GOLF CLUB HEAD HAVING MULTI-LAYERED STRIKING FACE

Abstract

A golf club head having a multi-layered striking face is disclosed herein. More specifically, the golf club head in accordance with the present invention has an external frontal face layer, an internal rear face layer, and an intermediary sandwiched face layer juxtaposed between the external frontal face layer and the internal rear face layer. The intermediary sandwiched face layer may generally be made out of a high flexural modulus polymeric material.

Claims

1. An iron type golf club head comprising: a striking face portion located at a frontal portion of said golf club head and an aft rear portion attached to said striking face portion forming an internal cavity therebetween; said striking face portion having a face center and further comprises; an external frontal face layer located at an external frontal portion of said striking face portion and having a thickness of between 0.8 mm and 1.4 mm at the face center; an internal rear face layer located at an internal rear portion of said striking face portion and having a thickness of between 0.5 mm and 1.2 mm at the face center; and an intermediary sandwiched face layer, juxtaposed between said external frontal face layer and said internal rear face layer, having an unconstrained perimeter and having a thickness of 0.8 mm and 1.2 mm at the face center; and wherein said intermediary sandwiched face layer is comprised of a polymeric material having a flexural modulus of between 30 ksi and 75 ksi.

2. The golf club head of claim 1, wherein said intermediary sandwiched face layer completely separates said external frontal face layer from said internal rear face layer and said external frontal face layer has an unconstrained external frontal face layer perimeter.

3. The golf club head of claim 1, wherein said intermediary sandwich face layer has a tensile strength to yield of between 1.5 ksi and 8 ksi.

4. The golf club head of claim 1, wherein said intermediary sandwiched face layer has a Shore D hardness of between about 55 to 75.

5. The golf club head of claim 1, wherein said intermediary sandwiched face layer has an intermediary sandwich face layer frontal surface area that is between 90 % and 99 % of an internal rear face layer frontal surface area.

6. The golf club head of claim 5, wherein said external frontal face layer has an external frontal face frontal surface area that is between 90 % and 99 % of said intermediary sandwich face layer frontal surface area.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

[0015] FIG. 1 of the accompanying drawings shows a frontal view of a golf club head in accordance with an embodiment of the present invention;

[0016] FIG. 2 of the accompanying drawings shows a toe view of a golf club head in accordance with an embodiment of the present invention;

[0017] FIG. 3 of the accompanying drawings shows a cross-sectional view of the golf club head in FIG. 2;

[0018] FIG. 4 of the accompanying drawings shows a toe view of a golf club head in accordance with an embodiment of the present invention;

[0019] FIG. 5 of the accompanying drawings shows a cross-sectional view the golf club head in FIG. 4; and

[0020] FIG. 6 of the accompanying drawings shows a cross-sectional view the golf club head in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The following detailed description describes the best currently contemplated modes of carrying out the invention. The description is not to be taken as limiting the invention, but is provided for the purpose of illustrating the general principles of the invention. The scope of the invention is best defined by the appended claims.

[0022] Various inventive features are described below and each can be used independently of one another or in combination with other features.

[0023] FIG. 1 of the accompanying drawings shows a golf club head 100 in accordance with an exemplary embodiment of the present invention. Golf club head 100 shown here may have striking face portion 110, an aft rear portion (not shown), a topline 112, a toe portion 114, a sole 116, a heel portion 118 and hosel 120. The striking face portion 110 includes a face center FC. FIG. 2 is a toe view of the golf club head in FIG. 1 and shows the striking face portion 110 and the aft rear portion 122. Furthermore, FIG. 2 illustrates the leading edge LE and the back edge BE. FIG. 3 shows a cross-sectional view of the golf club head 100 in FIGS. 1 and 2. The striking face portion 110 further comprises an external frontal face layer 124, an intermediary sandwiched face layer 126, and an internal rear face layer 128. This triple layered face improves the performance of the golf club head 100 by reducing unnecessary mass from the striking face portion 110 and as discussed below improve the interaction with a golf ball by producing more ball speed across the face. The present invention is particularly directed to the golf club head 100 comprising of a striking face portion 110 and the aft rear portion that form a hollow iron construction with an internal cavity 130 formed therein and having a multi-layer striking face portion 110.

[0024] The striking face portion 110 comprises the external frontal face layer 124 preferably formed of steel and located at an external frontal portion of the striking face portion 110. The external frontal face layer 124 has a substantially planar striking outer surface 132. More preferably, the external frontal face layer 124 is formed of a high strength steel having an Ultimate Tensile Strength of greater than 2000 MPa and more preferably greater than 2300 MPa. Most preferably, the external frontal face layer 124 is formed from AerMet 340 or the like. Moreover, it is preferred that the external frontal face layer 124 has a uniform thickness of about 0.8 mm to about 1.4 mm. Most preferably, the external frontal face layer 124 has a uniform thickness of about 0.9 mm to about 1.1 mm. This thin external frontal face layer 124 and its high strength assist in creating the high COR of the golf club head 100.

[0025] The internal rear face layer 128 is located at the internal rear portion of the striking face portion 110. The internal rear face layer 128 can be cast as a portion of the golf club head 100 or formed of sheet metal, stamped or forged to shape and welded to the golf club head body. Preferably, the internal rear face layer 128 has a thickness at face center that is between about 0.5 mm and 1.2 mm, and more preferably, between about 0.7 mm and 0.9 mm. This thin layer assist in creating the high COR of the golf club head 100. In order to reduce stresses, the internal rear face layer bottom portion 134 is thicker that the internal rear face layer at face center FC. More preferably, when measured in the vertical plane containing the face center and perpendicular to the planar striking outer surface 132, the internal rear face layer bottom portion 134 has a thickness of about 1.1 mm to 1.4 mm, and most preferably between about 1.15 mm and 1.3 mm, that is between about 20 % and 50 % greater than the internal rear face layer thickness at the face center FC. The height of the internal rear face layer bottom portion 134 BH is preferably between about 5 mm and 10 mm and is between about 10% and 15% of the face height FH, which is measured from the sole 116 to the topline 112 at face center. The internal rear face layer 128 also includes a transition portion 136 that extends between the thicker internal rear face layer bottom portion 134 and the remainder of the internal rear face layer 128. The transition portion 136 preferably has a transition height TH measured from the sole 116 toward the topline 112 of about 10 mm to 15 mm and between about 20% to 25% of the face height FH. In the most preferred embodiment, the transition height TH is approximately 70% to 100% larger than the internal rear face layer bottom portion height BH.

[0026] The striking face portion 110 is further comprised of the intermediary sandwiched face layer 126, which is juxtaposed between the external frontal face layer 124 and the internal rear face layer 128. Preferably, the intermediary sandwiched face layer 126 is completely unconstrained around its perimeter, i.e., the intermediary sandwiched face layer 126 does not sit in a cavity or is otherwise constrained on its perimeter. This helps improve the overall striking face COR. Moreover, it is preferred that the intermediary sandwiched face layer 126 has an outer surface with a frontal surface area that is less than a frontal area of the internal rear face layer. Preferably, the intermediary sandwiched face layer 126 frontal surface area is between about 90% to 99% of the frontal area of the internal rear face layer outer surface as shown best in FIG. 1. Still further, the external frontal face layer 124 has a frontal surface area that is between about 90% to 99% of the frontal surface area of the intermediary sandwiched face layer 126.

[0027] The intermediary sandwiched face layer 126 is a polymeric material having a flexural modulus within the range of about 30 ksi and 75 ksi, and more preferably, 50 ksi and 75 ksi, when measured according to ASTM D790. The high flexural modulus assists in creating a striking face portion with a very high COR. Moreover, the polymeric material preferably has a tensile strength to yield within the range of about 1.5 ksi and 8.5 ksi, and more preferably, 2 ksi and 8 ksi when measured according to ASTM D412, test method A. Still further, to keep the striking face portion from being too heavy, the specific gravity of the polymer is preferably between about 0.95 and 1.2. Preferably, the intermediary sandwiched face layer 126 is comprised of an ionomeric material, and more preferably, a blend of a sodium catalyzed ionomer with a lithium or zinc catalyzed ionomer such as those sold by Dow under the Surlyn™ brand. In another embodiment, the intermediary sandwiched face layer 126 is comprised of a thermoplastic urethane material such as Estane ETEs sold by Lubrizol. Preferably, the polymeric material also has a Shore D hardness of 55 to 75 when measured on a button according to ASTM 2240. More preferably, the polymeric material has a Shore D hardness of 60 to 70 when measured on a button. Moreover, the intermediary sandwiched face layer 126 is preferably comprised of a polymeric material having a Bayshore resilience of at least 70%, and more preferably, at least about 80% when measured according to ASTM 2632. Furthermore, the intermediary sandwiched face layer 126 preferably has a uniform face thickness of about 0.8 mm to 1.2 mm, and more preferably, between about 0.9 mm and 1.1 mm. The intermediary sandwiched face layer 126 is also preferably at least 10% thicker than the internal rear face layer thickness at the face center FC.

[0028] Referring now to FIGS. 4 and 5, the golf club head 200 of this embodiment of the invention has a frontal view that looks identical to the frontal view of the golf club head 100 as shown in FIG. 1. The striking face portion 210 includes a face center FC. FIG. 4 is a toe view and shows the striking face portion 210, the aft rear portion 222, the topline 212, the sole 216, the toe portion 214, and the hosel 220. Furthermore, FIG. 4 illustrates the leading edge LE and the back edge BE. FIG. 5 shows a cross-sectional view of the golf club head 200 in FIG. 4. The striking face portion 210 comprises an external frontal face layer 224, an intermediary sandwiched face layer 226, and an internal rear face layer 228. This triple layered face improves the performance of the golf club head 200 by reducing unnecessary mass from the striking face portion 210 and as discussed below improve the interaction with a golf ball by producing more ball speed across the face. The present invention is particularly directed to the golf club head 200 comprising of a striking face portion 210 and the aft rear portion that form a hollow iron construction with an internal cavity 230 formed therein and having a multi-layer striking face portion 210.

[0029] The striking face portion 210 comprises the external frontal face layer 224 preferably formed of steel and located at an external frontal portion of the striking face portion 210. The external frontal face layer 224 has a substantially planar striking outer surface 232. More preferably, the external frontal face layer 224 is formed of a high strength steel having an Ultimate Tensile Strength of greater than 2000 MPa and more preferably greater than 2300 MPa. Most preferably, the external frontal face layer 224 is formed from AerMet 340 or the like. Moreover, it is preferred that the external frontal face layer 224 has a first external frontal face layer thickness at the face center FC of about 0.8 mm to about 1.4 mm. Most preferably, the first external frontal face layer thickness is about 0.9 mm to about 1.1 mm. This thin external frontal face layer 224 and its high strength assist in creating the high COR of the golf club head 200. The external frontal face layer 224 has a second external frontal face layer thickness in a lower section extending up from the leading edge LE of about 0.4 mm to about 1.0 mm. Most preferably, the second external frontal face layer thickness is about 0.5 mm to about 0.7 mm.

[0030] The internal rear face layer 228 is located at the internal rear portion of the striking face portion 210. The internal rear face layer 228 can be cast as a portion of the golf club head 200 or formed of sheet metal, stamped or forged to shape and welded to the golf club head body. Preferably, the internal rear face layer 228 has a thickness at face center that is between about 0.5 mm and 1.2 mm, and more preferably, between about 0.7 mm and 0.9 mm. This thin layer assist in creating the high COR of the golf club head 200. In order to reduce stresses, the internal rear face layer bottom portion 234 is thicker than the internal rear face layer at face center FC. More preferably, when measured in the vertical plane containing the face center and perpendicular to the planar striking outer surface 232, the internal rear face layer bottom portion 234 has a thickness of about 1.1 mm to 1.4 mm, and most preferably between about 1.15 mm and 1.3 mm, that is between about 20 % and 50 % greater than the internal rear face layer thickness at the face center FC. In this embodiment, the internal rear face layer bottom portion 234 has the increased thickness on the outer surface as opposed to the inner surface on internal rear face layer 128 discussed above. Thus, this embodiment has the thinner section on the bottom portion of the external frontal face layer 224 as discussed above. The height of the internal rear face layer bottom portion 234 BH is preferably between about 5 mm and 10 mm and is between about 10% and 15% of the face height FH, which is measured from the sole 216 to the topline 212 at face center. The internal rear face layer 228 also includes a transition portion 236 that extends between the thicker internal rear face layer bottom portion 234 and the remainder of the internal rear face layer 228. The transition portion 236 preferably has a transition height TH measured from the sole 216 toward the topline 212 of about 10 mm to 15 mm and between about 20% to 25% of the face height FH. In the most preferred embodiment, the transition height TH is approximately 70% to 100% larger than the internal rear face layer bottom portion height BH.

[0031] The striking face portion 210 is further comprised of the intermediary sandwiched face layer 226, which is juxtaposed between the external frontal face layer 224 and the internal rear face layer 228. Preferably, the intermediary sandwiched face layer 226 is completely unconstrained around its perimeter, i.e., the intermediary sandwiched face layer 226 does not sit in a cavity or is otherwise constrained on its perimeter. This helps improve the overall striking face COR. Moreover, it is preferred that the intermediary sandwiched face layer 226 has an outer surface with a frontal surface area that is less than a frontal area of the internal rear face layer. Preferably, the intermediary sandwiched face layer 226 frontal surface area is between about 90% to 99% of the frontal area of the internal rear face layer as shown best in FIG. 1. Still further, the external frontal face layer 224 has a frontal area that is between about 90% to 99% of the frontal area of the intermediary sandwiched face layer 226.

[0032] The intermediary sandwiched face layer 226 is a polymeric material having a flexural modulus within the range of about 30 ksi and 75 ksi, and more preferably, 50 ksi and 75 ksi, when measured according to ASTM D790. The high flexural modulus assists in creating a striking face portion with a very high COR. Moreover, the polymeric material preferably has a tensile strength to yield within the range of about 1.5 ksi and 8.5 ksi, and more preferably, 2 ksi and 8 ksi when measured according to ASTM D412, test method A. Still further, to keep the striking face portion from being too heavy, the specific gravity of the polymer is preferably between about 0.95 and 1.2. Preferably, the intermediary sandwiched face layer 226 is comprised of an ionomeric material, and more preferably, a blend of a sodium catalyzed ionomer with a lithium or zinc catalyzed ionomer such as those sold by Dow under the Surlyn™ brand. In another embodiment, the intermediary sandwiched face layer 226 is comprised of a thermoplastic urethane material such as Estane ETEs sold by Lubrizol. Preferably, the polymeric material also has a Shore D hardness of 55 to 75 when measured on a button according to ASTM 2240. More preferably, the polymeric material has a Shore D hardness of 60 to 70 when measured on a button. Moreover, the intermediary sandwiched face layer 226 is preferably comprised of a polymeric material having a Bayshore resilience of at least 70%, and more preferably, at least about 80% when measured according to ASTM 2632. Furthermore, the intermediary sandwiched face layer 226 preferably has a uniform face thickness of about 0.8 mm to 1.2 mm, and more preferably, between about 0.9 mm and 1.1 mm. The intermediary sandwiched face layer 226 is also preferably at least 10% thicker than the internal rear face layer thickness at the face center FC.

[0033] Referring now to FIG. 6, the golf club head 300 of this embodiment of the invention looks identical to the golf club head 100 as shown in FIG. 1 and the golf club head 200 as shown in FIG. 2. The striking face portion 310 includes a face center FC. FIG. 6 is a cross-sectional view and shows the striking face portion 310, the aft rear portion 322, the topline 312, the sole 316, and the hosel 320. Furthermore, FIG. 6 illustrates the leading edge LE and the back edge BE. The striking face portion 310 comprises an external frontal face layer 324, an intermediary sandwiched face layer 326, and an internal rear face layer 328. This triple layered face improves the performance of the golf club head 300 by reducing unnecessary mass from the striking face portion 310 and as discussed below improve the interaction with a golf ball by producing more ball speed across the face. The present invention is particularly directed to the golf club head 300 comprising of a striking face portion 310 and the aft rear portion 322 that form a hollow iron construction with an internal cavity 330 formed therein and having a multi-layer striking face portion 310.

[0034] The striking face portion 310 comprises the external frontal face layer 324 preferably formed of steel and located at an external frontal portion of the striking face portion 310. The external frontal face layer 324 has a substantially planar striking outer surface 332. More preferably, the external frontal face layer 324 is formed of a high strength steel having an Ultimate Tensile Strength of greater than 2000 MPa and more preferably greater than 2300 MPa. Most preferably, the external frontal face layer 324 is formed from AerMet 340 or the like. Moreover, it is preferred that the external frontal face layer 324 has a uniform external frontal face layer thickness of about 0.8 mm to about 1.4 mm. Most preferably, the external frontal face layer thickness is about 0.9 mm to about 1.1 mm. This thin external frontal face layer 324 and its high strength assist in creating the high COR of the golf club head 300.

[0035] The internal rear face layer 328 is located at the internal rear portion of the striking face portion 310. The internal rear face layer 328 in this embodiment formed of sheet metal, stamped to an L-shape and welded to the golf club head 300 around the perimeter of the internal rear face layer 328 as shown at weld lines 340 along the topline 312, weld line 342 across the sole 316 and welds down the toe portion and heel portion (not shown). Preferably, the internal rear face layer 328 is a face insert that is welded to the aft rear portion adjacent the topline 312 and along the sole 316, between 20% and 70% of the distance from the leading edge LE to the back edge BE. Preferably, the internal rear face layer 228 has a thickness at face center that is between about 0.5 mm and 1.2 mm, and more preferably, between about 0.7 mm and 0.9 mm. This thin layer assist in creating the high COR of the golf club head 300. In order to reduce stresses, the internal rear face layer bottom portion 334 is thicker than the internal rear face layer at face center FC. More preferably, when measured in the vertical plane containing the face center and perpendicular to the planar striking outer surface 332, the internal rear face layer bottom portion 334 has a thickness of about 1.1 mm to 1.4 mm, and most preferably between about 1.15 mm and 1.3 mm. Preferably, the internal rear face layer bottom portion thickness is approximately 20% to 50% thicker than the internal rear face layer thickness at the face center FC.

[0036] In this embodiment, the internal rear face layer bottom portion 334 also has the increased thickness along the sole portion of the internal rear face layer 338 extending from the leading edge LE toward the back edge BE. The height of the internal rear face layer bottom portion 334 BH is preferably between about 5 mm and 10 mm and is between about 10% and 15% of the face height FH, which is measured from the sole 316 to the topline 312 at face center. The internal rear face layer 328 also includes a transition portion 336 that extends between the thicker internal rear face layer bottom portion 334 and the remainder of the internal rear face layer 328. The transition portion 336 preferably has a transition height TH measured from the sole 316 toward the topline 312 of about 10 mm to 15 mm and between about 20% to 25% of the face height FH. In the most preferred embodiment, the transition height TH is approximately 70% to 100% larger than the internal rear face layer bottom portion height BH. Still further, it is preferred that the height of the internal rear face layer bottom portion 334 BH and the transition height TH are greatest in the plane containing the face center FC. That is, the height of the internal rear face layer bottom portion 334 BH and the transition height TH are preferably less if measured in a plane ½ inch toward the heel portion from face center FC and ½ inch toward the toe portion from face center FC of the striking face portion 310. Preferably, the height of the internal rear face layer bottom portion 334 BH and the transition height TH are arcuate across the striking face portion 310 from the toe portion to the heel portion, with the peak being approximately at the face center FC. The sole portion of the internal rear face layer 338 preferably has a thickness that is approximate the thickness of the internal rear face layer bottom portion 334, between about 1.1 mm and 1.4 mm and preferably between 1.15 mm and 1.3 mm, and extends from the leading edge LE toward the back edge BE a distance TPD that is about 5% to 60%, and more preferably, 30% to 60%, of the total sole depth SD.

[0037] The striking face portion 310 is further comprised of the intermediary sandwiched face layer 326, which is juxtaposed between the external frontal face layer 324 and the internal rear face layer 328. Preferably, the intermediary sandwiched face layer 326 is completely unconstrained around its perimeter, i.e., the intermediary sandwiched face layer 326 does not sit in a cavity or is otherwise constrained on its perimeter. This helps improve the overall striking face COR. Moreover, it is preferred that the intermediary sandwiched face layer 326 has an outer surface with a frontal surface area that is less than a frontal surface area of the internal rear face layer. Preferably, the intermediary sandwiched face layer 326 frontal surface area is between about 90% to 99% of the frontal surface area of the internal rear face layer as shown best in FIG. 1. Still further, the external frontal face layer 324 has a frontal surface area that is between about 90% to 99% of the frontal surface area of the intermediary sandwiched face layer 326.

[0038] The intermediary sandwiched face layer 326 is a polymeric material having a flexural modulus within the range of about 30 ksi and 75 ksi, and more preferably, 50 ksi and 75 ksi, when measured according to ASTM D790. The high flexural modulus assists in creating a striking face portion with a very high COR. Moreover, the polymeric material preferably has a tensile strength to yield within the range of about 1.5 ksi and 8.5 ksi, and more preferably, 2 ksi and 8 ksi when measured according to ASTM D412, test method A. Still further, to keep the striking face portion from being too heavy, the specific gravity of the polymer is preferably between about 0.95 and 1.2. Preferably, the intermediary sandwiched face layer 326 is comprised of an ionomeric material, and more preferably, a blend of a sodium catalyzed ionomer with a lithium or zinc catalyzed ionomer such as those sold by Dow under the Surlyn™ brand. In another embodiment, the intermediary sandwiched face layer 326 is comprised of a thermoplastic urethane material such as Estane ETEs sold by Lubrizol. Preferably, the polymeric material also has a Shore D hardness of 55 to 75 when measured on a button according to ASTM 2240. More preferably, the polymeric material has a Shore D hardness of 60 to 70 when measured on a button. Moreover, the intermediary sandwiched face layer 326 is preferably comprised of a polymeric material having a Bayshore resilience of at least 70%, and more preferably, at least about 80% when measured according to ASTM 2632. Furthermore, the intermediary sandwiched face layer 326 preferably has a uniform face thickness of about 0.8 mm to 1.2 mm, and more preferably, between about 0.9 mm and 1.1 mm. The intermediary sandwiched face layer 326 is also preferably at least 10% thicker than the internal rear face layer thickness at the face center FC.

[0039] Other than in the operating example, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, moment of inertias, center of gravity locations, loft, draft angles, various performance ratios, and others in the aforementioned portions of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear in the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the above specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0040] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.

[0041] It should be understood, of course, that the foregoing relates to exemplary embodiments of the present invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.