, the mass of the front bodycan range between 40-50 grams, 50-60 grams, 60-70 grams, 70-80 grams, 80-90 grams, 90-100 grams, 100-110 grams, 110-120 grams, 120-130 grams, or 130 grams-140 grams.

a. Strike Face

Referring to, the front bodyof the golf club headcomprises a strike face, positioned to strike a golf ball. The strike facecomprises a centerpoint, a loft plane, and a midplane. The center pointis equidistant from the from the crownand soleof the club head, and equidistant from the edge of the face that is the most proximate to the toe regionand from the edge of the face that is the most proximate to the heel region. The loft planeis tangent to the centerpointof the strike faceof the club head. The loft planeintersects a ground plane.

The strike faceof the club headcomprises a thickness measured as the distance between the strike faceand the internal surfaceof the front body. The thickness of the strike facevaries at different locations defining a variable face thickness (VFT) or variable thickness profile. The variable thickness profilehaving a central regionand a peripheral region. In many embodiments, the central regionof the variable thickness profilecomprises an ellipse or oval or ovoid or egg-like shape. The central regionis generally oblong and extends from a portion of the strike facenear the soleand heel regionto a portion of the strike facenear the toe regionand crown.

Referring to, the central regionextends over or is positioned on or near the centerpointof the strike facesuch that the center pointof the strike faceis located in the central region. The central regioncomprises a maximum thickness of the strike face. In many embodiments, the thickness of the central regionis substantially constant. The peripheral regionis positioned around the perimeterof the strike faceand comprises a minimum thickness of the strike face. In many embodiments, the thickness of the peripheral regionis substantially constant. The thickness of the strike facein the central regionis greater than the thickness of the strike facein the peripheral region. A transition regionis positioned between the central regionand the peripheral region. The transient regionincludes a varying thickness that creates a transition between the central regionand the peripheral region.

Furthermore, the strike facecomprises a major axisextending in a general heelto toedirection. The major axisintersects the centerpointand forms an angle β with the ground plane. In many embodiments, the major axisreflects the oblong shape of the central region.

The major axisforms an approximate angle of 20 degrees with the ground plane. For example, the angle formed between the major axisof the central regionand the ground planecan vary from 0 to 60 degrees. In some embodiments, the angle formed between the major axisof the central regionand the ground planecan vary from 2 to 20, 2 to 30, 5 to 40, 10 to 50, or 15 to 60 degrees. In other embodiments, the major axiscan create an angle of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46,47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 degrees with ground plane. By disposing the center regionon an angle it further allows the elongated portion of the egg-shape to extend towards the upper-toe portion of the strike facewherein high CT values exist, thus improving resulting ball speed.

The oval or ovoid or egg-like shape, along with the angle of the central regionof the variable thickness profile, enables thicker regions of the strike faceto be positioned in regions having inherently high CT, and thinner regions of the strike faceto be positioned in regions having inherently low CT. Accordingly, regions of the face having inherently high CT are reduced, and regions of the face having inherently low CT are increased, resulting in normalized CT across the strike face. In many embodiments, the variable thickness profileresults in a range in characteristic time less than 115 micro-seconds (μs), less than 110 μs, less than 105 μs, less than 100 μs, less than 95 μs, less than 90 μs, or less than 85 μs. Further, in many embodiments, the variable thickness profileresults in an average characteristic time greater than 230 μs, greater than 235 μs, or greater than 240 μs. For example, in many embodiments, the average CT of the face platecan be between 230 μs and 240 μs, between 235 μs and 240 μs, or between 240 μs and 245 μs.

Further, because the angled VFT is designed to position thickened portions of the strike facein regions where it is required, the strike facecan experience a weight reduction compared to a strike face devoid of the variable thickness profiledescribed herein. The extra discretionary weight can be re-introduced in other regions of the club head to manipulate the club head center of gravity position and to increase club head moment of inertia, further improving the performance of the club head. In the illustrated embodiment, the club headhaving the variable thickness profile, as described herein, saves 2.1 grams of weight compared to a similar club head devoid of the variable thickness profile.

b. Hosel

The front bodyof the golf club headcomprises the hosel. The hoselincludes a hosel axisextending along a center of a bore of the hosel. Referring to, in the present example, a hosel coupling mechanism of the golf club headcomprises the hoseland a shaft sleeve (not shown), where the shaft sleeve can be coupled to an end of a golf shaft (not shown). The shaft sleeve can couple with the hoselin a plurality of configurations, thereby permitting the golf shaft to be secured to the hoselat a plurality of angles relative to the hosel axis. There can be other examples, however, where the shaft can be non-adjustably secured to the hosel. In the illustrated embodiment, the hosel axisis at an angle α with the ground planewith respect to a front view of the golf club head(). The illustrated angle α is approximately 60-degrees, but in other constructions, the angle α may be between approximately 40-80 degrees (e.g., approximately 40 degrees, approximately 45 degrees, approximately 50 degrees, approximately 55 degrees, approximately 60 degrees, approximately 65 degrees, approximately 70 degrees, approximately 75 degrees, or approximately 80 degrees).

Furthermore, the hosel axisand the major axisform an angle θ. In many embodiments, the angle θ formed between the hosel axisand the major axiscan range between 60 and 140 degrees. In most embodiments, the minimum angle θ formed between the hosel axisand the major axisis approximately 60 degrees. In some embodiments, the angle θ formed between the hosel axisand the major axiscan range between 60-70 degrees, 70-80 degrees, 80-90 degrees, 90-100 degrees, 100-110 degrees, 110-120 degrees, 120 degrees-130 degrees, or 130-140 degrees. In one embodiment, the angle the angle θ formed between the hosel axisand the major axiscan range between 80 degrees and 90 degrees.

c. Surrounding Frame

The front bodyof the golf club headcomprises the surrounding framethat extends rearward from the entire perimeterof the strike face. The surrounding framefurther comprises a flangethat is operative to couple the front bodyand the rear body.

The flangeprovides a surface, to achieve a lap joint, wherein the rear bodycan attach. The flangeextends rearward from the entire surrounding frame, and forms a step-type structure, down from the external surfaceof the surrounding frame. In many embodiments, the flangeof the front bodyallows the rear body to overlap the flangeand join to the front body, by way of epoxy, adhesion, welding, bonding, laser assisted metal-plastic welding, brazing, or any other suitable attachment method. The lap joint style flange, further allows the front bodyand rear bodyto securely mate, without the use of any mechanical fasteners.

Furthermore, the surrounding framecomprises the external surfaceand the internal surface, wherein additional aerodynamic features can be placed, to improve the overall speed of the golf club head. The surrounding frameof the front bodyof the golf club head, can include additional aerodynamic features, such as turbulators. The turbulatorscan be used to reduce club head drag and increase the speed of the club. These turbulatorsare further described in U.S. Pat. No. 9,555,294, which is incorporated by reference in its entirety.

Referring to, the rear bodyof the club headcomprises a crown member, a sole member, and a weight pad. The crown memberand sole memberare bonded together to form a portion of the crownand the soleof the golf club head. When the front bodyand rear bodyare joined, the external surfaceof the front body, the crown member, and the sole member, form the entire crownand soleof the golf club head. The sole memberof the rear bodycan further comprise a composite resilient layer, a composite structural layer, and a metallic weight pad.

In the present design, the rear bodymay include a mix of molded thermoplastic materials (e.g., injection molded thermoplastic materials) and fiber reinforced thermoplastic composite materials. As used herein, a molded thermoplastic material is one that relies on the polymer itself to provide structure and rigidity to the final component. The molded thermoplastic material is one that is readily adapted to molding techniques such as injection molding, whereby the material is freely flowable when in a heated to a temperature above the melting point of the polymer. A molded thermoplastic material with a mixed-in filler material is referred to as a filled thermoplastic (FT) material. Filled thermoplastic materials are freely flowable when in a heated/melted state. To facilitate the flowable characteristic, filler materials generally include discrete particulate having a maximum dimension of less than about 25 mm, or more commonly less than about 12 mm. For example, the filler materials can include discrete particulate having a maximum dimension of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. Filler materials useful for the present designs may include, for example, glass beads or discontinuous reinforcing fibers formed from carbon, glass, or an aramid polymer.

In contrast to molded and filled thermoplastic materials, fiber reinforced composite (FRC) materials generally include one or more layers of a uni- or multi-directional fiber fabric that extend across a larger portion of the polymer. Unlike the reinforcing fibers that may be used in FT materials, the maximum dimension of fibers used in FRCs may be substantially larger/longer than those used in FT materials and may have sufficient size and characteristics such that they may be provided as a continuous fabric separate from the polymer. When formed with a thermoplastic polymer, even if the polymer is freely flowable when melted, the included continuous fibers are generally not.

FRC materials are generally formed by arranging the fiber into a desired arrangement, and then impregnating the fiber material with a sufficient amount of a polymeric material to provide rigidity. In this manner, while FT materials may have a resin content of greater than about 45% by volume or more preferably greater than about 55% by volume, FRC materials desirably have a resin content of less than about 45% by volume, or more preferably less than about 35% by volume. FRC materials traditionally use two-part thermoset epoxies as the polymeric matrix, however, it is possible to also use thermoplastic polymers as the matrix. In many instances, FRC materials are pre-prepared prior to final manufacturing, and such intermediate material is often referred to as a prepreg. When a thermoset polymer is used, the prepreg is partially cured in intermediate form, and final curing occurs once the prepreg is formed into the final shape. When a thermoplastic polymer is used, the prepreg may include a cooled thermoplastic matrix that can subsequently be heated and molded into final shape. This technique enables complex and lightweight geometries to be made, such as the rear body, without sacrificing strength.

a. Crown Member

The rear body, comprises the crown member. Referring tothe crown membercomprises an external surface, such that when the rear bodyand front bodyare joined, the external surfaceof the crown memberand the external surfaceof the surrounding frameform the entire crownof the golf club head. The external surfaceof the crown membercomprises a generally curvilinear shape which is concave with respect to the ground plane. The generally curvilinear shape of the crown memberallows the rear bodyto seamlessly be joined to the front body, as the crown member is placed entirely over the flangeof the front body.

In many embodiments, the crown memberis comprised of a carbon fiber weave, devoid of any layering of composite plies or unidirectional composite plies. In one embodiment, the crown membermay be substantially formed from a formed fiber reinforced composite material that comprises a woven glass or carbon fiber reinforcing layer embedded in a polymeric matrix. In such an embodiment, the polymeric matrix is preferably a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. In other embodiments, the crown membermay instead be formed from a filled thermoplastic material that comprises a glass bead or discontinuous glass, carbon, or aramid polymer fiber filler embedded throughout a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or polyamide. In still other embodiments, the crown membermay have a mixed-material construction that includes both a filled thermoplastic material and a formed fiber reinforced composite material.

b. Sole Member

The rear body, comprises the sole member. Referring tothe sole membercomprises the structural layerand the resilient layer, providing a lightweight, but strong soleof the golf club head. In reference to the ground plane, the resilient layeris positioned tangent to the ground plane, and the structural layeris placed on top of the resilient layer, in the interior of the golf club head.

In one embodiment, the sole memberhas a mixed-material construction that includes both a fiber reinforced thermoplastic composite resilient layerand a molded thermoplastic structural layer. In a preferred embodiment, the molded thermoplastic structural layermay be formed from a filled thermoplastic material that comprises a glass bead or discontinuous glass, carbon, or aramid polymer fiber filler embedded throughout a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. The resilient layermay then comprise a woven glass, carbon fiber, or aramid polymer fiber reinforcing layer embedded in a thermoplastic polymeric matrix that includes, for example, a polyphenylene sulfide (PPS), a polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. In one particular embodiment, the crown memberand resilient layermay each comprise a woven carbon fiber fabric embedded in a polyphenylene sulfide (PPS), and the structural layermay comprise a filled polyphenylene sulfide (PPS) polymer.

The structural layermay generally include a forward portionand a peripheral portionthat define an outer perimeter of the sole member. In an assembled club head, the forward portionis bonded to the metallic front body, and the peripheral portionis bonded to the crown member. The structural layerdefines a plurality of apertureslocated interior to the perimeter that each extend through the thickness of the structural layer. Further, the structural layermay include one or more structural membersthat extend from the forward portionand between at least two of the plurality of apertures. Furthermore, as described below, the structural layercan be configured to comprise a metallic weight padand metallic weight.

The resilient layermay be bonded to the structural layersuch that it directly abuts or overlaps at least a portion of the forward portion, the peripheral portion, and the plurality of structural members. In doing so, the resilient layermay entirely cover each of the plurality of apertureswhen viewed from the exterior of the club head. Likewise, the one or more structural membersmay serve as selective reinforcement to an interior portion of the resilient layer, akin to a reinforcing rib or gusset.

With respect to both the polymeric construction of the crown memberand the sole member, any filled thermoplastics or fiber reinforced thermoplastic composites should preferably incorporate one or more engineering polymers that have sufficiently high material strengths and/or strength/weight ratio properties to withstand typical use while providing a weight savings benefit to the design. Specifically, it is important for the materials of the golf club headto efficiently withstand the stresses imparted during an impact between the strike faceand a golf ball, while not contributing substantially to the total weight of the golf club head. In general, preferred polymers may be characterized by a tensile strength at yield of greater than about 60 MPa (neat), and, when filled, may have a tensile strength at yield of greater than about 110 MPa, or more preferably greater than about 180 MPa, and even more preferably greater than about 220 MPa. In some embodiments, suitable filled thermoplastic polymers may have a tensile strength at yield of from about 60 MPa to about 350 MPa. In some embodiments, these polymers may have a density in the range of from about 1.15 to about 2.02 in either a filled or unfilled state and may preferably have a melting temperature of greater than about 210° C. or more preferably greater than about 250° C. c. Weight Pad

With reference to, in many embodiments, the structural layercan include a weight pad. The weight padcomprises a cavityadapted to receive a metallic weight. In some embodiments, the weight padis generally located toward the rear most point on the club head, and therefore may be integral to and/or directly coupled with the rear portionof the structural layer. In some embodiments, a hole or openingmay be provided in the resilient layer, through which a portion of the weight padmay extend. In some embodiments, the openingis spaced apart from the front bodyby a minimum distance of at least 25 mm, or at least 30 mm, or at least 35 mm (i.e., measured along the outer surface of the club head). As shown in, when assembled, an outer surface of the weight padmay sit flush with an outer surface of the directly adjacent sole memberand/or resilient layer. In this manner, a portion of the weight padmay form part of the eternal soleof the golf club head. Additionally, in some embodiments, an internal surface of the weight padmay be exposed on an interior of the clubhead. The weight padfunctions to provide a dense rearward mass to improve the overall MOI of the golf club head. The weight padprovides a portion to place a high concentration of discretionary mass, since there are substantially weight savings achieved from forming a composite rear body.