Golf Club Head

This application is a continuation of U.S. application Ser. No. 17/164,033, filed on Feb. 1, 2021, which is a continuation of U.S. application Ser. No. 16/673,060, filed on November 4 2019, which is a continuation of U.S. application Ser. No. 15/370,530, filed on Dec. 6, 2016. Each of these applications is incorporated herein in its entirety by reference thereto.

The present disclosure relates to a golf club head. More specifically, the present disclosure relates to a golf club head, such as a wood-type golf club head, having a lightweight crown construction.

A wood-type golf club head includes a load-bearing outer shell with an integral or attached strike plate. Some club heads are formed of metal material and have a hollow cavity. The metal body may comprise several portions welded together or may include a cast body with a separate sole plate or strike plate that is welded in the appropriate location.

Most club heads today are made of a strong, yet lightweight metal material such as, for example, a titanium, steel or aluminum alloy. There have also been heads formed of carbon fiber composite material. The use of these materials is advantageous for the larger club heads now sought by golfers, i.e., at least 300 cc and up to about 500 cc in volume. The larger sized, yet conventionally weighted, club heads strive to provide larger “sweet spots” on the striking face and club moments of inertia that, for some golfers, make it easier to get a golf ball up in the air and with greater accuracy.

Titanium alloys are particularly favored in club head designs for their combination of strength and light weight. However, the material can be quite costly. Steel alloys are more economical; however, since the density of steel alloys is greater than for titanium alloys, steel club heads are limited in size in order to remain within conventional head weights while maintaining durability.

Composite club heads, such as a carbon fiber reinforced epoxy or carbon fiber reinforced polymer, for example, are an alternative to metal club heads. A notable advantage is the relatively light weight compared to stainless steel alloys. However, these club heads have suffered from durability and performance qualities associated with composite materials. These include higher labor costs in manufacture, undesirable acoustic properties of the composite material.

A lightweight and durable golf club head that can be manufactured using a cost effective process may be desirable. Therefore, there is a continuing need for innovations in construction and manufacturing of golf club heads. Embodiments discussed herein fulfill this need and others.

The present disclosure describes a golf club head comprising a heel portion, a toe portion, a crown, a sole, and a face.

The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

Some embodiments are direct towards a golf club including a grip, a golf club shaft, a golf club head having a hosel portion, a crown, and a sole portion, the crown defining the top surface of the club head and including a crown portion that includes a crown recess region formed in the crown portion and defined by a crown ledge and a bonding wall, and a crown insert disposed at least partially within the crown recess region. The golf club also including a width dimension measured along an X-axis from a toe side of the golf club head to the heel side of the golf club head; a depth dimension measured along a Y-axis from a forward most point of the golf club head to a rearward most point of the golf club head; a central Z-axis extending in a vertical direction through the crown at a midpoint of the width dimension and a midpoint of the depth dimension; a central Y-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the Y-axis; a central X-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the X-axis; a first vertical plane defined by the central Z axis and the central Y-axis; a second vertical plane defined by rotating the first vertical plane 30 degrees clockwise about the central Z-axis; a third vertical plane defined by rotating the first vertical plane 30 degrees counter-clockwise about the central Z-axis; a fourth vertical plane defined by the central Z-axis and the central X-axis; a fifth vertical plane defined by rotating the fourth vertical plane 30 degrees clockwise about the central Z-axis; a sixth vertical plane defined by rotating the fourth vertical plane 30 degrees counter-clockwise about the central Z-axis; an X-Y plane defined by the central Y-axis and the central X-axis; a first critical point located on a front portion of the club head at the intersection between the first vertical plane and a top edge of the bonding wall, and a first cross-section taken on a vertical plane perpendicular to the bonding wall at the first critical point; a second critical point located on the front portion of the club head at the intersection between the second vertical plane and the top edge of the bonding wall, and a second cross-section taken on a vertical plane perpendicular to the bonding wall at the second critical point; a third critical point located on the front portion of the club head at the intersection between the third vertical plane and the top edge of the bonding wall, and a third cross-section taken on a vertical plane perpendicular to the bonding wall at the third critical point; a fourth critical point located on the front portion of the club head at the intersection between the fifth vertical plane and the top edge of the bonding wall, and a fourth cross-section taken on a vertical plane perpendicular to the bonding wall at the fourth critical point; and a fifth critical point located on the front portion of the club head at the intersection between the sixth vertical plane and the top edge of the bonding wall, and a fifth cross-section taken on a vertical plane perpendicular to the bonding wall at the fifth critical point. Each cross-section having a first critical dimension defining a bond gap between the crown insert and the bonding wall and measured parallel to the X-Y plane between the top edge of the bonding wall and a top perimeter edge of the crown insert, where the first critical dimension of each cross-section is no more than A mm, and where the average variation of the first critical dimensions between two or more of the cross-sections is no more than 0.2 mm.

In some embodiments, A may be 1.0 mm. In some embodiments, the average variation of the first critical dimensions between the two or more cross-sections is no more than 0.15 mm. In some embodiments, the average variation of the first critical dimensions between the two or more cross-sections is between 0.1 mm and 0 mm.

In some embodiments, a portion of the crown insert and a portion of the crown portion may be contrasting colors. In some embodiments, the crown insert may include an upper layer that extends to the top perimeter edge of the crown insert and is visible at the top perimeter edge of the crown insert located in the front portion of the golf club head. In some embodiments, the bond gap may be visible and not covered by a masking layer.

In some embodiments, the golf club may include a sole recess region formed in the sole portion and defined by a sole ledge and a bonding wall, and a sole insert disposed at least partially within the sole recess region.

In some embodiments, each cross-section may have a second critical dimension measured parallel to the X-Y plane between the bonding wall and a bottom perimeter edge of the crown insert, the second critical dimension of each cross-section may be no more than B mm, and the average variation of the second critical dimensions between two or more of the cross-sections may be no more than 0.2 mm. In some embodiments, B may be 1.0 mm.

In some embodiments, the average variation of the second critical dimensions between the two or more cross-sections is no more than 0.15 mm. In some embodiments, the average variation of the second critical dimensions between the two or more cross-sections is between 0.2 mm and 0 mm.

In some embodiments, at least a portion of the top surface of the crown insert at the top perimeter edge of the crown insert may be disposed below a top surface of the crown portion at the bonding wall. In some embodiments, at least a portion of the top surface of the crown insert at the top perimeter edge of the crown insert may be disposed below the top surface of the crown portion at the bonding wall by a vertical distance between 0.1 mm to 0.3 mm.

In some embodiments, the hosel portion may be configured to receive a sleeve attached to the golf club shaft, the sleeve being capable of being positioned to adjust the loft, lie, or face angle of the golf club head.

In some embodiments, the crown ledge may include a ledge surface defining a ledge gap between the ledge surface and the crown insert and the ledge gap may be no more than 0.3 mm.

In some embodiments, the thickness of the crown insert may be no greater than 1 mm.

In some embodiments, the golf club may include a sixth critical point located on a toe portion of the club head at the intersection between the fourth vertical plane and the top edge of the bonding wall, and a sixth cross-section taken on a vertical plane perpendicular to the bonding wall at the sixth critical point; and a seventh critical point located on a heel portion of the club head at the intersection between the fourth vertical plane and the top edge of the bonding wall, and a seventh cross-section take on a vertical plane perpendicular to the bonding wall at the seventh critical point.

In some embodiments, the golf club head may include a movable weight configured to be moved from a first position to a second position in the golf club head.

Some embodiments are directed towards a golf club head including a crown defining the top surface of the club head, the crown including a crown portion, a crown recess region formed in the crown portion and defined by a crown ledge and a bonding wall, and a crown insert disposed at least partially within the crown recess region. The golf club head also including a width dimension measured along an X-axis from a toe side of the golf club head to the heel side of the golf club head; a depth dimension measured along a Y-axis from a forward most point of the golf club head to a rearward most point of the golf club head; a central Z-axis extending in a vertical direction through the crown at a midpoint of the width dimension and a midpoint of the depth dimension; a central Y-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the Y-axis; a central X-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the X-axis; a first vertical plane defined by the central Z axis and the central Y-axis; a second vertical plane defined by rotating the first vertical plane θ degrees clockwise about the central Z-axis; a third vertical plane defined by rotating the first vertical plane θ degrees counter-clockwise about the central Z-axis; a fourth vertical plane defined by the central Z-axis and the central X-axis; a fifth vertical plane defined by rotating the fourth vertical plane β degrees clockwise about the central Z-axis; a sixth vertical plane defined by rotating the fourth vertical plane β degrees counter-clockwise about the central Z-axis; an X-Y plane defined by the central Y-axis and the central X-axis; a first critical point located on a front portion of the club head at the intersection between the first vertical plane and a top edge of the bonding wall, and a first cross-section taken on a vertical plane perpendicular to the bonding wall at the first critical point; a second critical point located on the front portion of the club head at the intersection between the second vertical plane and the top edge of the bonding wall, and a second cross-section taken on a vertical plane perpendicular to the bonding wall at the second critical point; a third critical point located on the front portion of the club head at the intersection between the third vertical plane and the top edge of the bonding wall, and a third cross-section taken on a vertical plane perpendicular to the bonding wall at the third critical point; a fourth critical point located on the front portion of the club head at the intersection between the fifth vertical plane and the top edge of the bonding wall, and a fourth cross-section taken on a vertical plane perpendicular to the bonding wall at the fourth critical point; and a fifth critical point located on the front portion of the club head at the intersection between the sixth vertical plane and the top edge of the bonding wall, and a fifth cross-section taken on a vertical plane perpendicular to the bonding wall at the fifth critical point. Each cross-section having a first critical dimension defining a bond gap between the crown insert and the bonding wall and measured parallel to the X-Y plane between the top edge of the bonding wall and a top perimeter edge of the crown insert, where the first critical dimension of each cross-section is no more than A mm, the average variation of the first critical dimensions between seven or more of the cross-sections is no more than 0.15 mm, θ is the range of 1 degree to 45 degrees, and β is the range of 1 degree to 44 degrees.

In some embodiments, A may be 1.0 mm and θ and β may be 30 degrees.

Some embodiments are directed towards a golf club head including a hosel portion, a crown and a sole portion, the crown defining the top surface of the club head and including a crown portion that includes a crown recess region formed in the crown portion and defined by a crown ledge and a bonding wall, and a crown insert disposed at least partially within the crown recess region. The golf club head also including a width dimension measured along an X-axis from a toe side of the golf club head to the heel side of the golf club head; a depth dimension measured along a Y-axis from a forward most point of the golf club head to a rearward most point of the golf club head; a central Z-axis extending in a vertical direction through the crown at a midpoint of the width dimension and a midpoint of the depth dimension; a central Y-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the Y-axis; a central X-axis intersecting the central Z-axis at the top surface of the club head and extending parallel to the X-axis; a first vertical plane defined by the central Z axis and the central Y-axis; a second vertical plane defined by rotating the first vertical plane 30 degrees clockwise about the central Z-axis; a third vertical plane defined by rotating the first vertical plane 30 degrees counter-clockwise about the central Z-axis; a fourth vertical plane defined by the central Z-axis and the central X-axis; a fifth vertical plane defined by rotating the fourth vertical plane 30 degrees clockwise about the central Z-axis; a sixth vertical plane defined by rotating the fourth vertical plane 30 degrees counter-clockwise about the central Z-axis; an X-Y plane defined by the central Y-axis and the central X-axis; a first critical point located on a front portion of the club head at the intersection between the first vertical plane and a top edge of the bonding wall, and a first cross-section taken on a vertical plane perpendicular to the bonding wall at the first critical point; a second critical point located on the front portion of the club head at the intersection between the second vertical plane and the top edge of the bonding wall, and a second cross-section taken on a vertical plane perpendicular to the bonding wall at the second critical point; a third critical point located on the front portion of the club head at the intersection between the third vertical plane and the top edge of the bonding wall, and a third cross-section taken on a vertical plane perpendicular to the bonding wall at the third critical point; a fourth critical point located on the front portion of the club head at the intersection between the fifth vertical plane and the top edge of the bonding wall, and a fourth cross-section taken on a vertical plane perpendicular to the bonding wall at the fourth critical point; and a fifth critical point located on the front portion of the club head at the intersection between the sixth vertical plane and the top edge of the bonding wall, and a fifth cross-section taken on a vertical plane perpendicular to the bonding wall at the fifth critical point. Each cross-section having a first critical dimension defining a bond gap between the crown insert and the bonding wall and measured parallel to the X-Y plane between the top edge of the bonding wall and a top perimeter edge of the crown insert, where the first critical dimension of each cross-section is no more than A mm and the average variation of the first critical dimensions between five or more cross-sections is no more than 0.2 mm.

In some embodiments, the hosel portion may be configured to receive a sleeve, the sleeve being capable of being positioned to adjust the loft, lie, or face angle of the golf club head and being connected to the golf club head by a mechanical fastener.

In some embodiments, the average variation of the first critical dimensions between the five or more cross-sections may be no more than 0.15 mm.

Various embodiments and aspects of the invention(s) will be described with reference to details discussed below. The following description and drawings are illustrative of the invention(s) and are not to be construed as limiting the invention(s). Numerous specific details are described to provide a thorough understanding of various embodiments of the present invention(s). However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present invention(s).

A golf club head composed of two or more materials (e.g., a metal material and a composite material) may provide beneficial properties (e.g., weight, sound, size, and center of gravity properties) for a golfer. In some cases, a composite club head may include a metal body and one or more inserts comprising a composite material. For example, a composite material insert may define a portion of a crown of the club head. The composite insert may serve to reduce the weight of a given club head geometry without sacrificing mechanical properties of the club head (e.g., strength and impact performance characteristics) due to the composite material's lightweight and high strength properties.

However, durability at a junction between a two materials (i.e., the location where the first material is bonded to the second material) may be problematic. For example, the durability at a junction between a composite material and a metal material may be problematic. Junctions between a composite material and metal material, often bonded via an adhesive, may be centers of stress concentrations, which may lead to undesirable cracking at these junctions. In order to avoid high amounts of stress concentrations, the junction between the composite material and a metal material should be uniform and consistent. For example, the separation between the composite material and metal material at the junction (e.g., the location of a bonding adhesive) should be uniform and consistent along the junction between the materials. Further, minimizing the amount of separation between the composite and metal materials at the junction may help avoid the formation of cracks because it may reduce the amount of adhesive located at the junction, which may be more susceptible to cracking than the composite and metal materials.

However, while creating uniform, consistent, and and/or minimally sized junctions between a composite material and a metal material may be desirable, the cost of manufacturing such junctions may be a concern. A composite insert that can be separately machined and placed into a recess or cavity on a metal club head body without the need for further machining steps is described herein. Such a process may reduce costs for a manufacturer and/or a consumer of a golf club head and/or golf club.

The uniformity, consistency, and size of a junction between two materials may be characterized by measuring one or more dimensions of the separation between the two materials at the junction. The dimensions of the separation may be measured at specific locations on a club head (i.e., the critical points discussed herein) to determine the uniformity, consistency, and/or size of the junction between two materials. A club head having junction dimensions tailored to be highly uniform and highly consistent may help avoid the formation of undesirable stress concentrations at the junction between two materials. Undesirable stress concentrations due to non-uniform or inconsistent dimensional tolerances may result in mechanical and/or visual defects (e.g., cracks) on a club head.

illustrate a golf club headhaving a heel side, a toe side, front sidehaving a club faceand a striking face, a rear side, a top side(also called a crown) having top surface, a bottom side(also called a sole or sole portion) having a bottom surface, a hosel (also called a hosel portion), a hosel axis, a hosel insert, and a lie angle. Golf club headhas a width dimension W, a height dimension H, and a depth dimension D measured when the golf club head is positioned in an address position. The address position for a golf club head is defined as the golf club head in a lie angle of fifty-seven degrees and the loft of the club adjusted to the designated loft of the club head. Unless otherwise stated, all the measured dimensions described herein are evaluated when a golf club head is oriented in the address position. If a golf club head at a fifty-seven degree lie angle visually appears to be unlevel from a front face perspective, an alternative lie angle called the “scoreline lie” may be used. The scoreline lie is defined as the lie angle at which the substantially horizontal face scorelines are parallel to a perfectly flat ground plane.

The width dimension W of golf club headmay not be greater than 5 inches, and the depth dimension D of golf club headmay not be greater than the width dimension W. The height dimension H of golf club head 100 may not be greater than 2.8 inches. In some embodiments, the depth dimension D or the width dimension W may be greater than 4.4″, greater than 4.5″, greater than 4.6″, greater than 4.7″, greater than 4.8″, greater than 4.9″, or between 4.6″ and 5″. In some embodiments, the height dimension H may be greater than 2.7″, greater than 2.6″, greater than 2.5″, greater than 2.4″, greater than 2.3″, greater than 2.2″, greater than 2.1″, greater than 2″, greater than 1.9″ or greater than 1.8″. In certain embodiments, the height dimension H of golf club headmay be between about 63.5 mm to 71 mm (2.5″ to 2.8″), the width dimension W may be between about 116.84 mm to about 127 mm (4.6″ to 5.0″), and the depth dimension D may be between about 111.76 mm to about 127 mm (4.4″ to 5.0″).

Dimensions W, D, and H are measured on horizontal lines (axes,, andshown in) between vertical projections of the outermost points of heel sideand toe side, front sideand rear side, and top sideand bottom side, respectively. The outermost point of heel sideis defined as the point on the heel that is 0.875″ above a horizontal ground planeat the address position. The outermost point on front side may be forward most pointand the outermost point on rear sidemay be rearward most point, as shown for example in. W is measured on X-axis. D is measured on Y-axis. H is measured on Z-axis. X-axisand Y-axisare parallel to ground planeand Z-axisis perpendicular to ground plane.

further illustrates a face center location. Face center locationis found by utilizing the USGA Procedure for Measuring the Flexibility of a Golf Clubhead, Revision 2.0 published on Mar. 25, 2005, herein incorporated by reference in its entirety. Specifically, face center locationis found by utilizing the template method described in section 6.1.4 and FIG. 6.1 described in the USGA document mentioned above.

A coordinate system for measuring the CG (center of gravity) location for golf club headis located at face center location. In one embodiment, the positive center face X-axisprojects toward heel sideof club head, the positive center face Z-axisprojects toward top sideof club head, and the positive center face Y-axisprojects towards rear sideof club headparallel to ground plane.

In some embodiments, golf club headmay have a CG with a CG x-axis coordinate between about −5 mm and about 10 mm, a CG y-axis coordinate between about 15 mm and about 50 mm, and a CG z-axis coordinate between about −10 mm and about 5 mm. In some embodiments, the CG y-axis coordinate may be between about 20 mm and about 50 mm.

In some embodiments, scorelinesmay be located on striking faceof club face. In some embodiments, a projected CG locationshown on club faceis considered the “sweet spot” of golf club head. Projected CG locationis found by balancing golf club headon a point. Projected CG locationis generally projected along a line that is perpendicular to club faceof golf club head. In some embodiments, projected CG locationmay be less than 2 mm above face center location, less than 1 mm above face center location, or up to 1 mm or 2 mm below face center location.

illustrates a bottom side view of golf club headshowing bottom sideand an edgebetween top sideand bottom side. In some embodiments, golf club headmay be provided with a weight portand an adjustable weightlocated in weight port. In some embodiments, weight portand adjustable weightmay be the same as or similar to the ports and weights described in U.S. Pat. No. 7,407,447 patented on Aug. 5, 2008, herein incorporated by reference in its entirety by reference thereto.

In some embodiments, golf club headmay include a recessed channel portionhaving a channel sidewallin a front portion of bottom sideof golf club headproximate to club face. Within channel portion, a fastener openingmay be provided to allow the insertion of a mechanical fastener, such as a screw, for engaging with hosel insertfor attaching a shaft (e.g., club shaft) to golf club headand/or to allow for an adjustable loft, lie, and/or face angle. In some embodiments, hosel insertmay be configured to allow for the adjustment of at least one of a loft, lie, or face angle described in U.S. Pat. No. 8,303,431, patented on Nov. 6, 2012, herein incorporated by reference in its entirety by reference thereto.

illustrates a cross-sectional view taken along linesC-C in. In some embodiments, a machined face insertmay be welded to a front openingon golf club head. Face insertmay have a variable face thickness having an inverted recess in the center portion of the back surface of the face insert. In some embodiments, a crown insertmay define all or a portion of top surfaceof top sideof golf club head. Crown insertmay be bonded to top sideof golf club head. In some embodiments, crown insertmay rest on a crown ledge. In some embodiments, crown insertmay be bonded to crown ledge. In some embodiments, crown insertmay comprise a composite material. In some embodiments, the composite material of crown insertmay be a composite lay-up including a plurality plies or layers.

In some embodiments, crown ledgemay have a length in range between 1-7 mm, 1-5 mm, or 1-3 mm. In some embodiments, crown ledgemay continuously extend around a circumference of an openingformed on top sideof golf club head. In some embodiments, crown ledgemay extend around a portion of a circumference of an openingformed on top sideof golf club head. In some embodiments, crown ledgemay include a plurality of discontinuous segments extending around all or a portion of openingformed on top sideof golf club head. Crown insertand crown ledgemay be considered to be the same element to crown insertand crown ledgediscussed herein.

In some embodiments, a plurality of ribsmay be connected to an interior portion of channel portionto improve the sound of golf club headupon impact with a golf ball.

illustrates a top view of golf club headin the address position. A hosel planeis shown being perpendicular to ground planeand containing hosel axis. In addition, a center face nominal face angleis shown which may be adjusted by hosel insert. A positive normal face angle indicates golf club faceis pointed to the right of a center line target at a given measured point. A negative normal face angle indicates the golf club faceis pointed to the left of a centerline target at a given measured point. A toplineis also shown in. Toplineis defined as the intersection of top surfaceand club faceof golf club head. In some embodiments, the paint line of top surfacemay stop at topline.

show golf club head'smoments of inertia may be defined about three axes extending through golf club head'sCGincluding: a CG Z-axisextending through CGin a generally vertical direction relative to ground planewhen club headis at address position, a CG X-axisextending through CGin a heel-to-toe direction generally parallel to striking faceand generally perpendicular to CG Z-axis, and a CG Y-axisextending through CGin a front-to-back direction and generally perpendicular to CG X-axisand CG Z-axis. CG X-axisand CG Y-axisboth extend in a generally horizontal direction relative to ground planewhen club headis at the address position.

The moment of inertia about golf club head CG X-axisis calculated by the following equation:

In equation 1 above, y is the distance from a golf club head CG xz-plane to an infinitesimal mass dm and z is the distance from a golf club head CG xy-plane to the infinitesimal mass dm. The golf club head CG xz-plane is a plane defined by CG X-axisand CG Z-axis. The CG xy-plane is a plane defined by CG X-axisand CG Y-axis.

Moreover, a moment of inertia about golf club head CG Z-axisis calculated by the following equation: