Golf Club Head with Variable Face Thickness

A golf club head forms part of a golf club and is used to strike a golf ball during a golf swing. The ball flight characteristics of a golf ball after being struck depend not only on how the golf club is swung but also on the design and configuration of the golf club itself. For example, ball flight characteristics, such as launch angles, ball speed, and uniformity of ball speed across the striking face of the golf club head can be impacted by the design of the golf club. By adjusting one or more elements or features of the golf club head, the ball flight characteristics of the golf ball can be improved, thereby increasing a person's performance during a game of golf. Additional considerations, such as structural integrity and durability of the golf club head may be accounted for when configuring the golf club head. For example, adjusting one element or feature of a golf club head could improve certain ball flight characteristics but jeopardize the golf club head's structural integrity or decrease its durability.

It is with respect to these and other general considerations that aspects of the technology disclosed herein have been made. Also, although relatively specific problems may be discussed, it should be understood that the examples disclosed herein should not be limited to solving the specific problems identified in the background or discussed elsewhere in this disclosure.

This background sections is provided only for purposes of introducing certain background material relating to the present disclosure and, thus, is not an admission of prior art.

This Summary section introduces some features of nonlimiting and non-exhaustive examples of the present disclosure, and is not intended to limit the scope of the claims.

In an aspect, the technology relates to an iron type golf club head, including: a striking face having a substantially flat frontal striking surface, and having a lower leading edge and an opposite upper topline edge; a topline extending rearward from the upper topline edge; a sole extending rearward from the lower leading edge; a support bar protruding rearwardly from the striking face and extending in a toe-heel direction of the golf club head; an upper cavity at least partially surrounded by the topline, an upper section of the striking face, and the support bar; and a lower cavity at least partially surrounded by the support bar, a lower section of the striking face, and the sole, wherein the lower section of the striking face includes a heel portion, a toe portion, and a thick portion between the heel portion and the toe portion, and wherein a first thickness of the thick portion is greater than each of a second thickness of the heel portion and a third thickness of the toe portion.

In some examples, the lower cavity is entirely enclosed by the golf club head, and wherein the upper cavity is exposed, at a rear of the upper cavity, to the exterior of the golf club head. In some examples, the first thickness is greater than a thickness of the upper section of the striking face at any position on the upper section of the striking face. In some examples, the thick portion includes: a flat portion having a substantially uniform thickness; and a tapered edge at least partially surrounding the flat portion and having a tapered thickness. In some examples, the first thickness is greater than a thickness of the lower section of the striking face at any position over the heel portion and the toe portion. In some examples, the thick portion has a shape extending from the sole toward the support bar. In some examples, the shape of the thick portion extends to the support bar. In some examples, the shape of the thick portion extends only part way to the support bar, and a greatest thickness of the thick portion is greater than a greatest thickness of a portion of the lower section of the striking face between the thick portion and the support bar. In some examples, the second thickness is measured on the heel portion at a first height from the lower leading edge along a first direction parallel to the frontal striking surface and perpendicular to the toc-heel direction, and a fourth thickness on the heel portion, at a second height from the lower leading edge along the first direction, is greater than the second thickness, the second height being greater than the first height. In some examples, the golf club head includes a cradle defining a rear portion of a body of the golf club head and being attached to a front portion of the body, the cradle including at least part of the sole and at least part of a back portion coupled between the sole and the support bar; a first weight attached to the cradle and positioned in the lower cavity rearward to, and spaced apart from, the heel portion of the striking face; and a second weight attached to the cradle and positioned in the lower cavity rearward to, and spaced apart from, the toe portion of the striking face.

In another aspect, the technology relates to an iron type golf club head, including: a striking face having a substantially flat frontal striking surface, and having a lower leading edge and an opposite upper topline edge; a sole extending rearward from the lower leading edge; and a support bar protruding rearwardly from the striking face, wherein the striking face includes an upper section above the support bar and a lower section below the support bar, wherein the lower section of the striking face includes a heel portion, a toe portion, and a thick portion between the heel portion and the toe portion, wherein a first thickness of the thick portion, as measured at a first height from the lower leading edge, is greater than a second thickness of the heel portion, as measured at the first height from the lower leading edge, and wherein the second thickness of the heel portion is less than a third thickness of the heel portion, as measured at a second height from the lower leading edge, the second height being greater than the first height.

In some examples, the golf club head includes a topline extending rearwardly from the upper topline edge of the striking face; a back portion coupled between the sole and the support bar; an upper cavity partially surrounded by the topline, the upper section of the striking face, and the support bar, and being exposed to the exterior of the golf club head at a rear of the upper cavity; and a lower cavity at least partially surrounded by the support bar, the lower section of the striking face, the back portion, and the sole. In some examples, the golf club head includes a first weight attached to the back portion and positioned in the lower cavity rearward to the heel portion; and a second weight attached to the back portion and positioned in the lower cavity rearward to the toe portion. In some examples, the first thickness of the thick portion is substantially equal to a fourth thickness of the thick portion, as measured at the second height from the lower leading edge. In some examples, a thickness of the heel portion gradually increases from the lower leading edge toward the support bar, and a thickness of the toe portion gradually increases from the lower leading edge toward the support bar.

In an aspect, the technology relates to an iron type golf club head, including: a striking face having a substantially flat frontal striking surface, and having a lower leading edge and an opposite upper topline edge; a cradle defining a rear portion of a body of the golf club head and attached to a front portion of the body, the cradle including: at least part of a sole extending rearward from the lower leading edge to a distal edge, and at least part of a back portion extending from the distal edge of the sole, wherein a lower cavity of the golf club head is at least partially surrounded by a lower section of the striking face, the sole, and the back portion; and a first weight in the lower cavity, wherein the lower section of the striking face includes a heel portion, a toe portion, and a thick portion between the heel portion and the toc portion, wherein a first thickness of the thick portion is greater than each of a second thickness of the heel portion and a third thickness of the toe portion, wherein the first weight is attached to the cradle and positioned in the lower cavity rearward to the heel portion, and wherein a difference between the first thickness and the second thickness is greater than or equal to a separation distance between the first weight and the heel portion.

In some examples, the golf club head includes a topline extending rearwardly from the upper topline edge of the striking face; a support bar protruding rearwardly from the striking face and extending in a toe-heel direction of the golf club head; an upper cavity partially surrounded by the topline, an upper section of the striking face, and the support bar, and being exposed to the exterior of the golf club head at a rear of the upper cavity, wherein the lower cavity is at least partially surrounded by the support bar. In some examples, the first thickness is greater than the thickness of the upper section at any position on the upper section. In some examples, the golf club head includes a second weight attached to the cradle and positioned in the lower cavity rearward to, and spaced apart from, the toe portion. In some examples, the thick portion includes a flat portion having a substantially uniform thickness.

Golf club heads, which may have a striking face with a variable thickness configured to improve certain golf club and ball flight characteristics, will now be described below in more detail with reference to the drawings.

is a partially exploded perspective view of a golf club headaccording to some examples. In the depicted example, the golf club headis an iron type golf club head.is a back view of a front portionof the golf club headof.is a cross-sectional view of the golf club headofalong the line′-′ in.is a cross-sectional view of the golf club headofalong the line′-′ in.is a cross-sectional view of the golf club headofalong the line′-′ in.

Referring concurrently to, the golf club headincludes a bodyincluding a toe, a heel, a striking faceextending between the toeand the heeland having a lower leading edgeand an opposite upper topline edge, a soleextending rearward from the lower leading edgeto a distal edge, a toplineextending rearward from the upper topline edge, a support barthat protrudes rearwardly from the striking faceand generally extends along a toe-heel direction, and a back portioncoupled between the distal edgeof the soleand the support barto form part of a cradle. As used herein, the toe-heel direction of the golf club headincludes both a toc-to-heel direction and a heel-to-toe direction of the golf club head. The striking facemay have a substantially flat frontal striking surfaceFS and an opposite rear surfaceR. One or more groovesmay be defined in the frontal striking surfaceFS of the striking face. The golf club headmay include a hoselthat is disposed at the heeland that is configured to attach to a golf club shaft (not shown).

An elongated cavitymay be defined in the support barand may generally extend in the toc-heel direction. An elongated polymer(e.g., a polymer strip) may be positioned at least partially (i.e., partially or entirely) in the cavityand generally extend along the toe-heel direction. The polymercan improve various performance properties of the golf club head, such as providing a more solid feel when striking a golf ball. In some other examples, the cavityand polymerare omitted. For example, the support barmay be a solid, continuous piece of metal.

A rear portion of the bodymay be defined by a cradlethat is attached (e.g., during the manufacturing of the golf club head) to a front portionof the body. The cradlemay include at least part (i.e., part or all) of the soleand at least part of the back portion. In some examples, the front portionincludes the striking face, the support bar, and at least part of the sole.

The golf club headmay have an upper cavityand a lower cavity. The upper cavitymay be at least partially surrounded by the topline, an upper sectionof the striking face, and the support bar. The upper cavitymay be exposed to the exterior of the golf club headat a rear of the upper cavity. The lower cavitymay be at least partially surrounded by the support bar, a lower sectionof the striking face, the sole, and the back portion. In some examples, the lower cavityis entirely surrounded. For example, the lower cavitymay be fluidically sealed or fluidically separated from the exterior of the golf club head. The lower sectionmay be entirely below the support bar, and the upper sectionmay be entirely above the support bar.

Referring to, the lower sectionof the striking facemay include a heel portionadjacent to the heel, a toe portionadjacent to the toe, and a thick portionbetween the heel portionand the toe portion. In the depicted example, the lower sectionalso include an intermediate thin portionthat is both positioned between the heel portionand the toe portionand also positioned between the thick portionand the support bar. In some examples, the rear surfaceR at the intermediate thin portionis continuous and contiguous with the rear surfaceR at the heel and toe portionsand.

As explained in more detail below, a thickness of the lower sectionmay be configured (e.g., varied across the lower section) such that ball speed across the lower sectioncan be increased and made more uniform, golf ball launch angle can be increased, and flexure of the lower sectionnear the soleand at the heel and toe portionsandcan be improved. This can lead to improved aerodynamic properties of the golf club head and improved performance of a person using the golf club head.

As used herein, thicknesses of the striking facemay be measured along a first direction that is perpendicular to the frontal striking surfaceFS and between the rear surfaceR of the striking faceand a frontal planeFP that is parallel and tangential to the frontal striking surfaceFS. In some examples, the frontal striking surfaceFS is an outer-most surface of the striking face(ignoring any grooves in the striking face). A second direction is also referred to herein and may be defined to be parallel to the frontal striking surfaceFS and generally perpendicular to the toe-heel direction. For example, the second direction may be perpendicular to both the first direction and the toe-heel direction. In some other examples, the second direction may be defined to be perpendicular to a ground plane when the golf club headis in the address position on the ground plane. The address position, as defined by the current application, sets up the golf club headat an orientation that has a lie angle of 60 degrees similar to the requirements of the USGA. Once the lie angle is set at 60 degrees, the face angle of the golf club head is set to be square, which is defined as having a face angle of 0 degrees.

The thickness of the lower sectionwill be described in more detail below with reference to seven different positions on the lower section. These seven positions include first and second positionsandon the toe portion, third and fourth positionsandon the thick portion, fifth and sixth positionsandon the heel portion, and a seventh positionon the intermediate thin position. The first, third, and fifth positions,, andmay have a same first height along the second direction from the lower leading edgeor from the ground plane, depending on how the second direction is defined. The second, fourth, and sixth positions,, andmay have a same second height along the second direction from the lower leading edgeor the ground plane, depending on how the second direction is defined. The seventh positionmay have a third height along the second direction from the lower leading edgeor the ground plane, depending on how the second direction is defined. The second height may be greater than the first height, and the third height may be greater than the second height. For example, a difference between the first height and the second height may be any value within, or within any subrange within, 20% to 60% of a maximum height of the lower sectionalong the second direction. In some examples where the second direction is parallel to the frontal striking surfaceFS, the first and second positionsandmay be aligned along a line parallel to the second direction, the third, fourth, and seventh positions,, andmay be aligned along a line parallel to the second direction, and the fifth and sixth positionsandmay be aligned along a line parallel to the second direction.

The thick portionmay include a flat portionF and a tapered portionT at least partially surrounding the flat portionF. In the depicted example, the thick portionand the flat portionF each extend from the soleonly part way (e.g., along the second direction) toward the support bar, and the tapered portionT has an upside down U-like shape that surrounds part of the flat portionF. By shaping and sizing the thick portionto extend from the soleonly part way toward the support bar, a center of gravity (COG) can be controllably shifted downward compared to if the thick portion were to extend all the way up to the support bar. A greatest width of each of the thick portionand the flat portionF along the toe-heel direction may be at least 5 mm.

The flat portionF may have substantially uniform thickness, for example, a thickness that deviates by less than 5%, 3%, 1%, or 0.5% across the flat portionF. For example, thicknesses at the third and fourth positionsandmay be substantially the same (e.g., within 5%, 3%, 1%, or 0.5% of each other). A thickness of the tapered portionT may decrease via a taper (e.g., a gradual taper) in a direction away from the flat portionF.

A thickness of the thick portion(e.g., a thickness of the flat portionF) may be greater than each of a thickness of the heel portionand a thickness of the toe portion. For example, the thick portionmay protrude further rearwardly compared to the heel and toe portionsand. A thickness at the third positionmay be greater than each of a thickness at the first positionand a thickness at the fifth position. A thickness at the fourth positionmay be greater than each of a thickness at the second positionand a thickness at the sixth position. In some examples, the thickness of the flat portionF may be greater than a thickness at any position across the heel and toe portionsand.

A thickness of the thick portion(e.g., the thickness at the third positionor at the fourth position) may be greater than a thickness of the upper sectionat any position across the upper section.

A thickness of the intermediate thin portionmay be less than a thickness of the thick portion(e.g., a thickness of the flat portionF). For example, a thickness at the seventh positionmay be less than each of the thickness at the third positionand the thickness at the fourth position. In some examples, the thickness at the seventh positionis greater than each of thicknesses at the first position, the second position, the fifth position, and the sixth position.

Each of the heel portionand the toe portionmay have a tapered thickness, where the thickness is greater near the support barthan it is near the sole. For example, thicknesses of the heel and toe portionsandmay gradually increase along a direction (e.g., along the second direction) from the soletoward the support bar. In some examples, the thickness at the second positionat the second height is greater than the thickness at the first positionat the first height. The thickness at the sixth positionat the second height may be greater than the thickness at the fifth positionat the first height. In some examples, a difference between the thickness at the fourth positionand the thickness at the second positionis less than a difference between the thickness at the third positionand the thickness at the first position. A difference between the thickness at the fourth positionand the thickness at the sixth positionmay be less than a difference between the thickness at the third positionand the thickness at the fifth position.

Each of the heel and toe portionsandmay taper at a rate such that a thickness at the top of the lower sectionadjacent to the support baris 10% to 40% greater than a thickness at the bottom of the lower sectionadjacent to the sole. In some examples, each of the heel and toe portionsandtapers at a rate such that a greatest thickness is 10% to 40% greater than a smallest thickness.

By increasing a thickness of the lower sectionat the thick portionin a central region, and thinning out the lower sections of the heel and toe portionsandnear the sole, the stiffness of the lower sectioncan be increased in the central region and reduced in the heel and toe portionsandnear the sole. Accordingly, the flexure of the lower sectioncan be concentrated in the heel and toe portionsandnear the solewithout sacrificing the overall stiffness and structural integrity of the lower section. This configuration of the lower sectioncan increase ball speed at the heel and toe portionsand, improve uniformity of ball speed for golf shots taken across the lower sectionalong the toe-heel direction, and increase ball launch angle.

In some other examples, the thick portionis provided and the thickness of each of the heel and toe portionsanddo not taper (e.g., the heel and toe portionsandeach have substantially uniform thickness). In such examples, the golf club headcan still exhibit the above-described performance improvements. For example, the thick portionmay be provided and the thickness of the heel and toe portionsandmay be uniformly thinned down so that the resulting heel and toe portionsandeach have uniform thickness. However, tapering the thickness of the heel and toe portionsand, as described herein, can increase the structural integrity and stiffness near the support bar, which can, among other things, concentrate flexure of the lower sectionnearer to the sole. This can increase golf ball launch angle compared to when the heel and toe portionsandare provided with uniform thicknesses.

The golf club headmay include a first weightpositioned within the lower cavityand rearward to the heel portion. In some examples, the first weightis entirely spaced apart from any line extending through the thick portionalong the first direction. The golf club head may include a second weight positioned within the lower cavityand rearward to the toe portion. In some examples, the second weightis entirely spaced apart from any line extending through the thick portionalong the first direction.

The first and second weightsandmay be attached (e.g., brazed, welded, adhered, etc.) to the cradleand spaced apart from the rear surfaceR of the striking face. For example, each of the first and second weightsandmay directly contact at least one of an internal surface of the back portionor an internal surface of the sole.

In some other examples, the first and second weightsandare attached to the rear surfaceR of the striking face. However, this can increase stress at the brazed joint between the first and second weightsandand the striking face, limit the flexure across the striking face, and limit the coefficient of restitution (COR) of the striking face. By instead attaching the first and second weightsandto the cradleand spacing them apart from the striking face, the flexure of the heel and toe portionsandcan be increased, and the COR of the lower sectioncan be increased.

In some examples, the thick portionmay protrude rearwardly compared to the heel portionby a distance (as measured along the first direction) greater than a separation distance (as measured along the first direction) between the first weightand the rear surfaceR of the heel portion. For example, the difference between the thickness at the third positionon the thick portionand the thickness at the fifth positionon the heel portionmay be greater than a separation distance between a forward surface of the first weightand the rear surfaceR of the heel portion, as measured along a line parallel to the first direction and extending through the fifth position. In some examples, a maximum difference between a thickness of the thick portionand a thickness of the heel portionis greater than a maximum separation distance between the first weightand the rear surfaceR of the heel portion. In examples, a line drawn in a heel-to-toe direction tangential to a rearward-most point of the thick portion(as measured along the first direction) intersects the first weight.

In some examples, the thick portionmay protrude rearwardly from the toe portionby a distance (as measured along the first direction) greater than a separation distance (as measured along the first direction) between the second weightand the rear surfaceR of the toe portion. For example, the difference between the thickness at the third positionon the thick portionand the thickness at the first positionon the toc portionmay be greater than a separation distance between a forward surface of the second weightand the rear surfaceR of the toe portion, as measured along a line parallel to the first direction and extending through the first position. In some examples, a maximum difference between a thickness of the thick portionand a thickness of the toc portionis greater than a maximum separation distance, as measured along the first direction, between the second weightand the rear surfaceR of the toe portion. In examples, a line drawn in a heel-to-toe direction tangential to a rearward-most point of the thick portion(as measured along the first direction) intersects the second weight.

is a back view of a front portionof another golf club head according to some examples. The golf club head ofmay have some features similar to, or the same as, features of the golf club headillustrated and described herein with reference to. Therefore, redundant descriptions may not be repeated.

The lower sectionof the striking facemay include the heel portion, the toe portion, and a thick portionbetween the heel and toe portionsand. The thick portionincludes a flat portionF and a tapered portionT that at least partially surrounds the flat portionF. The thickness of the flat portionF is substantially uniform across the flat portionF, and the thickness of the tapered portionT decreases, via a taper, along a direction away from the flat portionF.

In the depicted example, the thick portionand the flat portionF each has a quadrangular shape that extends from the soletoward the support bar, and the tapered portionT has a generally upside down U-like shape that surrounds three generally flat sides of the flat portionF. In the depicted example, the thick portionextends all the way to the support bar.

It will be understood that, although the terms “first”, “second”, “third”, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Thus, a first element discussed herein could be termed a second element, without departing from the spirit and scope of the present disclosure.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be understood that the terms “comprises,” “comprising,” “includes,” “including,” and similar terms, when used in this specification, specify the presence of stated elements, but do not preclude the presence or addition of one or more other elements. Further, the use of “may” when describing embodiments of the present disclosure refers to “one or more embodiments of the present disclosure.”

It will be understood that when an element is referred to as being “on”, “connected to”, “coupled to”, or “adjacent to” another element, it can be directly on, connected to, coupled to, or adjacent to the other element, or one or more intervening element(s) may be present. In contrast, when an element or layer is referred to as being “directly on,” “directly connected to”, “directly coupled to”, or “immediately adjacent to” another element, there are no intervening elements present. Similar terms and phrases should be understood in a similar manner to encompass both direct and indirect affiliations between two or more elements being discussed.

Also, any numerical range recited herein is intended to include all sub-ranges of the same numerical precision subsumed within the recited range. For example, a range of “1.0 to 10.0” is intended to include all subranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0, that is, having a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limitation recited herein is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited herein.

Although specific embodiments are described herein, the scope of the technology is not limited to those specific embodiments. Moreover, while different examples and embodiments may be described separately, such embodiments and examples may be combined with one another in implementing the technology described herein. One skilled in the art will recognize other embodiments or improvements that are within the scope and spirit of the present technology. Therefore, the specific embodiments described herein are only provided as illustrative embodiments. The scope of the technology is defined by the following claims and any equivalents therein.