GOLF CLUB HAVING COMPOSITE SUBSTRATE WITH EMBEDDED INDICIA AND METHODS FOR EMBEDDING INDICIA IN COMPOSITE SUBSTRATES ON GOLF CLUBS
20260069935 ยท 2026-03-12
Assignee
Inventors
- Evan R. Greer (Peoria, AZ, US)
- David A. Higdon (Cave Creek, AZ, US)
- Jack D. Calaway (Phoenix, AZ, US)
- John A. Solheim (Phoenix, AZ, US)
Cpc classification
A63B53/022
HUMAN NECESSITIES
A63B2209/02
HUMAN NECESSITIES
A63B2053/0491
HUMAN NECESSITIES
International classification
Abstract
Golf club heads have an opening for receiving a panel with embedded indicia. The panel extends over the opening and includes a composite layer having an interior surface and an exterior surface, embedded indicium coupled to the exterior surface of the composite layer, and a resin layer covering the embedded indicium and the exterior surface of the composite layer. By contemporaneously encapsulating the indicium and composite layer, the resin layer increases durability and prevents the indicium from peeling or falling off of the sole panel upon repeated impacts of the golf club head with a golf ball.
Claims
1. A golf club head, comprising: a body comprising a strike face, a crown, a sole, a rear, a toe end, a heel end, and a skirt portion; the body further comprising a sole recessed ledge offset inwardly from an exterior surface of the sole and extending around a perimeter of a sole opening such that the sole recessed ledge defines the sole opening; a sole panel coupled to the sole recessed ledge and extending over the sole opening, the sole panel comprising: a sole panel composite layer having a sole panel interior surface and a sole panel exterior surface; a sole panel indicium coupled to the sole panel exterior surface; and a sole panel resin layer covering the sole panel indicium and the sole panel exterior surface, wherein the sole panel resin layer has a smooth outer surface.
2. The golf club head of claim 1, wherein the body further comprises a crown opening and a crown panel configured to cover the crown opening.
3. The golf club head of claim 2, wherein the crown panel comprises: a crown panel composite layer having a crown panel interior surface and a crown panel exterior surface; a crown panel indicium coupled to the crown panel exterior surface; and a crown panel resin layer covering the crown panel indicium and the crown panel exterior surface, wherein the crown panel resin layer has a smooth outer surface.
4. The golf club head of claim 1, wherein the sole panel indicium is positioned on a backing layer comprising adhesive prior to assembly of the sole panel.
5. The golf club head of claim 1, wherein the sole panel composite layer further comprises seven plies of fiber reinforced composite.
6. The golf club head of claim 1, wherein the sole panel resin layer comprises a transparent resin that maintains visibility of the sole panel indicium from an exterior of the golf club head.
7. The golf club head of claim 1, wherein the sole panel indicium has a thickness measured from an indicium top surface to an indicium bottom surface of 0.004 inch.
8. The golf club head of claim 1, wherein the sole panel indicium comprises a peripheral edge extending from an indicium top surface to an indicium bottom surface, a contour of the peripheral edge is concave, and a thickness of the peripheral edge extends outwardly from the indicium top surface to the indicium bottom surface.
9. The golf club head of claim 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is the same as the indicia material.
10. A golf club head, comprising: a body comprising a strike face, a crown, a sole, a rear, a toe end, a heel end, and a skirt portion; the body further comprising: a crown recessed ledge offset inwardly from an exterior surface of the crown and extending around a perimeter of a crown opening such that the crown recessed ledge defines the crown opening; a crown panel coupled the crown recessed ledge and extending over the crown opening, the crown panel comprising: a crown panel composite layer having a crown panel interior surface and a crown panel exterior surface; a crown panel indicium coupled to the crown panel exterior surface; and a crown panel resin layer covering the crown panel indicium and the crown panel exterior surface, wherein the crown panel resin layer has a smooth outer surface; a sole recessed ledge offset inwardly from an exterior surface of the sole and extending around a perimeter of a sole opening such that the sole recessed ledge defines the sole opening; an extension piece integral with a sole recessed ledge forward side and extending rearward to a sole recessed ledge rear side; and a sole panel coupled to the sole recessed ledge and extending over the sole opening, the sole panel comprising: a sole panel composite layer having a sole panel interior surface and a sole panel exterior surface; a sole panel indicium coupled to the sole panel exterior surface; and a sole panel resin layer covering the sole panel indicium and the sole panel exterior surface, wherein the sole panel resin layer has a smooth outer surface.
11. The golf club head of claim 10, wherein the sole panel indicium is positioned on a backing layer comprising adhesive prior to assembly of the sole panel.
12. The golf club head of claim 10, wherein the sole panel further comprises seven plies of fiber reinforced composite.
13. The golf club head of claim 10, wherein the sole panel resin layer comprises a transparent resin that maintains visibility of the indicium from an exterior of the golf club head.
14. The golf club head of claim 10, wherein the sole panel indicium has a thickness measured from an indicium top surface to an indicium bottom surface of 0.004 inch.
15. The golf club head of claim 10, further comprising an adjustable weighting system.
16. The golf club head of claim 10, further comprising an adjustable hosel feature.
17. The golf club head of claim 10, wherein the sole panel indicium comprises a peripheral edge extending from an indicium top surface to an indicium bottom surface, a contour of the peripheral edge is concave, and a thickness of the peripheral edge extends outwardly from the indicium top surface to the indicium bottom surface.
18. The golf club head of claim 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is the same as the indicium material.
19. The golf club head of claim 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is different from the indicium material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] To facilitate further description of the embodiments, the following drawings are provided in which:
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[0019] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denote the same elements.
DEFINITIONS
[0020] 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 invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
[0021] The terms couple, coupled, couples, coupling, and the like should be broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and/or otherwise.
[0022] An XYZ coordinate system of the golf club head, as described herein, is based upon the geometric center of the strike face. The golf club head dimensions as described herein can be measured based on a coordinate system as defined below. The geometric center of the strike face defines a coordinate system having an origin located at the geometric center of the strike face. The coordinate system defines an X axis 1040, a Y axis 1050, and a Z axis 1060. The X axis 1040 extends through the geometric center of the strike face in a direction from the heel to the toe of the fairway-type club head. The Y axis 1050 extends through the geometric center of the strike face in a direction from the crown to the sole of golf club head. The Y axis 1050 is perpendicular to the X axis 1040. The Z axis 1060 extends through the geometric center of the strike face in a direction from the front end to the rear end of the golf club head. The Z axis 1060 is perpendicular to both the X axis 1040 and the Y axis 1050.
[0023] The term or phrase center of gravity position or CG location can refer to the location of the club head center of gravity (CG) with respect to the XYZ coordinate system, wherein the CG position is characterized by locations along the X-axis 1040, the Y-axis 1050, and the Z-axis 1060. The term CGx can refer to the CG location along the X-axis 1040, measured from the origin point. The term CG height can refer to the CG location along the Y-axis 1050, measured from the origin point. The term CGy can be synonymous with the CG height. The term CG depth can refer to the CG location along the Z-axis 1060, measured from the origin point. The term CGz can be synonymous with the CG depth.
[0024] The XYZ coordinate system of the golf club head, as described herein defines an XY plane extending through the X axis 1040 and the Y axis 1050. The coordinate system defines XZ plane extending through the X axis 1040 and the Z axis 1060. The coordinate system further defines a YZ plane extending through the Y axis 1050 and the Z axis 1060. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the coordinate system origin located at the geometric center of the strike face. In these or other embodiments, the golf club head can be viewed from a front view when the strike face is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head can be viewed from a side view or side cross-sectional view when the heel is viewed from a direction perpendicular to the YZ plane.
[0025] The term or phrase moment of inertia (hereafter MOI) can refer to values measured about the CG. The term MOIxx can refer to the MOI measured in the heel-to-toe direction, parallel to the X'-axis 1070. The term MOIyy can refer to the MOI measured in the sole-to-crown direction, parallel to the Y-axis 1080. The term MOIzz can refer to the MOI measured in the front-to-back direction, parallel to the Z-axis 1090. The MOI values MOIxx, MOIyy, and MOIzz determine how forgiving the club head is for off-center impacts with a golf ball.
[0026] The golf club head described herein can be part of a golf club. A golf club is generally understood to comprise a golf club head, which is configured to receive either a shaft or an adjustable hosel feature 165, and a grip, which is secured to the shaft or the adjustable hosel feature 165. A driver-type golf club head, also referred to as a driver, as described herein, can be defined by specific dimensional ranges. In particular, the driver, as described with regard to the invention disclosed herein, includes a loft angle, volume, length, depth, and height within the ranges defined below.
[0027] A golf club is generally understood to comprise a golf club head 100, which is configured to receive either a shaft or an adjustable hosel feature 165 (shown in
[0028] The loft angle 10 of the driver 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.
[0029] The volume of the driver can be greater than approximately 300 cm.sup.3, greater than approximately 350 cm.sup.3, greater than approximately 400 cm.sup.3, greater than approximately 425 cm.sup.3, greater than approximately 450 cm.sup.3, greater than approximately 475 cm.sup.3, greater than approximately 500 cm.sup.3, greater than approximately 525 cm.sup.3, greater than approximately 550 cm.sup.3, greater than approximately 575 cm.sup.3, greater than approximately 600 cm.sup.3, greater than approximately 625 cm.sup.3, greater than approximately 650 cm.sup.3, greater than approximately 675 cm.sup.3, or greater than approximately 700 cm.sup.3.
[0030] The height of the driver can be greater than 2.0 inches and less than 3.0 inches, less than 2.9 inches, less than 2.8 inches, less than 2.7, or less than 2.6 inches.
[0031] The face height of the driver can be between 1.3 inches (33 mm) and 3.8 inches (71 mm).
[0032] The driver can comprise a mass between 185 grams and 225 grams. The mass of the driver can range between 185 grams and 190 grams, between 190 grams and 195 grams, between 195 grams and 200 grams, between 200 grams and 205 grams, between 205 grams and 210 grams, between 210 grams and 215 grams, between 215 grams and 220 grams, or between 220 grams and 225 grams.
[0033] A fairway-type golf club head as defined herein is a club head having particular lofts, volumes, and dimensions that can be defined by specific dimensional ranges. In particular, the fairway-type club head, as described with regard to the invention disclosed herein, includes a loft angle, volume, length, depth, height, and face height within the ranges defined below. The specified ranges below limit the fairway-type golf club head to a fairway-type club head. In other words, the fairway-type golf club head cannot be a driver type, a hybrid-type, an iron-type, or a putter-type golf club head.
[0034] The loft angle of the fairway-type club head as defined herein 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. In some embodiments, the loft angle of the fairway-type golf 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 fairway-type golf club head can be between 14 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.
[0035] The volume of the fairway-type club as described herein can be less than approximately 170 cm3, less than approximately 180 cm3, less than approximately 190 cm3, or less than approximately 200 cm3. However, the volume of the fairway-type club cannot be less than 160 cm3. In some embodiments, the volume of the fairway-type club head can be between approximately 150 cm3 to 200 cm3, between approximately 160 cm3 to 170 cm3, between approximately 160 cm3 to 180 cm3, or between approximately 170 cm3 to 190 cm3. The volume of the fairway-type club cannot be greater than 200 cm3. In one exemplary embodiment, the volume of the fairway-type club is 169 cm3.
[0036] The depth of the fairway-type golf club can be in a range of between 3.00 inches to 4.00 inches. In some embodiments, the depth can be between 3.00 inches to 3.40 inches, between 3.25 inches to 3.40 inches, between 3.30 inches to 3.50 inches, or between 3.50 inches to 4.00 inches. The depth cannot be greater than 4.00 inches.
[0037] The height of the fairway-type golf club head can be in a range of between 1.25 inches to 2.00 inches. In some embodiments, the height 164 can be between 1.25 inches to 1.50 inches, between 1.30 inches to 1.50 inches, between 1.35 inches to 1.75 inches, between 1.45 inches to 1.80 inches, or between 1.50 inches to 2.00 inches. In one exemplary embodiment, the height is 1.424 inches. The height is not greater than 2.00 inches.
[0038] The length of the fairway-type golf club head can be in a range of between 3.00 inches to 4.60 inches. In some embodiments, the length can be between 3.00 inches to 4.00 inches to 4.40 inches, between 4.25 inches to 4.40 inches, or between 4.30 inches to 4.60 inches. The length is not greater than 4.60 inches.
[0039] The face height of the fairway-type golf club head can range from 1.00 inches to 1.50 inches. In some embodiments, the face height can be between 1.00 inches to 1.25 inches, between 1.00 inches to 1.15 inches, between 1.15 inches to 1.35 inches, or between 1.15 inches to 1.50 inches.
[0040] The geometric center height of the fairway-type golf club head can range from 0.40 inch to 0.75 inch. For example, the geometric center height can be between 0.40 inch to 0.60 inch, between 0.50 inch to 0.70 inch, or between 0.65 inch to 0.75 inch.
[0041] Any one or combination of the features described herein can be applied to any wood-type golf club head, including a driver-type golf club head, a fairway wood-type golf club head, or a hybrid-type golf club head. While the present disclosure focuses on a wood-type golf club head, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of golf club heads such as an iron-type golf club head, a wedge-type golf club head, or a putter-type golf club head.
DESCRIPTION
[0042] Described herein are various embodiments of golf clubs having substrates with embedded indicia, and methods for embedding indicia within such substrates. More specifically, described herein are various embodiments of golf club heads having at least one non-metallic panel, body, body region, or other substrate having embedded indicia 150 that is contemporaneously cured within the non-metallic substrate. The non-metallic substrate can form one or more portions of the golf club head 100, such as a crown 110, sole 112, skirt 113, or panel 130 provided anywhere on the golf club head 100. The metal indicia 150 can be embedded into a non-metallic (such as composite) panel 130 of the golf club head 100. The invention described herein does not depend on adhesive alone to secure the indicia 150 to the golf club head 100. Instead, the indicia 150 can be overlaid and cured with a resin layer 140 that is contemporaneously encapsulated with a non-metallic substrate of the club head 100, increasing durability and preventing the indicia 150 from peeling or falling off. In some embodiments, the indicia 150 are entirely embedded within a resin layer 140 of the substrate such that the indicia 150 do not protrude outward, thereby allowing an exposed surface of the resin layer 140 to form a smooth, uniform outer surface of the club head 100.
[0043] As shown in
[0044] The frame 120 can be configured with openings 121 and lightweight internal supports 129 that reduce the amount of metallic material used to form the frame 120, thereby decreasing the structural mass of the frame 120. In an exemplary embodiment, the frame 120 can comprise a crown opening 122 and a sole opening 125. The frame 120 may have recessed ledges 124, 127 for locating and receiving the panels 130 during assembly. For example, a crown recessed ledge 124 can be offset inwardly from an exterior surface of the crown 110, extending around the perimeter 123 of the crown opening 122 such that the crown recessed ledge 124 defines the crown opening 122. A sole recessed ledge 128 can be offset inwardly from an exterior surface of the sole 112, extending around the perimeter 126 of the sole opening 125 such that the sole recessed ledge 128 defines the sole opening 125.
[0045] The frame 120 is formed of a frame material that is sufficiently durable to maintain structural integrity of the golf club head 100 through repeated impacts with a golf ball. Suitable frame material include metal, composite, metal-composite mixtures, or any combination thereof. The panel 130 may be formed of a panel material having a lower density than the frame material to increase discretionary mass, thereby expanding design options for CG location and MOI.
[0046] The frame 120 can comprise one or more frame materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the frame material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the frame material can be formed from C300, C350, Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, a titanium alloy, for example, but not limited to Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, or Ti-8-1-1 titanium alloy, an amorphous metal alloy, or other similar metals.
[0047] The panel 130 can be formed from a lightweight composite material, which effectively replaces portions of the body 101 that would otherwise be formed of a metallic material. For example, the midsection 114 of the body 101 typically experiences relatively low stress during impact with a golf ball. Therefore, the midsection 114 can be formed with less dense, less durable, non-metallic material without compromising the overall durability of the golf club head 100. The discretionary mass associated with lightweight panels 130 can be placed near the body perimeter 115 or used to increase the mass of any weight members provided on the club head.
[0048] In some embodiments, the panel material can be a composite formed from polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic. The composite can be either a filled thermoplastic (FT) or a fiber-reinforced composite (FRC). In some embodiments, the composite can comprise a FT bonded together with a FRC. Filled thermoplastics (FT) are typically injection molded into the desired shape. As the name implies, filled thermoplastics (FT) can comprise a thermoplastic resin and randomly-oriented, non-continuous fibers. In contrast, fiber-reinforced composites (FRCs) are formed from resin-impregnated (prepreg) sheets of continuous fibers comprising a specific prepreg thickness. Fiber-reinforced composites (FRCs) can comprise either thermoplastic or thermoset resin.
[0049] In embodiments with a resin, the resin can comprise a polyurethane (TPU) or a elastomer (TPE). For example, the resin can comprise polyphenylene sulfide (PPS), polyetheretheretherketone (PEEK), polyimides, polyamides such as PA6 or PA66, polyamide-imides, polyphenylene sulfides (PPS), polycarbonates, engineering polyurethanes, and/or other similar materials. Although strength and weight are the two main properties under consideration for the composite material, a suitable composite material may also exhibit secondary benefits, such as acoustic properties. PPS and PEEK can emit a generally metallic-sounding acoustic response when the club head 100 is impacted. The metallic-sounding acoustic response produced by a golf club head having PPS or PEEK can emulate the acoustic response of a more traditional all metal golf club head.
[0050] The reinforcing fiber can comprise carbon fibers (or chopped carbon fibers), glass fibers (or chopped glass fibers), graphene fibers (or chopped graphite fibers), or any other suitable filler material. In other embodiments, the composite material may comprise any reinforcing filler that adds strength, durability, and/or weighting.
[0051] In some embodiments, the panel material is an FRC having a plurality of plies or lamina of a uni-or multi-directional fiber fabric that extend across the polymer. Each ply or lamina comprises a thickness that is the same as the prepreg thickness. Further, each layer or lamina comprise either a unidirectional fiber fabric (UD) or a multi-directional fiber fabric (weave). In some embodiments, the plurality of plies can comprise at least five UD plies and at least one multi-directional weave ply, typically positioned as the top ply to improve the appearance of the FRC.
[0052] In one embodiment, as shown in
[0053] The composite material can have a polymer resin content between 40% to 90% by weight. In another embodiment, the composite material has a polymer resin content between 55% to 70% by weight. The composite material can have a fiber content between 10% to 60% by weight. In some embodiments, the composite material has a fiber content between 20% to 50% by weight, between 30% to 40% by weight. In some embodiments, the composite material has a fiber content of between 10% and 15%, between 15% and 20%, between 20% and 25 %, between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, or between 55% and 60% by weight.
[0054] The density of the non-metallic material (combined resin and fibers), can range from about 1.15 g/cc to about 2.02 g/cc. In some embodiments, the composite material density ranges between about 1.20 g/cc and about 1.90 g/cc, about 1.25 g/cc and about 1.85 g/cc, about 1.30 g/cc and about 1.80 g/cc, about 1.40 g/cc and about 1.70 g/cc, about 1.30 g/cc and about 1.40 g/cc, or about 1.40 g/cc to about 1.45 g/cc.
[0055] The panel 130 can comprise 10% to 80% of the club head total surface area. In some embodiments, the panel(s) 130 can comprise 10% to 20%, 20% to 30%, 30% to 40%, 40% to 50%, 50% to 60%, 60% to 70%, or 70% to 80% of the total surface area. The greater the surface area that the panel 130 covers is, the greater the amount of discretionary mass is available to reallocate to the periphery of the golf club head 100.
[0056] The panel 130 can comprise a panel thickness 139, measured from an internal surface 131a of the internal ply 131 to an external surface 137b of the external ply 137, as illustrated in
[0057] As shown in
[0058] The external surface 137b of the external layer may further comprise a recess. The recess can be configured to have complimentary geometry to the one or more indicium 150. The one or more indicium 150 can be inserted into the recess to further promote a smooth surface by not extruding out past the external surface 137b of the external layer 137.
[0059] The resin layer 140 affixes and seals advantageously the indicium 150 to the exterior ply 138. The one or more indicium 150 are completely covered and sealed by the resin layer 140. Once the resin layer 140 has been heated and cooled, it is left with a colorless and water-clear appearance allowing for the one or more indicium 150 to be visible from an exterior of the golf club head 100. The resin layer 140 can comprise an inner surface 141 and exterior surface 142. The inner surface 141 may be proximate the external layer 138 of the panel 130 or the one or more indicium 150. The resin layer inner surface 141 can comprise an uneven topography depending on whether the one or more indicium 150 is seated within the recess. The resin layer exterior surface 142 will always have a smooth topography to ensure nothing catches on the ground through impact, allowing for the one or more indicium 150 to stay embedded.
[0060] The resin layer 140 can comprise a resin layer thickness 143 measured from the inner surface 141 to the external surface 142 of the resin layer 140, as illustrated in
[0061] The resin layer 140 can comprise a resin density. In some embodiments, the resin density can be between 0.8 g/cm.sup.3 and 2.0 g/cm.sup.3. In some embodiments, the resin density can be between 0.8 g/cm.sup.3 and 0.9 g/cm.sup.3, 0.9 g/cm.sup.3 and 1.0 g/cm.sup.3, 1.0 g/cm.sup.3 and 1.1 g/cm.sup.3, 1.1 g/cm.sup.3 and 1.2 g/cm.sup.3, 1.2 g/cm.sup.3 and 1.3 g/cm.sup.3, 1.3 g/cm.sup.3 and 1.4 g/cm.sup.3, 1.4 g/cm.sup.3 and 1.5 g/cm.sup.3, 1.5 g/cm.sup.3 and 1.6 g/cm.sup.3, 1.6 g/cm.sup.3, and 1.7 g/cm.sup.3, 1.7 g/cm.sup.3 and 1.8 g/cm.sup.3, 1.8 g/cm.sup.3 and 1.9 g/cm.sup.3, and between 1.9 g/cm.sup.3 and 2.0 g/cm.sup.3. In an exemplary embodiment, the resin density is 1.21 g/cm.sup.3.
[0062] The resin layer 140 can further comprise a glass transition temperature. The glass transition temperature is the point at which amorphous solids transition from a hard, glassy, brittle state to a softer, more flexible rubbery state. In some embodiments, the glass transition temperature can be between 100 C. and 200 C. In some embodiments, the glass transition temperature can be between 100 C. and 110 C., 110 C. and 120 C., 120 C. and 130 C., 130 C. and 140 C., 140 C. and 150 C., 150 C. and 160 C., 160 C. and 170 C., 170 C. and 180 C., 180 C. and 190 C., and between 190 C. and 200 C.. In an exemplary embodiment, the glass transition temperature is 125 C..
[0063] The golf club head 100 can have a club radius of curvature. The club radius of curvature can further be broken down into a front-to-rear club radius of curvature and a heel-to-toe radius of curvature. The front-to-rear radius of curvature can be defined as the radius of curvature running between the front end 108 of the golf club head 100 and the rear end 111 of the golf club head 100. The heel-to-toe radius of curvature can be defined as the radius of curvature running between the heel end 104 of the golf club head 100 and the toe end 106 of the golf club head 100. The club radius of curvature can be measured either along the crown or along the sole. In some embodiments, the front-to-ear radius of curvature can be between 5 inches to 19 inches. In some embodiments, the front-to-rear radius of curvature can be between 5 inches and 7 inches, 7 inches and 9 inches, 9 inches and 11 inches, 11 inches and 13 inches, 13 inches and 15 inches, 15 inches and 17 inches, and between 17 inches and 19 inches. In an exemplary embodiment, the front-to rear radius of curvature is 7 inches. In another exemplary embodiment, the front-to-rear radius of curvature is 17 inches. In some embodiments, the heel-to-toe radius of curvature can be between 1.5 inches to 7.5 inches. In some embodiments, the heel-to-toe radius of curvature can be between 1.5 inches and 2.5 inches, 2.5 inches and 3.5 inches, 3.5 inches and 4.5 inches, 4.5 inches and 5.5 inches, 5.5 inches and 6.5 inches, and between 6.5 inches and 7.5 inches. In an exemplary embodiment, the heel-to-toe radius of curvature is 2.9 inches. In another exemplary embodiment, the heel-to-toe radius of curvature is 5.5 inches.
[0064] As the one or more indicium 150 are hot pressed (explained below) they can naturally match the curvature of the panel 130. To further promote the smooth exterior contour and prevent the indicia 150 from cracking during the hot pressing methods, as described below, the one or more indicium 150 can have chamfered or rounded edges 151, as illustrated in
[0065] The chamfered or rounded edges 151 can comprise a radius of curvature. The radius of curvature can be measured from the indicium top surface to the indicium bottom surface along a peripheral edge. In some embodiments, the radius of curvature can be between 0.005 inch and 0.015 inch. In some embodiments, the radius of curvature can be between 0.005 inch and 0.006 inch, 0.006 inch and 0.007 inch, 0.007 inch and 0.008 inch, 0.008 inch and 0.009 inch, 0.009 inch and 0.010 inch, 0.010 inch and 0.011 inch, 0.011 inch and 0.012 inch, 0.012 inch and 0.013, 0.013 inch and 0.014, and between 0.014 inch and 0.015. In an exemplary embodiment, the radius of curvature is 0.010 inch.
[0066] Additionally, as shown in
[0067] The extension piece 160 can be affixed to the crown recessed ledge 124 and/or sole recessed ledge 127 and extend across the corresponding opening 121. In an exemplary embodiment, the extension piece 160 can be affixed to the sole recessed ledge 127, shown in
[0068] The extension piece 160 can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the frame material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the frame material can be formed from C300, C350, Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, a titanium alloy, for example, but not limited to Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, or Ti-8-1-1 titanium alloy, an amorphous metal alloy, or other similar metals. In one exemplary embodiment, the material of the extension piece 160 and the frame 120 are the same material. In another exemplary embodiment, the material of the extension piece 160 and the frame 120 are different materials.
[0069] The one or more indicium 150 further can comprise a metallic material. The one or more indicium 150 material can be formed from steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In one embodiment, the metallic material can comprise a nickel alloy. The use of a metallic material can allow for brushing and polishing to create a high-end metallic appearance. Additionally, the metallic material has performance and mechanical properties that can reduce wear and facilitate shaping to better match the curvature of the club head 100. In one exemplary embodiment, the material of the one or more indicium 150 and the frame 120 are the same material. In another exemplary embodiment, the material of the one or more indicium 150 is different from the material of the frame 120.
[0070] The indicium 150 can comprise an indicium thickness 152, as illustrated in
[0071] The indicium 150 can cover between 10% and 95% of the composite substrate. The indicium 150 can cover more than 10%, more than 20%, more than 30%, more than 40%, more than 50%, more than 60%, more than 70%, more than 80%, or more than 90%.
[0072] Hot pressing is a high pressure, low-strain-rate powder metallurgy process for forming a structure at a temperature sufficiently high to induce sintering and creep processes. This can be achieved by the simultaneous application of both heat and pressure. In one embodiment, a single step process (hereafter referred to as the first process) includes curing the UD plies 132, 133, 134, 135, weave plies 131, 138, pure resin layer 140, and the one or more indicium 150 together in a single step process. In such embodiments, the area where the one or more indicium 150 are placed can comprise a thin non-metallic region and a constant pure resin thickness 143. In another embodiment, a two-step process (hereafter referred to as the second process) includes forming the UD plies 132, 133, 134, 135 and weave plies 131, 138 in a first step. In a second step, the one or more indicium 150 and pure resin layer 140 can be placed on top to form the substrate. In such embodiments, the area where the one or more indicium 150 are placed can comprise a constant thickness substrate and a thinner region of the pure resin layer 140. The varying thickness between the different layers can allow for all layers to combine to form a smooth outer exterior of the club head 100.
[0073] In some embodiments where there are two or more indicium 150 it can be crucial to ensure they are aligned with one another before curing, otherwise the two or more indicium 150 can appear askew and disjointed. A backing layer 155 can be used to ensure that the two or more indicium 150 are aligned before they are placed upon the panel 130. As shown in
[0074] In many further embodiments, the golf club head 100 can further comprise an adjustable weighting system 170 that provides CG adjustability, as illustrated in
EXAMPLE
A. Example 1Durability Performance of Club Head Comprising Composite Sole Panel with Embedded Indicia
[0075] The durability performance characteristics of golf club heads with various sole panel indicia embodiments were tested via an air cannon. All the sole panels were formed of the same composite layer arrangement, and all of the indicia were constructed from the same metallic material. A very basic adhesive was sued to align and maintain initial positioning of the indicia in the sole panel.
[0076] Each sole panel embodiment, however, either employed different means for adhering the indicia to the sole panel or featured different sole panel support structures. For this air cannon test, golf balls repeatedly impacted the strike face at 130 miles per hour (MPH) until the indicia exhibited signs of damage or began to peel away from the exterior surface of the sole panel. The durability comparison was made between: (1) a control sole panel attached to a sole opening and comprising indicia adhesively coupled to the exterior surface of the sole panel; (2) a sole panel attached to a sole opening and comprising adhesively coupled indicia with an external resin layer; and (3) a sole panel attached to a sole opening with an extension piece and comprising adhesively coupled indicia with an external resin layer.
[0077] Sole panel (1) exhibited the worst durability performance and sole panel (3) exhibited the greatest structural and adhesive integrity of the three sole panel embodiments. In particular, sole panel (1) exhibited sole panel cracking and indicia peeling after 200 impacts. Sole panel (2) performed better than sole panel (1) but exhibited sole cracking after 1677 impacts. Lastly, sole panel (3) exhibited the best durability performance of the three sole panel embodiments as it showed no sign of sole panel or indicia damage after 4000 impacts. As proven by the durability testing results, implementing an external resin layer over the adhered indicia contributed to better structural integrity and more reliable indicia retention (and would hold up to normal use of most golfers).
[0078] Further, incorporation of the extension piece in the sole opening with the external resin layer over the adhered indicia collectively provided sole panel (3) with a level of durability capable of withstanding repeated impacts and exceeding the performance of sole panels (1) and (2).
[0079] Clause 1. A golf club head, comprising: a body comprising a strike face, a crown, a sole, a rear, a toe end, a heel end, and a skirt portion; the body further comprising a sole recessed ledge offset inwardly from an exterior surface of the sole and extending around a perimeter of a sole opening such that the sole recessed ledge defines the sole opening; a sole panel coupled to the sole recessed ledge and extending over the sole opening, the sole panel comprising: a sole panel composite layer having a sole panel interior surface and a sole panel exterior surface; a sole panel indicium coupled to the sole panel exterior surface; and a sole panel resin layer covering the sole panel indicium and the sole panel exterior surface, wherein the sole panel resin layer has a smooth outer surface.
[0080] Clause 2. The golf club head of clause 1, wherein the body further comprises a crown opening and a crown panel configured to cover the crown opening.
[0081] Clause 3. The golf club head of clause 2, wherein the crown panel comprises: a crown panel composite layer having a crown panel interior surface and a crown panel exterior surface; a crown panel indicium coupled to the crown panel exterior surface; and a crown panel resin layer covering the crown panel indicium and the crown panel exterior surface, wherein the crown panel resin layer has a smooth outer surface.
[0082] Clause 4. The golf club head of clause 1, wherein the sole panel indicium is positioned on a backing layer comprising adhesive prior to assembly of the sole panel.
[0083] Clause 5. The golf club head of clause 1, wherein the sole panel composite layer further comprises seven plies of fiber reinforced composite.
[0084] Clause 6. The golf club head of clause 1, wherein the sole panel resin layer comprises a transparent resin that maintains visibility of the sole panel indicium from an exterior of the golf club head.
[0085] Clause 7. The golf club head of clause 1, wherein the sole panel indicium has a thickness measured from an indicium top surface to an indicium bottom surface of 0.004 inch.
[0086] Clause 8. The golf club head of clause 1, wherein the sole panel indicium comprises a peripheral edge extending from an indicium top surface to an indicium bottom surface, a contour of the peripheral edge is concave, and a thickness of the peripheral edge extends outwardly from the indicium top surface to the indicium bottom surface.
[0087] Clause 9. The golf club head of clause 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is the same as the indicia material.
[0088] Clause 10. A golf club head, comprising: a body comprising a strike face, a crown, a sole, a rear, a toe end, a heel end, and a skirt portion; the body further comprising: a crown recessed ledge offset inwardly from an exterior surface of the crown and extending around a perimeter of a crown opening such that the crown recessed ledge defines the crown opening; a crown panel coupled the crown recessed ledge and extending over the crown opening, the crown panel comprising: a crown panel composite layer having a crown panel interior surface and a crown panel exterior surface; a crown panel indicium coupled to the crown panel exterior surface; and a crown panel resin layer covering the crown panel indicium and the crown panel exterior surface, wherein the crown panel resin layer has a smooth outer surface; a sole recessed ledge offset inwardly from an exterior surface of the sole and extending around a perimeter of a sole opening such that the sole recessed ledge defines the sole opening; an extension piece integral with a sole recessed ledge forward side and extending rearward to a sole recessed ledge rear side; and a sole panel coupled to the sole recessed ledge and extending over the sole opening, the sole panel comprising: a sole panel composite layer having a sole panel interior surface and a sole panel exterior surface; a sole panel indicium coupled to the sole panel exterior surface; and a sole panel resin layer covering the sole panel indicium and the sole panel exterior surface, wherein the sole panel resin layer has a smooth outer surface.
[0089] Clause 11. The golf club head of clause 10, wherein the sole panel indicium is positioned on a backing layer comprising adhesive prior to assembly of the sole panel.
[0090] Clause 12. The golf club head of clause 10, wherein the sole panel further comprises seven plies of fiber reinforced composite.
[0091] Clause 13. The golf club head of clause 10, wherein the sole panel resin layer comprises a transparent resin that maintains visibility of the indicium from an exterior of the golf club head.
[0092] Clause 14. The golf club head of clause 10, wherein the sole panel indicium has a thickness measured from an indicium top surface to an indicium bottom surface of 0.004 inch.
[0093] Clause 15. The golf club head of clause 10, further comprising an adjustable weighting system.
[0094] Clause 16. The golf club head of clause 10, further comprising an adjustable hosel feature.
[0095] Clause 17. The golf club head of clause 10, wherein the sole panel indicium comprises a peripheral edge extending from an indicium top surface to an indicium bottom surface, a contour of the peripheral edge is concave, and a thickness of the peripheral edge extends outwardly from the indicium top surface to the indicium bottom surface.
[0096] Clause 18. The golf club head of clause 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is the same as the indicium material.
[0097] Clause 19. The golf club head of clause 1, wherein: the sole panel indicium comprises an indicium material; the body comprises a body material; and the body material is different from the indicium material.
[0098] Clause 20. The golf club head of clause 1, wherein the sole comprises a front-to-rear radius of curvature between 16.5 and 17.5 inches.
[0099] Clause 21. The golf club head of clause 1, wherein the sole comprises a heel-to-toe radius of curvature between 2.5 and 3.5 inches.
[0100] Clause 22. The golf club head of clause 1, wherein the crown comprises a front-to-rear radius of curvature between 6 and 8 inches.
[0101] Clause 23. The golf club head of clause 1, wherein the crown comprises a heel-to-toe radius of curvature between 5 and 7 inches.
[0102] Clause 24. A golf club head, comprising: a body comprising a strike face, a crown, a sole, a rear, a toe end, a heel end, and a skirt portion; the body further comprising a recessed ledge offset inwardly from an exterior surface of the sole and extending around a perimeter of an opening such that the recessed ledge defines the opening; a panel coupled to the recessed ledge and extending over the opening, the panel comprising: an exterior layer with an exterior surface; one or more indicium coupled to the exterior surface; and a resin layer covering the one or more indicium and the exterior surface, wherein the resin layer has a smooth outer surface.
[0103] Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to ocm3ur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.
[0104] Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.