Mixed material golf club head

Abstract

To provide means which maximizes discretionary weight to maximize inertia moment (MOI) of a club head and to lower / retract a center of gravity (COG).SOLUTION: A golf club head 10 includes a metallic front body 14 coupled with a rear body 16 to define a hollow structure. The metallic front body includes a strike face 30 and a surrounding frame 32 that extends rearward from a perimeter of the strike face. The rear body includes a crown member 50 and a sole member 52 coupled to the crown member. The sole member comprises a structural layer 56 of fiber reinforced composite formed from a filled thermoplastic material. The structural layer includes a plurality of apertures 66 extending through thickness of the structural layer, and a resilient layer 54 extends across each of the plurality of apertures. The structural layer and the resilient layer each include a common thermoplastic resin component, and are directly bonded to each other without using an intermediate adhesive.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of priority from U.S. Provisional Patent Application No. 62 / 342,741, filed May 27, 2016, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention generally relates to golf club heads using hybrid material configurations.

Background Art

[0003] In an ideal club design for a given total swing weight, in an effort to customize club performance, the magnitude of the structural mass is minimized (without sacrificing elasticity) so as to provide the designer with additional discretionary mass that is specially positioned. Generally, the total of all golf club head masses is the sum of the total structural mass and the total discretionary mass. Structural mass generally refers to the mass of the materials necessary to provide the club head with the structural elasticity required to withstand repeated impacts. Structural mass is highly dependent on the design and provides the designer with a relatively low level of control over a particular mass distribution. In contrast, discretionary mass is any additional mass (beyond the minimal structural requirements) that can be added to the club head design for the sole purpose of customizing the performance and / or resiliency tolerance of the club. There is a need in the art for alternative designs for all - metal golf club heads that provide means for maximizing the discretionary weight so as to maximize the moment of inertia (MOI) of the club head and lower / retreat the center of gravity (COG).

[0004] The background description provided herein is intended to clarify some of the terminology related to clubs, but it is exemplary and not meant to be limiting. Industry practices, rules set by golf organizations such as the United States Golf Association (USGA) or The R&A, and nomenclature rules can supplement this description of the terminology without departing from the scope of the present application.

Brief Description of the Drawings

[0005]

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Modes for Carrying Out the Invention

[0006] The present embodiment discussed below is directed to a club head that utilizes a rear body configuration of a hybrid material combined with a metallic striking face and a front frame structure. The rear body of the hybrid material is composed of an elastic layer of a fiber reinforced thermoplastic composite and a molded thermoplastic structural layer. Utilizing the rear body configuration of the hybrid material significantly reduces structural weight without sacrificing any design flexibility.

[0007] A further advantage of the embodiments of the rear body of the hybrid material described below is that the manufacturer has the ability to provide robust means for reintroducing discretionary mass. Such a design can be formed entirely from a filled thermoplastic resin such as polyphenylene sulfide (PPS), and using a fiber reinforced composite provides a stronger and lighter configuration over the continuous outer surface. The molded elastic layer further comprises a filled thermoplastic resin. Having a thermoplastic resin in both the elastic layer of the fiber reinforced thermoplastic composite and the molded thermoplastic structural layer provides the ability to integrally mold these materials. This provides a club head design with a unique geometry for weight savings by the thermoplastic structural layer, but also provides the manufacturing ability to incorporate a layer with rigid strength by the composite elastic layer. Overall, integrating these rear configurations of the hybrid material with a metallic striking face and a front frame structure facilitates the transfer of dynamic impact loads from the weight / weighting portion to the metallic front of the club head.

[0008] Furthermore, using a thermoplastic resin can provide several acoustic advantages not possible with other polymers. Using the thermoplastic polymer of the present configuration enables the assembled golf club head to react acoustically more closely to that of an all-metal design.

[0009] The terms "a", "an", "the", "at least one", and "one or more" are used interchangeably to indicate that there is at least one item, and multiple such items may exist unless the context clearly indicates otherwise. All values of parameters (e.g., amounts or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term "about", whether or not the term "about" actually appears before the value. "About" indicates that the stated value allows for some slight inaccuracy (some proximity to the exact value, approximately, or reasonably close to, or nigh). If the inaccuracy provided by "about" is not otherwise understood in the art in this ordinary sense, then as used herein, "about" indicates at least the variation that may arise from the normal methods of measuring and using such parameters. Additionally, the disclosure of a range includes the disclosure of all values and further divided ranges subsumed within the entire range. Each value within the range, and the endpoints of the range, are all disclosed herein as separate embodiments. The terms "comprises", "comprising", "including", and "having" are inclusive. Thus, they specify the presence of the stated items but do not preclude the presence of other items. As used herein, the term "or" includes any and all combinations of one or more of the recited items. When terms such as first, second, third, etc. are used to distinguish various items from one another, these designations are merely for convenience and do not limit the items.

[0010] The term "loft" or "loft angle" of a golf club, as described herein, represents the angle formed between the club face and the shaft as measured by any suitable loft and lie machine.

[0011] The terms "first", "second", "third", and "fourth", etc. in the detailed description and claims are used, if any, to distinguish between similar elements and are not necessarily used to describe a particular sequential or chronological order. Such terms are interchangeable under appropriate circumstances, and it should be understood that the embodiments described herein are capable of operating in sequences other than, for example, those illustrated or otherwise described herein. Moreover, the terms "comprise" and "have", and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that includes a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0012] In this specification and the claims, the terms "left", "right", "front", "back", "top", "bottom", "above", "below", and similar terms, if any, are used for illustrative purposes to generally refer to a golf club addressed on a horizontal ground surface and held at a given loft and lie angle, but are not necessarily intended to describe a permanent relative position. Such terms are interchangeable under appropriate circumstances. Thus, it should be understood that the embodiments of the apparatus, method, and / or product described herein are capable of operating in an orientation different from that shown or otherwise described herein.

[0013] The terms "connecting", "connected", "connect", and "connection" should be understood broadly and represent connecting two or more elements mechanically or otherwise. The connection (either mechanically or otherwise) can be, for example, permanent or semi-permanent, or for any length of time such as only instantaneously.

[0014] Other features and aspects will become apparent upon consideration of the following detailed description and the accompanying drawings. Before any particular embodiment of the present disclosure is described in detail, it is to be understood that the present disclosure is not limited in its application to the details of components or to the construction and arrangement thereof as set forth in the following description or as illustrated in the drawings. The present disclosure is capable of supporting other embodiments and of being practiced or carried out in various ways. It is to be understood that the description of specific embodiments is not intended to limit the present disclosure, which is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. Also, the terminology and phraseology used herein are for the purpose of description and should not be regarded as limiting.

[0015] Like reference numerals are used in the various figures to identify like or identical components. Referring to the drawings, FIG. 1 schematically shows a perspective view of a golf club head 10. In particular, the present technology relates to a wood-style head design, such as a driver, a fairway wood, or a hybrid iron.

[0016] The golf club head 10 includes a front body portion 14 (front body 14) and a rear body portion 16 (rear body 16) that are both fixed to define a substantially closed / hollow interior volume. As is conventional in wood-style heads, the golf club head 10 includes a crown 18 and a sole 20 and may generally be divided into a heel portion 22, a toe portion 24, and a center portion 26 located between the heel portion 22 and the toe portion 24.

[0017] The club head 10 generally includes a striking face 30 intended to impact a golf ball, a frame 32 that surrounds the periphery 34 of the striking face 30 and extends rearward therefrom to provide a cup-shaped profile to the club head 10, and a hosel 36 for receiving a golf club shaft or shaft adapter. The club head 10 is formed from a metal or metal alloy, preferably a lightweight metal alloy such as, for example, stainless steel or alloy steel (e.g., C300, C350, Ni (nickel)-Co (cobalt)-Cr (chromium)-alloy steel, 565 steel, AISI type 304 or AISI type 630 stainless steel), a titanium alloy (e.g., Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti15-3-3-3, Ti15-5-3, Ti185, Ti6-6-2, Ti-7s, Ti-92, or Ti-8-1-1 titanium alloy), an amorphous metal alloy, or other similar materials, in order to withstand the impact stresses that occur when the club head 10 strikes a golf ball.

[0018] To reduce the structural mass of the club head beyond what is possible with conventional metal forming techniques, the rear body 16 may be formed substantially from one or more polymeric materials and / or fiber-reinforced polymer composites. The structural weight reduction achieved by this design can be used to reduce the overall weight of the club head 10 (which can provide a higher club head speed and / or a longer carry distance), or to increase the amount of discretionary mass available for placement in the club head 10 (i.e., for a given club head weight). In a preferred embodiment, additional discretionary mass is included in the final club head design by one or more metal weights 40 coupled to the sole 20 and / or the most rearward portion of the club head 10.

[0019] Referring to FIG. 3, the rear body 16 can generally be formed by joining a crown member 50 to a sole member 52. In a preferred embodiment, the crown member 50 forms part of the crown 18 and the sole member 52 forms part of the sole 20, and they generally meet at an outer joint line where the tangent to the club head surface lies in a vertical plane (i.e., when the club head 10 is held in a neutral impact position according to a predetermined loft and lie angle), or slightly below it.

[0020] In this design, the rear body 16 can comprise a mixture of a thermoplastic material to be molded (e.g., an injection-molded thermoplastic material) and a fiber-reinforced thermoplastic composite material. As used herein, the thermoplastic material to be molded depends on the polymer itself and provides structure and rigidity to the final component. The thermoplastic material to be molded is readily adaptable to molding techniques such as injection molding, such that when heated to a temperature above the melting point of the polymer, the material flows freely. The thermoplastic material for molding with a filler material incorporated is called a filled thermoplastic (FT) material. The filled thermoplastic material is freely flowable when in a heated / melted state. To facilitate the flowable characteristics, the filler material generally comprises discrete fine particles having a maximum dimension of less than about 25 mm, or more typically less than about 12 mm. For example, the filler material can comprise discrete fine particles having a maximum dimension of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. Filler materials useful in this design may comprise, for example, glass beads or discontinuous reinforcing fibers formed from carbon, glass, or aramid polymers.

[0021] In contrast to thermoplastic materials with filler for shaping, fiber-reinforced composite (FRC) materials generally comprise one or more layers of unidirectional or multi-directional fiber fabrics that extend over a larger portion of the polymer. Unlike the reinforcing fibers that can be used in FT materials, the maximum dimension of the fibers used in FRC materials is substantially larger / longer than those used in FT materials and can have sufficient size and properties such that they can be provided as a continuous fabric separate from the polymer. When formed with a thermoplastic polymer, even though the polymer can flow freely during melting, generally the continuous fibers contained therein do not flow.

[0022] FRC materials are generally formed by arranging the fibers in a desired configuration and then impregnating the fiber material with a sufficient amount of polymer material to provide rigidity. Thus, while FT materials can have a resin content of more than about 45% by volume, or more preferably more than about 55% by volume, it is desirable for FRC materials to have a resin content of less than about 45% by volume, or more preferably less than about 35% by volume. FRC materials conventionally use a two-component thermosetting epoxy as the polymer matrix, but it is also possible to use a thermoplastic polymer as the matrix. In many cases, FRC materials are pre-treated before final manufacture, and such intermediate materials are often called prepregs. When a thermosetting polymer is used, the prepreg is partially cured in an intermediate form and the final curing is carried out after the prepreg is formed into its final shape. When a thermoplastic polymer is used, the prepreg can comprise a cooled thermoplastic matrix, which can then be heated and formed into its final shape.

[0023] Continuing to refer to FIG. 3, in an embodiment, the crown member 50 can be substantially formed from a fiber-reinforced composite material formed with a woven glass or carbon fiber reinforcement layer embedded in a polymer matrix. In such an embodiment, the polymer matrix is preferably a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. In other embodiments, instead, the crown member 50 can be formed from a filled thermoplastic material containing glass beads, or discontinuous glass, carbon, or aramid polymer fiber fillers embedded throughout a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide. Further, in other embodiments, the crown member 50 can have a hybrid material configuration including both a filled thermoplastic material and a fiber-reinforced composite material formed with a thermoplastic material, such as those described below with respect to FIGS. 9 and 10.

[0024] In the embodiment shown in FIG. 3, the sole member 52 has a hybrid material configuration including both an elastic layer 54 of a fiber-reinforced thermoplastic composite and a molded thermoplastic structural layer 56. In a preferred embodiment, the molded thermoplastic structural layer 56 can be formed from a filled thermoplastic material, for example, a thermoplastic material such as polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66, with glass beads embedded throughout, or discontinuous glass, carbon, or aramid polymer fiber fillers. The elastic layer 54 can, in that case, include a woven glass, carbon fiber, or aramid polymer fiber reinforcement layer embedded in a thermoplastic polymer matrix including, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. In a particular embodiment, the crown member 50 and the elastic layer 54 each include a woven carbon fiber fabric embedded in polyphenylene sulfide (PPS), and the structural layer 56 may include a filled polyphenylene sulfide (PPS) polymer.

[0025] Regarding the polymer composition of both the crown member 50 and the sole member 52, any filled thermoplastic resin and any fiber-reinforced thermoplastic composite material, preferably, should incorporate one or more engineering polymers that can withstand typical use and provide the benefit of weight savings with sufficiently high material strength and / or strength / weight ratio characteristics. Specifically, it is important for the design and materials that it can efficiently withstand the stress applied during impact between the strike face 30 and the golf ball, but does not substantially contribute to the total weight of the golf club head 10. Generally, preferred polymers can be characterized by a tensile strength exceeding about 60 MPa (net) at yield. Also, in the case of filled materials, it may have a tensile strength exceeding about 110 MPa at yield, or more preferably, exceeding about 180 MPa, and even more preferably, exceeding about 220 MPa. In some embodiments, suitable filled thermoplastic polymers may have a tensile strength ranging from about 60 MPa to about 350 MPa at yield. In some embodiments, these polymers can have a density in the range of about 1.15 to about 2.02, either in the filled or unfilled state. Also, preferably, it can have a melting temperature exceeding about 210 °C, or more preferably, exceeding about 250 °C.

[0026] PPS and PEEK are two exemplary thermoplastic polymers that meet the strength and weight requirements of this design. However, unlike many other polymers, the use of PPS or PEEK is further advantageous due to their unique acoustic properties. Specifically, in many situations, PPS and PEEK generally exhibit an acoustic response of a metallic sound upon impact. Therefore, this design can utilize the strength / weight benefit of the polymer by using PPS or PEEK polymers without compromising the desirable metallic club head sound upon impact.

[0027] Continuing to refer to FIG. 3, the present design uses a hybrid sole construction to take advantage of the strength-to-weight ratio benefits of FRC, as well as the design flexibility and dimensional stability / consistency provided by FT. More specifically, FRC is typically stronger and lower density than FT of the same polymer, but its strength typically depends on a smooth and continuous geometry. Conversely, FT is slightly higher density than FRC, but can form much more complex geometries and is generally stronger than FRC in intricate or discontinuous designs. These differences are thought to be largely due to the fact that FRC relies heavily on continuous fibers to provide strength, while FT relies more on the structure of the polymer itself.

[0028] Accordingly, the present design uses FT materials to locally enhance the design flexibility and / or strength and FRC materials to form most of the resilient outer shell of the sole 20 in order to maximize the strength of the design with the lowest possible structural weight. More specifically, the FT material is utilized to provide optimized selective structural reinforcement (i.e., voids / openings would otherwise compromise the strength of the FRC), to add one or more metallic swing weights 40 (i.e., FT makes it easier to attach discretionary metallic swing weights than to mold complex receiving cavities or overmold weights), and / or to provide a dimensionally consistent joint structure that facilitates the structural attachment between the crown member 50 and the sole member 52 while providing a continuous club head outer surface.

[0029] FIG. 4 more clearly shows an embodiment of the sole member 52 in a state where the FRC elastic layer 54 is joined to the FT structural layer 56. As shown, the structural layer 56 may generally include a front portion 60 and a rear peripheral portion 62 that defines the outer peripheral portion 64 of the sole member 52. In the assembled club head 10, the front portion 60 is joined to the metal front body 14, and the rear peripheral portion 62 is joined to the crown member 50. The structural layer 56 defines a plurality of openings 66 that are each located inside the peripheral portion 64 and extend through the thickness of the layer 56. Finally, the structural layer 56 may include one or more structural members 68 that extend between at least two of the plurality of openings 66 from the front portion 60.

[0030] As shown in FIG. 4 and more clearly shown in FIGS. 5 - 7, the elastic layer 54 may be joined to the outer surface 70 of the structural layer 56. Thus, it comes into direct contact with and / or overlaps at least a portion of the front portion 60, the rear peripheral portion 62, and the one or more structural members 68. When so arranged, the elastic layer 54 can completely cover each of the plurality of openings 66 when viewed from the outside of the club head 10. Similarly, the one or more structural members 68 can act as selective reinforcement to the inner portion of the elastic layer 54 similar to reinforcing ribs or gussets.

[0031] Referring to FIGS. 2-4, in some embodiments, the structural layer 56 can be adapted to receive one or more metallic weights 40 (e.g., tungsten-based swing weights, etc.) by directly adhering or incorporating weights into the formed cavities, or by providing recesses 74 that can function to receive removable metallic masses. The weighted portion 72 can be generally located toward the most rearward point on the club head 10. Thus, the weighted portion 72 can be integral with and / or directly coupled to the rear peripheral portion 62 of the structural layer 56 and spaced from the front portion 60. As described above, the filled thermoplastic construction of the structural layer 56 is particularly suitable for receiving one or more weights 40 due to its ability to form complex geometries in a structurally stable manner. More specifically, the filled thermoplastic construction of the structural layer 56 allows for the inclusion of one or more dimensional recesses in the design that are not generally possible with all FRC constructions (i.e., the strength benefits of FRC are typically only available over a continuous surface geometry). For example, as shown in FIG. 3 and more clearly shown in the cross-sectional view of FIG. 11, the weighted portion 72 can be formed to have a non-uniform thickness and define grooves or recesses that extend around corners and / or receive one or more weights that are joined to other surfaces at acute angles. All of these are difficult or impossible to precisely form using fiber-reinforced composites.

[0032] At the rear portion of the club head 10, attaching one or more weights 40 to the structural layer 56 desirably shifts the center of gravity of the club head 10 rearward and downward, and can create a cantilevered mass that is more separated from the more structural metal front body 14 while increasing the moment of inertia of the club head. Thus, in some embodiments, one or more structural members 68 may extend between the weighted portion 72 and the front portion 60 to provide a strengthened load path between the one or more weights 40 and the metal front body 14. In this way, the one or more reinforcing members 68 can serve to assist in transmitting dynamic loads between the weighted portion 72 and the front body 14 during impact between the striking face 30 and the golf ball. At the same time, these same rib-like reinforcing members 68 can strengthen the elastic layer 54 and act to increase the mode frequency of the club head during impact. Thus, the natural frequency exceeds about 3500 Hz during impact and exists without substantial attenuation by the polymer. When this surface reinforcement is combined with the desirable metallic acoustic impact characteristics of a polymer such as PPS or PEEK, the user can perceive that the club head 10 is acoustically similar to an all-metal club head, and the design can provide significantly improved mass properties (CG position and / or moment of inertia).

[0033] In a preferred embodiment, the elastic layer 54 and the structural layer 56 may be integrally joined to each other without using an intermediate adhesive. Such a configuration can simplify manufacturing, reduce problems related to component tolerances, and provide a better bond between the constituent layers than can be achieved by adhesives or other joining methods. To achieve an integral bond, each of the elastic layer 54 and the structural layer 56 may comprise a compatible thermoplastic polymer that can be thermally bonded to the polymer of the mating layer.

[0034] FIG. 8 shows an embodiment of a method 80 for manufacturing a golf club head 10 having an elastic layer 54 and a structural layer 56 integrally joined to a sole member 52. Method 80 comprises, in step 82, thermoforming a fiber-reinforced thermoplastic composite into an outer shell portion of the club head 10. The thermoforming process may comprise, for example, preheating the thermoplastic prepreg to a forming temperature that at least exceeds the glass transition temperature of the thermoplastic polymer, shaping the prepreg into the shape of the outer shell portion, and then trimming the shaped portion to size.

[0035] In step 84, after the composite outer shell portion has achieved the proper shape, a polymer support structure with a filler may be injection molded so as to be in direct contact with the outer shell. Such a process is generally referred to as insert molding. In this process, the outer shell is placed directly into a heated mold having a gated cavity that is exposed in a portion of the outer shell. Molten polymer is forced into the cavity and then is either directly mixed with the molten polymer of the heated composite outer shell or is locally joined to the softened outer shell. When the mold is cooled, the polymer of the composite outer shell and the support structure cure together in a fused relationship. The joining is improved if the polymers of the outer shell portion and the support structure are compatible and is further improved if the two components comprise a common thermoplastic resin component. Insert molding is a preferred technique for forming the structure, but other molding techniques such as compression molding may be used.

[0036] Continuing with reference to FIG. 8, through steps 82 and 84, when the sole member 52 is formed, the FRC crown member 50 is joined to the sole member 52 to substantially complete the structure of the rear body 16 (step 86). In a preferred embodiment, the crown member 50 may be formed from a thermoplastic FRC material formed into a shape using a thermoforming technique similar to that described with respect to step 82. Forming the crown member 50 from a thermoplastic composite material allows the crown member 50 to be joined to the sole member 52 using a localized welding technique. Such welding techniques can include, for example, laser welding, ultrasonic welding, or potentially resistance welding if the polymer is conductive. If the crown member 50 is formed using a thermosetting polymer, the crown member 50 may be joined to the sole member 52 using, for example, an adhesive or a mechanical fastening technique (studs, screws, posts, mechanical interference fits, etc.).

[0037] FIG. 6 schematically shows an embodiment of a joint 90 that acts to couple the crown member 50 and the sole member 52. As shown, the structural layer 56 separately receives the elastic layer 54 and the crown member 50 to form a continuous outer surface 92 (i.e., the outer surface 92 of the rear body 16 includes the outer surface 94 of the crown member 50, the outer surface 70 of the structural layer 56, and the outer surface 96 of the elastic layer 54).

[0038] Referring again to FIG. 8, at step 88, the rear body 16 comprising the fixed crown member 50 and sole member 52 can then be joined to the metal front body structure 14 with an adhesive. The adhesive adheres readily to most metals, but the process of adhering to a polymer may require the use of one or more adhesion promoters or surface treatments to enhance the bond between the adhesive and the polymer of the rear body 16.

[0039] FIG. 7 schematically shows an example of a joint interface 100 between the sole member 52 and the frame 32 of the front body 14. As shown, the joint interface 100 is similar to an overlapping joint where the structural layer 56 and / or the elastic layer 54 overlap a joint flange 102 that is recessed inward from the outer surface 104 of the frame 32. In the illustrated embodiment, the structural layer 56 may be directly bonded to the joint flange 102 with an adhesive via an intermediate adhesive 106. Also, the elastic layer 54 may extend over the entire front portion 60 of the structural layer 56 such that the outer surface 96 of the elastic layer 54 is flush with the outer surface 104 of the frame 32. By recessing the joint flange 102 as shown, the structural layer 56 and / or the elastic layer 54 can directly contact an extension wall 108 that joins the frame 32 and the flange 102, further facilitating the transfer of dynamic impact loads from the weight 40 / weight portion 72 to the frame 32.

[0040] In some embodiments, the elastic layer 54 may have a substantially uniform thickness in the range of about 0.5 mm to about 0.7 mm, about 0.5 mm to about 1.0 mm, about 0.6 mm to about 0.9 mm, or about 0.7 mm to about 0.8 mm. In some embodiments, the elastic layer 54 may have a non-uniform thickness of 0.5 mm, 0.55 mm, 0.60 mm, 0.65 mm, or 0.70 mm. In the region where the structural layer 56 abuts directly against the elastic layer 54 (i.e., the region where the elastic layer 54 is located outside the structural layer 56), the structural layer 56 of some embodiments may have a substantially uniform thickness in the range of about 0.5 mm to about 0.7 mm, about 0.5 mm to about 1.0 mm, about 0.6 mm to about 0.9 mm, or about 0.7 mm to about 0.8 mm. In some embodiments, the structural layer 56 may have a non-uniform thickness of 0.5 mm, 0.55 mm, 0.60 mm, 0.65 mm, or 0.70 mm. The substantially uniform structures of both the elastic layer 54 and the structural layer 56 are shown in FIGS. 4-7, 11. In these embodiments, the total thickness of the elastic layer 54 and the structural layer 56 may be, for example, about 1.0 mm to about 1.5 mm, about 1.0 mm to about 2.0 mm, about 1.25 mm to about 1.75 mm, or about 1.4 mm to about 1.6 mm. In some embodiments, the total thickness of the elastic layer 54 and the structural layer 56 may be 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, or 1.5 mm.

[0041] Referring again to FIGS. 3 and 6, in an embodiment, the recessed joint flange 102 may completely surround the strike face 30 and / or may extend from the frame 32 across all portions of the crown 18 and the sole 20. In this way, as shown in FIG. 6, the rear body 16 can be adhesively bonded to the front body 14 by adhering the crown member 50 to the joint flange 102.

[0042] The method 80 described with reference to FIG. 8 focuses primarily on forming a club head similar to that shown in FIG. 3 (i.e., step 82 forms the elastic layer 54 of the sole member 52 and step 84 forms the structural layer 56 of the sole member 52), but the processes described with respect to steps 82 and 84 can alternatively be used to form the crown member 50. For example, as shown in FIGS. 9 and 10, the crown member 50 may comprise one or both of an outer structural layer 110 and an inner structural layer 112 that are joined to a thermoplastic FRC elastic crown layer 114. The inner structural layer 112 can generally function in a manner similar to the structural layer 56 of the sole member 52, and the outer structural layer 110 can provide the benefit of further weight savings by concentrating the reinforcement structure in the areas that provide the most structural benefit, allowing for a thinner component thickness in the spaces between the grids. The general concept of the structural ribs will generally result in creating weight reduction zones between the ribs. These weight reduction zones can be present in the sole or the crown and are further described in U.S. Patent No. 7,361,100 and U.S. Patent No. 7,686,708, which are hereby incorporated by reference in their entirety.

[0043] Specific to the construction of the hybrid material crown member 50, a formation similar to that described above with respect to the sole member 52 can be initiated by thermoforming a fiber reinforced thermoplastic composite into the outer shell portion of the club head 10. The thermoforming process may comprise, for example, preheating the thermoplastic prepreg to a forming temperature that at least exceeds the glass transition temperature of the thermoplastic polymer, forming the prepreg into the shape of the outer shell portion, and then trimming the formed portion to size.

[0044] After the composite outer shell portion is in the proper shape, a filled polymer support structure (i.e., one or both of the inner structural layer 112 and the outer structural layer 110) may then be injection molded so as to be in direct contact with the outer shell (e.g., by insert molding as described above).

[0045] The further aerodynamic mechanisms 116, such as a turbulator, shown in FIG. 1 can be used to reduce the air resistance of the club head and increase the speed of the club. These aerodynamic mechanisms 116 are further described in U.S. Patent No. 9,555,294 (the "294" patent), which is hereby incorporated by reference in its entirety.

[0046] Referring to FIG. 2, the frame 32 may define a front sole portion 120 that abuts directly against the striking face 30. The front sole portion 120 may terminate at a rear edge 122 that mates with the rear body 16. In some embodiments, this rear edge 122 may define a section 124 that projects rearwardly within the central region 26, which has an overall convex shape and extends by an average distance D from the striking face 30 that exceeds both a first average distance d1 between the rear edge 122 and the striking face 30 in the toe region 24, and a second average distance d2 between the rear edge 122 and the striking face 30 in the heel region 22. In some configurations, the convex shape may be defined by a radius of curvature in the range of about 25 mm to about 125 mm, and an arc length in the range of about 12 mm to about 50 mm. The rearwardly projecting section 124 is generally under maximum stress and defines the boundary of the region of the sole 20 that exhibits the greatest deflection in an all-metal club head (not shown) of the same dimensions and shape compared to the exemplary embodiment. The rear edge 122 of the projecting section 124 essentially corresponds to the nodal line in the first vibration mode of the club head sole 20 and thus experiences little or no deflection during impact.

[0047] The configuration of the front sole portion 120 having the geometric shape shown ensures that the portion of the sole 20 having the highest stress concentration is formed from metal. This has the practical effect of allowing a thinner and lighter sole member 52 of the rear body 16, which requires less structural reinforcement, and further maintains a desirable major natural frequency of at least 3500H during impact, without substantial damping by the polymer. A similar geometry can be provided in the crown 18 of the club head 10 described in U.S. Patent No. 7,601,078, which is hereby incorporated by reference in its entirety.

[0048] Utilizing a hybrid material rear body configuration can provide a significant reduction in structural weight and provide a robust means for reintroducing discretionary mass without sacrificing any design flexibility. Such a design, as previously discussed, can be formed entirely from a filled thermoplastic resin such as polyphenylene sulfide (PPS), but the use of fiber-reinforced composites provides a stronger and lighter configuration over the continuous outer surface. Conversely, an all-FRC design should not be able to easily incorporate a weight-bearing structure and thus cannot easily utilize the increased discretionary mass.

[0049] Table 1 provides a mass estimate based on a comparison of the all-filled PPS configuration described above and the hybrid material design for the rear body 16 design shown in FIG. 3. As shown, the hybrid material design contributes to significant weight savings over the all-filled PPS configuration, which can be reintroduced into the weighted portion 72 to lower the center of mass and further move it rearward, enhancing the recovery tolerance and dynamic loft.

[0050]

Table 1

[0051] When all of the restored mass is repositioned to the weight portion behind the sole member 52, the hybrid material design can result in a net movement of the center of gravity that is approximately 0.008 mm lower and 0.058 mm rearward (with respect to a club head having a total mass of 205 g) when compared to a configuration of all PPS with filler.

[0052] Table 2 shows the effect of this hybrid material configuration on the moment of inertia of the club head with respect to a club head having a total mass of 205 g. Specifically, Table 2 shows, for a metal reference design having a similar outer shape, for a club head having a sole member configuration of all PPS with filler, and for a club head having the hybrid material sole member configuration described above, the club head moments of inertia about a vertical axis (I YY ) and about a horizontal axis (I XX ) extending from heel to toe are compared.

[0053]

Table 2

[0054] As shown in Table 2, this hybrid material design can result in an increase of about 6.3% in I XX with respect to a sole member club head of all PPS with filler, and an increase of about 31.8% in I XX with respect to the reference metal design. Similarly, this hybrid material design can result in an increase of about 3.3% in I YY with respect to a sole member club head of all PPS with filler, and an increase of about 6.6% in I YY with respect to the reference metal design. Thus, this hybrid material configuration results in a club head that is significantly more stable at off-center impacts than either a sole member configuration of all PPS with filler or the reference metal design. Further, the hybrid material design results in an increase of 2.5 to 3.0 times in sole strength / elasticity when compared to a configuration of all PPS with filler, and exhibits about 90% to 98% of the strength / elasticity of the all-metal reference design.

[0055] Again, as described above, these stability benefits are produced without sacrificing the impact sound quality. In particular, using PPS or PEEK thermoplastic resins can provide certain acoustic advantages not possible with other polymers. In particular, PPS or PEEK has metallic acoustic characteristics when impacted. Thus, using these polymers in the present configuration allows the assembled golf club head 10 to have an acoustic response closer to that of an all-metal design. Polyamides and some thermoplastic polyurethane materials can have sufficient strength for current designs, but using them can result in a substantially different acoustic response.

[0056] Figures 11-13 show alternative sole member designs that can be similarly used in the present golf club head configuration. For example, FIG. 11 shows an embodiment in which at least one of the plurality of reinforcing members 68 extends to a rear peripheral portion 62 away from the weight portion 72. In this embodiment, the reinforcing member 68 can resemble a "Y" extending between the front portion 60, the weight portion 72, and the rear peripheral portion 62 away from the weight portion 72. This design can further utilize a reinforced "skirt" (i.e., a reinforced band of material where the crown 18 meets the sole 20) that operably reinforces the sole and provides an additional load path from the weight portion 72.

[0057] FIG. 12 shows an embodiment of the sole member 52 in which a plurality of reinforcing members 68 extend directly from the front portion 60 of the structural layer 56 away from the weighted portion 72 to the rear peripheral portion 62. However, one reinforcing member 68 remains extending directly between the weighted portion 72 and the front portion. Further, FIG. 12 schematically shows an embodiment in which the structural layer 56 can have a non-uniform / non-sheet-like geometry. Such a configuration, at least for the reinforcing members 68, can be used equally in any of the previously shown embodiments. In embodiments having a non-uniform structural layer, such as that schematically shown in FIG. 12, some configurations can provide an elastic layer 54 with a substantially uniform thickness attributable to the properties of the fiber-reinforced composite material. This thickness can be in the range of, for example, about 0.5 mm to about 1.0 mm, about 0.6 mm to about 0.9 mm, or about 0.7 mm to about 0.8 mm. Finally, FIG. 13 shows an embodiment in which the weighted portion 72 is supported only by the rear peripheral portion 62 and the structural member 68 is not connected thereto.

[0058] The substitution of one or more claim elements constitutes a rearrangement and not a patch. Further, advantages, other advantageous points and solutions to problems have been described in relation to particular embodiments. However, advantages, other advantageous points and solutions to problems, and any one or more elements that give rise to or make apparent any advantage, advantageous point or solution, do not constitute a material, essential or essential feature or element of any or all of the claim elements, unless such advantage, advantageous point, solution or element is expressly stated in such claims.

[0059] The rules for golf are sometimes changed (for example, new rules may be applied by golf standard organizations and / or regulatory bodies such as the United States Golf Association (USGA), the Royal & Ancient Golf Club of St Andrews (R&A), etc., or old rules may be abolished or changed). Therefore, the golf supplies related to the devices, methods, and products described in this specification may or may not conform to the golf rules at any given time. Accordingly, the golf supplies related to the devices, methods, and products described in this specification may be published, sold, and / or sold as conforming or non-conforming golf supplies. The devices, methods, and products described in this specification are not limited in this regard.

[0060] The above embodiments are described in connection with iron-type golf clubs, but the devices, methods, and products described in this specification may be applicable to other types of golf clubs such as driver-type golf clubs, fairway wood-type golf clubs, hybrid-type golf clubs, iron-type golf clubs, wedge-type golf clubs, or putter-type golf clubs. On the other hand, the devices, methods, and products described in this specification may also be applicable to other types of sports equipment such as hockey sticks, tennis rackets, fishing rods, ski stocks, etc.

[0061] Furthermore, the embodiments and limitations described in this specification are not provided to the public under the doctrine of disclosure when the embodiments and / or limitations are (1) not expressly claimed in the claims and (2) equivalent or potentially equivalent to the claimed elements and / or limitations in the claims under the doctrine of equivalents.

[0062] The various features and advantages of the present disclosure are set forth in the following clauses.

[0063] (Clause 1) A golf club head comprising a metal front body having a striking face and a peripheral frame extending rearward from around the striking face, and a rear body coupled to the metal front body and defining a substantially hollow structure, the rear body comprising a crown member and a sole member coupled to the crown member, the sole member being formed of a thermoplastic material with a filler and being a structural layer joined to the crown member and having a plurality of openings extending through the thickness of the structural layer, and an elastic layer joined to the outer surface of the structural layer so as to extend across each of the plurality of openings and being formed of a fiber-reinforced thermoplastic composite material, wherein the structural layer and the elastic layer each comprise a common thermoplastic resin component, and the structural layer is directly joined to the elastic layer without using an intermediate adhesive.

[0064] (Clause 2) The structural layer further comprises a front portion in contact with and joined to the metal front body, a weighted portion spaced apart from the front portion, and a structural member extending from the front portion between the weighted portion and at least two of the plurality of openings, the structural member being integrally formed with both the front portion and the weighted portion, and the sole member further comprises a metal weight at least partially embedded in or joined with an adhesive to the weighted portion of the structural layer. The golf club head according to Clause 1.

[0065] (Clause 3) The outer surface of the rear body comprises the outer surface of the crown member, the outer surface of the elastic layer, and a part of the outer surface of the structural layer. The golf club head according to Clause 1 or 2.

[0066] (Clause 4) The metal front body further comprises a joining flange recessed inward from the outer surface of the frame, the structural layer is adhesively joined to the joining flange, and the outer surface of the elastic layer is flush with the outer surface of the frame. The golf club head according to any one of Clauses 1 to 3.

[0067] (Clause 5) The metal front body further includes an extension wall that couples the frame to the joining flange, the structural layer and the elastic layer each abut the extension wall, and the reinforcing member acts to transmit a dynamic load between the weighted portion and the extension wall during impact between the strike face and the golf ball. The golf club head according to clause 4.

[0068] (Clause 6) The common thermoplastic resin component includes polyphenylene sulfide or polyether ether ketone. The golf club head according to any one of clauses 1 to 5.

[0069] (Clause 7) The frame includes a crown portion and a sole portion, the golf club head includes a heel region, a toe region, and a center region disposed between the heel region and the toe region, and the sole portion of the frame defines a rear edge extending a first average distance from the strike face within the heel region, a second average distance from the strike face within the toe region, and a third average distance from the strike face within the center region, and the third average distance is greater than both the first average distance and the second average distance. The golf club head according to any one of clauses 1 to 6.

[0070] (Clause 8) A golf club head comprising a metal front body having a striking face and a peripheral frame extending rearward from around the striking face, and a rear body coupled to the metal front body and defining a substantially hollow structure, wherein the rear body comprises a crown member coupled to a sole member, the sole member being a structural layer that contacts and is joined to the metal front body, having a front portion and a weighted portion spaced apart from the front portion, and a plurality of openings extending through the thickness of the structural layer, wherein the front portion and the weighted portion are disposed on opposite sides of at least one of the plurality of openings, the plurality of openings, and a plurality of reinforcing members, each of the plurality of reinforcing members extending from the front portion to the weighted portion and extending between at least two of the plurality of openings, the structural layer comprising the plurality of reinforcing members, an elastic layer abutting the metal front body and joined to an outer surface of the structural layer so as to extend across each of the plurality of openings, and a metal weight at least partially embedded in or adhesively joined to the weighted portion of the structural layer, wherein the structural layer is formed from a filled thermoplastic material and the elastic layer is formed from a fiber-reinforced thermoplastic composite material, the golf club head.

[0071] (Clause 9) The golf club head according to clause 8, wherein the elastic layer is directly joined to the structural layer without using an intermediate adhesive.

[0072] (Clause 10) The golf club head according to clause 8 or 9, wherein the structural layer further comprises a rear peripheral portion extending between the weighted portion and the front portion, and the rear peripheral portion is joined to the crown member.

[0073] (Clause 11) The golf club head according to clause 10, wherein at least one of the plurality of reinforcing members extends to the rear peripheral portion away from the weighted portion.

[0074] (Clause 12) The outer surface of the rear body includes the outer surface of the crown member, the outer surface of the elastic layer, and a part of the outer surface of the structural layer, and is the golf club head according to any one of Clauses 8 to 11.

[0075] (Clause 13) The metal front body further includes a joining flange recessed inward from the outer surface of the frame, the structural layer is adhesively joined to the joining flange, and the outer surface of the elastic layer is flush with the outer surface of the frame, and is the golf club head according to any one of Clauses 8 to 12.

[0076] (Clause 14) The metal front body further includes an extension wall that couples the frame to the joining flange, each of the structural layer and the elastic layer abuts against the extension wall, and the plurality of reinforcing members act to transmit a dynamic load to the weighted portion and the extension wall during impact between the strike face and the golf ball, and is the golf club head according to Clause 13.

[0077] (Clause 15) The frame includes a crown portion and a sole portion, the golf club head includes a heel region, a toe region, and a center region disposed between the heel region and the toe region, the sole portion of the frame defines a rear edge extending a first average distance from the strike face within the heel region, a second average distance from the strike face within the toe region, and a third average distance from the strike face within the center region, and the third average distance is greater than both the first average distance and the second average distance, and is the golf club head according to any one of Clauses 8 to 14.

[0078] (Clause 16) The weighted portion and the geometric center of the strike face are located within the center region, and is the golf club head according to Clause 15.

[0079] (Clause 17) Each of the thermoplastic material with filler and the fiber-reinforced thermoplastic composite material contains a common resin component, and the common resin component is present in a first amount in the thermoplastic material with filler and in a second amount less than the first amount in the fiber-reinforced thermoplastic composite material. The golf club head according to any one of Clauses 8 to 16.

[0080] (Clause 18) The common resin component includes polyphenylene sulfide or polyether ether ketone. The golf club head according to Clause 17.

[0081] (Clause 19) The first amount exceeds about 55% by volume, and the second amount is less than about 35% by volume. The golf club head according to Clause 17 or 18.

[0082] (Clause 20) A method for manufacturing a multi-material golf club head, comprising the steps of thermoforming a first sole layer from a fiber-reinforced composite material comprising a thermoplastic resin base material and a woven fiber-reinforced layer; injection molding a second sole layer in direct contact with the thermoformed first sole layer, wherein the second sole layer comprises a thermoplastic resin with filler, and the thermoplastic resin base material and the thermoplastic resin with filler each comprise a common thermoplastic polymer; joining a crown member to the second sole layer; and joining the first sole layer and the crown member to a metal front body to define a substantially hollow structure, wherein the metal front body comprises a striking face and a hosel.

[0083] (Clause 21) The step of joining the crown member to the second sole layer comprises welding the crown member to the second sole layer by at least one of laser welding, ultrasonic welding, or electric resistance welding. The method according to Clause 21.

[0084] (Clause 22) The method further comprises forming a first crown layer by thermoforming a fiber-reinforced composite material including a thermoplastic resin base material and a woven fiber reinforcement layer, and injection molding a second crown layer in direct contact with the thermoformed first crown layer to form a crown member, wherein the second crown layer includes a filler-containing thermoplastic resin, and the thermoplastic resin base material and the filler-containing thermoplastic resin each include a common thermoplastic polymer, the method according to Clause 20 or 21.

[0085] (Clause 23) A golf club head comprising a metallic front body having a striking face and a peripheral frame extending rearward from around the striking face, and a rear body coupled to the metallic front body and defining a substantially hollow structure, the rear body including a crown member and a sole member coupled to the crown member, the crown member being formed from a filler-containing thermoplastic material and being a structural layer joined to the sole member, the structural layer including a plurality of openings extending through the thickness of the structural layer, and an elastic layer joined to the structural layer so as to extend across each of the plurality of openings, the elastic layer being formed from a fiber-reinforced thermoplastic composite material, the structural layer and the elastic layer each including a common thermoplastic resin component, the structural layer being directly joined to the elastic layer without using an intermediate adhesive, the golf club head.

Claims

1. A golf club head, A metal front body including a strike face and a peripheral frame extending rearward from a periphery of the strike face; a rear body coupled to the metallic front body to define a substantially hollow structure; The rear body includes a crown member and a sole member coupled to the crown member. The sole member is a structural layer formed from a filled thermoplastic material and bonded to the crown member, the structural layer including a plurality of openings extending through a thickness of the structural layer; a resilient layer joined to an outer surface of the structural layer so as to extend across each of the plurality of openings, the resilient layer being formed from a fiber reinforced thermoplastic composite material; the structural layer and the elastic layer each have a common thermoplastic resin component; the structural layer is bonded directly to the elastic layer without the use of an intermediate adhesive; Golf club head.

2. The structure layer further comprises: a front portion that is in contact with and joined to the metal front body; a weighted portion spaced from the forward portion; a structural member extending from the forward portion between the weighted portion and at least two of the plurality of openings, the structural member being integrally molded with both the forward portion and the weighted portion; The golf club head of claim 1 , wherein the sole member further comprises a metal weight at least partially embedded in or adhesively bonded to the weighted portion of the structural layer.

3. The golf club head of claim 1 , wherein the outer surface of the rear body comprises an outer surface of the crown member, an outer surface of the elastic layer, and a portion of the outer surface of the structural layer.

4. The metal front body further includes a joint flange recessed inwardly from an outer surface of the frame, the structural layer is adhesively bonded to the interface flange; The golf club head of claim 1 , wherein an outer surface of the elastic layer is flush with an outer surface of the frame.

5. The metal front body further includes an extension wall that connects the frame to the joint flange; the structural layer and the elastic layer each abut against the extension wall; The golf club head of claim 4 , wherein the reinforcing member acts to transfer dynamic loads between the weighted portion and the extension wall during impact between the strike face and a golf ball.

6. 2. The golf club head of claim 1, wherein the common thermoplastic resin component comprises polyphenylene sulfide or polyether ether ketone.

7. the frame includes a crown portion and a sole portion; the golf club head comprises a heel region, a toe region, and a central region disposed between the heel region and the toe region; the sole portion of the frame defines a rear edge that extends a first average distance from the strike face in the heel region, a second average distance from the strike face in the toe region, and a third average distance from the strike face in the central region; The golf club head of claim 1 , wherein the third average distance is greater than both the first average distance and the second average distance.

8. A golf club head, A metal front body including a strike face and a peripheral frame extending rearward from a periphery of the strike face; a rear body coupled to the metallic front body to define a substantially hollow structure; The rear body includes a crown member coupled to a sole member; The sole member is A structural layer, a front portion that is in contact with and joined to the metal front body; a weighted portion spaced from the forward portion; a plurality of apertures extending through a thickness of the structural layer, the forward portion and the weighted portion being disposed on opposite sides of at least one of the plurality of apertures; the structural layer comprising a plurality of reinforcing members, each of the plurality of reinforcing members extending from the forward portion to the weighted portion and extending between at least two of the plurality of openings; a resilient layer bonded to an outer surface of the structural layer so as to abut the metal front body and extend across each of the plurality of openings; a metal weight at least partially embedded or adhesively bonded to the weighted portion of the structural layer; the structural layer is formed from a filled thermoplastic material; The golf club head, wherein the elastic layer is formed from a fiber reinforced thermoplastic composite material.

9. The golf club head of claim 8 , wherein the resilient layer is bonded directly to the structural layer without the use of an intermediate adhesive.

10. the structural layer further comprising a rear peripheral portion extending between the weighted portion and the forward portion; The golf club head of claim 8 , wherein the rear peripheral portion is joined to the crown member.

11. The golf club head of claim 10 , wherein at least one of the plurality of reinforcing members extends toward the rear perimeter portion away from the weighted portion.

12. The golf club head of claim 8 , wherein the outer surface of the rear body comprises an outer surface of the crown member, an outer surface of the elastic layer, and a portion of the outer surface of the structural layer.

13. The metal front body further includes a joint flange recessed inwardly from an outer surface of the frame, the structural layer is adhesively bonded to the interface flange; The golf club head of claim 8 , wherein an outer surface of the resilient layer is flush with an outer surface of the frame.

14. The metal front body further includes an extension wall that connects the frame to the joint flange; each of the structural layer and the elastic layer abuts the extension wall; 14. The golf club head of claim 13, wherein the plurality of reinforcing members act to transfer dynamic loads to the weighted portion and the extension wall during impact between the strike face and a golf ball.

15. the frame includes a crown portion and a sole portion; the golf club head comprises a heel region, a toe region, and a central region disposed between the heel region and the toe region; the sole portion of the frame defines a rear edge that extends a first average distance from the strike face in the heel region, a second average distance from the strike face in the toe region, and a third average distance from the strike face in the central region; The golf club head of claim 8 , wherein the third average distance is greater than both the first average distance and the second average distance.

16. The golf club head of claim 15 , wherein the weighted portion and the geometric center of the strike face are located within the central region.

17. each of the filled thermoplastic material and the fiber reinforced thermoplastic composite material comprises a common resin component; 9. The golf club head of claim 8, wherein the common resin component is present in the filled thermoplastic material in a first amount and in the fiber reinforced thermoplastic composite material in a second amount that is less than the first amount.

18. 18. The golf club head of claim 17, wherein the common resin component comprises polyphenylene sulfide or polyether ether ketone.

19. the first amount being greater than about 55% by volume; The golf club head of claim 17 , wherein the second amount is less than about 35% by volume.

20. 1. A method of manufacturing a multi-material golf club head, comprising: - thermoforming a first sole layer from a fiber reinforced composite material comprising a thermoplastic resin matrix and a woven fiber reinforced layer; Injection molding a second sole layer in direct contact with the thermoformed first sole layer, the second sole layer comprising a filled thermoplastic resin, the thermoplastic resin matrix and the filled thermoplastic resin each comprising a common thermoplastic polymer; joining a crown member to the second sole layer; joining the first sole layer and the crown member to a metal forward body to define a substantially hollow construction, the metal forward body including a strike face and a hosel; A method for providing the above.

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