Mixed material golf club head

Abstract

To provide a golf club head that comprises a mixed material rear body in combination with a metallic front body.SOLUTION: A hollow golf club head includes a metallic front body coupled with a composite rear body. The front body includes a strike face and a surrounding frame that extends rearward from a perimeter of the strike face. The rear body includes a crown member coupled to a sole member. The sole member comprises a structural layer formed from a filled thermoplastic material, and a resilient layer is bonded to an external surface of the structural layer and formed from a fiber-reinforced thermoplastic composite material. The resilient layer has an opening through which a metallic weight pad at least partially extends. The weight pad is bonded to the structural layer and includes an aperture for attaching a metallic weight.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This Agreement claims the benefit of U.S. Provisional Application No. 62 / 779,335, filed December 13, 2018, the contents of which are incorporated herein by reference in their entirety. Additionally, it is a continuation-in-part of U.S. Patent Application No. 16 / 380,873, filed April 10, 2019, the contents of which are incorporated herein by reference in their entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to golf club heads having mixed material construction. [Background technology]

[0003] Generally, there are many important physical parameters (i.e., volume, mass, etc.) that affect the overall performance of a golf club head. One of the most important physical parameters is the total mass of the golf club head. The total mass of a golf club head is the sum of the total structural mass and the total discretionary mass. Structural mass generally refers to the mass of material required to provide the club head with the structural resilience necessary to withstand repeated impacts. Structural mass is highly design-dependent, offering designers relatively little control over the specific mass distribution. Conversely, discretionary mass is any additional mass (beyond the minimum structural requirements of the golf club head) that may be added to a club head design for the sole purpose of customizing the club's performance and / or forgiveness. There is a need in the art for an alternative design for all-metal golf club heads to provide a means to maximize discretionary weight to maximize the club head's moment of inertia (MOI) and bottom / rear center of gravity (CG). [Brief explanation of the drawings]

[0004] FIELD OF THE DISCLOSURE The present disclosure relates generally to sports equipment, and more particularly to golf club heads and related methods. [Figure 1] 1 shows a bottom view of a mixed material golf club head. [Figure 2]2 shows a top view of the golf club head of FIG. 1. [Figure 3] 2 shows a rear view of the golf club head of FIG. 1. [Figure 4] 2 shows an exploded view of the golf club head of FIG. 1. [Figure 5] FIG. 2 is a front view of the golf club head of FIG. 1. [Figure 6] 2 is a rear plan view of the front body of the golf club head of FIG. 1. [Figure 7] 2 shows a rear view of the front body of the golf club head of FIG. 1. [Figure 8] 2 shows an exploded view of the front body and rear body of the golf club head of FIG. 1. [Figure 9] 2 shows a cross-sectional view of the golf club head of FIG. 1. [Figure 10] 2 shows an enlarged view of the weight pad and weight in the golf club head of FIG. 1. [Figure 11] 2 shows an assembly diagram of the weights, fasteners, and washers in the golf club head of FIG. 1. FIG. [Figure 12] 2 shows an internal view of the rear body of the golf club head of FIG. 1. [Figure 13] 2 shows another internal view of the rear body of the golf club head of FIG. 1. [Figure 14] 2 is a schematic flowchart showing a method for manufacturing the golf club head of FIG. 1.

[0005] Other aspects of the present disclosure will become apparent by consideration of the detailed description and accompanying drawings. DETAILED DESCRIPTION OF THE INVENTION

[0006] Described herein is a golf club head with a mixed-material rear body combined with a metal front body. The golf club head includes a striking face and a perimeter frame. The mixed-material rear body is composed of a fiber-reinforced thermoplastic composite elastic layer, a molded thermoplastic structural layer, a metal weight pad, and a metal weight secured within the metal weight pad. The mixed-material rear body structure provides a significant reduction in structural mass, allowing for improved distribution of discretionary mass, and therefore improved MOI and CG of the golf club head.

[0007] In the description and claims, the terms "first," "second," "third," "fourth," etc., if any, are used to distinguish between similar elements and are not necessarily used to describe a particular sequence or chronological order; it should be understood that terms so used are interchangeable under appropriate circumstances; for example, the embodiments described herein may operate in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprise," "have," and any variations thereof are intended to cover an exclusive inclusion; a process, method, system, article, device, or apparatus comprising a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent in such process, method, system, article, device, or apparatus.

[0008] The terms "left," "right," "front," "rear," "top," "bottom," "upper," "lower," etc. in the specification and claims, if any, are used for descriptive purposes and not necessarily to describe permanent relative positions. It should be understood that terms so used are interchangeable under appropriate circumstances, such that embodiments of the apparatus, methods, and / or articles of manufacture described herein can, for example, operate in other orientations other than those illustrated or otherwise described herein.

[0009] Before any embodiments of the present disclosure are described in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or carried out in various ways.

[0010] Various embodiments of golf heads having mixed-material construction are described herein. The mixed-material construction includes a metal front body and a mixed-material rear body. One embodiment of the club head includes a composite rear body with a metal weight pad. In these or other embodiments, the rear body of the club head can include a fiber-reinforced thermoplastic composite resilient layer, a molded thermoplastic structural layer, and a metal weight secured within the metal weight pad. In another embodiment, the rear body of the club head can include a composite crown and sole with a metal weight secured within the metal weight pad. In many embodiments, the golf club head can be a wood-type golf club head (i.e., driver, fairway wood, hybrid).

[0011] In some embodiments, the club head may include a driver. In these examples, the loft angle of the club head may be less than about 16 degrees, less than about 15 degrees, less than about 14 degrees, less than about 13 degrees, less than about 12 degrees, less than about 11 degrees, or less than about 10 degrees. Further, in these examples, the volume of the club head may be greater than about 400 cc, greater than about 425 cc, greater than about 450 cc, greater than about 475 cc, greater than about 500 cc, greater than about 525 cc, greater than about 550 cc, greater than about 575 cc, greater than about 600 cc, greater than about 625 cc, greater than about 650 cc, greater than about 675 cc, or greater than about 700 cc. In some embodiments, the club head volume can be between about 400cc and 600cc, between 425cc and 500cc, between about 500cc and 600cc, between about 500cc and 650cc, between about 550cc and 700cc, between about 600cc and 650cc, between about 600cc and 700cc, or between about 600cc and 800cc.

[0012] In some embodiments, the club head may comprise a fairway wood. In these examples, the loft angle of the club head may be less than about 35 degrees, less than about 34 degrees, less than about 33 degrees, less than about 32 degrees, less than about 31 degrees, or less than about 30 degrees. Further, in these examples, the loft angle of the club head may be greater than about 12 degrees, greater than about 13 degrees, greater than about 14 degrees, greater than about 15 degrees, greater than about 16 degrees, greater than about 17 degrees, greater than about 18 degrees, greater than about 19 degrees, or greater than about 20 degrees. For example, in some embodiments, the loft angle of the club head may be between 12 and 35 degrees, between 15 and 35 degrees, between 20 and 35 degrees, or between 12 and 30 degrees.

[0013] In embodiments in which the club head comprises a fairway wood, the volume of the club head can be less than about 400 cc, less than about 375 cc, less than about 350 cc, less than about 325 cc, less than about 300 cc, less than about 275 cc, less than about 250 cc, less than about 225 cc, or less than about 200 cc. In these embodiments, the volume of the club head can be between about 150 cc and 200 cc, between about 150 cc and 250 cc, between about 150 cc and 300 cc, between about 150 cc and 350 cc, between about 150 cc and 400 cc, between about 300 cc and 400 cc, between about 325 cc and 400 cc, between about 350 cc and 400 cc, between about 250 cc and 400 cc, between about 250 cc and 350 cc, or between about 275 cc and 375 cc.

[0014] In some embodiments, the club head may comprise a hybrid. In these examples, the loft angle of the club head may be less than about 40 degrees, less than about 39 degrees, less than about 38 degrees, less than about 37 degrees, less than about 36 degrees, less than about 35 degrees, less than about 34 degrees, less than about 33 degrees, less than about 32 degrees, less than about 31 degrees, or less than about 30 degrees. Further, in these examples, the loft angle of the club head may be greater than about 16 degrees, greater than about 17 degrees, greater than about 18 degrees, greater than about 19 degrees, greater than about 20 degrees, greater than about 21 degrees, greater than about 22 degrees, greater than about 23 degrees, greater than about 24 degrees, or greater than about 25 degrees.

[0015] In embodiments where the club head comprises a hybrid, the volume of the club head is less than about 200 cc, less than about 175 cc, less than about 150 cc, less than about 125 cc, less than about 100 cc, or less than about 75 cc. In some embodiments, the volume of the club head can be between about 100 cc and 150 cc, between about 75 cc and 150 cc, between about 100 cc and 125 cc, or between about 75 cc and 125 cc.

[0016] 1-10 illustrate an embodiment of a golf club head 100 having a metal front body 104 and a rear body 108. The front body 104 and rear body 108 are secured together to define a substantially closed / hollow interior volume. Similar to a wood-style golf head, the golf club head 100 includes a crown 112 and a sole 116, which can be divided into a heel region 124 and a toe region 128.

[0017] In some embodiments, golf club head 100 includes a metal front body 104 and a composite rear body 108, the rear body including a woven fiber reinforced thermoplastic elastomeric layer 148, a molded thermoplastic structural layer 152, and a metal weight pad 156. The combination of woven fiber reinforced thermoplastic elastomeric layer 148 and molded thermoplastic structural layer 152 allows for structural mass savings compared to a similar club head made entirely from metal.

[0018] The structural weight savings achieved by using the resilient layer 148 and the structural layer 152 can be used to either reduce the overall weight of the club head 100 (which may provide faster club head speeds and / or longer strike distances) or to increase the amount of discretionary mass available to place on the golf club head 100. In one embodiment, the additional discretionary mass gained from using the composite resilient layer 148 and the composite structural layer 152 can be reintroduced into the club head 100 in the form of a metal weight pad 156. The combination of the lightweight composite rear body 108 and the metal weight pad 156 allows the club head 100 to allocate the majority of the club head's mass to a location that maximizes MOI and CG, leading to more forgiveness and longer shots.

[0019] I. Front body 4-7 , the front body 104 of the club head 100 includes a striking face 120 for striking a golf ball. The front body 104 includes a perimeter frame 136 extending rearward from a perimeter 140 of the striking face 120 to give the front body 104 a cup-like appearance. The perimeter frame 136 has an inner surface 170 and an outer surface 172. Additionally, the perimeter frame 136 may include a flange 174 to provide a mounting surface connecting the front body 104 and the rear body 108. When the front body 104 is mated with the rear body 108, the outer surface 172 of the front body 104 forms a portion of the crown 112 and a portion of the sole 116 of the club head 100. The front body 104 further includes a hosel 144 for receiving a golf club shaft or shaft adapter in the heel region 124 of the golf club head 100.

[0020] In some embodiments, the strike face 120 and the surrounding frame 136 can be integrally formed. In other embodiments, the strike face 120 and the surrounding frame 136 may be formed separately and joined together. In one embodiment, the strike face 120 is forged and the surrounding frame 136 is cast, and then the strike face 120 and the surrounding frame 136 are joined via welding, brazing, plasma welding, low-power laser welding, forging, or another suitable joining technique.

[0021] In many embodiments, the front body 104 is made from a metallic material to withstand repeated impact stresses from hitting a golf ball. In some embodiments, the front body 104 may be formed from stainless steel, titanium, aluminum, a steel alloy (e.g., 455 steel, 475 steel, 431 steel, 17-4 stainless steel, maraging steel), a titanium alloy (e.g., Ti 7-4, Ti 6-4, T-9S), an aluminum alloy, or a composite material. In some embodiments, the strike face 120 of the golf club head 100 may include stainless steel, titanium, aluminum, a steel alloy (e.g., 455 steel, 475 steel, 431 steel, 17-4 stainless steel, maraging steel), a titanium alloy (e.g., Ti 7-4, Ti 6-4, T-9S), an aluminum alloy, an amorphous metal alloy, or a composite material.

[0022] The forward body 104 includes a mass. In some embodiments in which the strike face 120 and the surrounding frame 136 are separate, the mass of the forward body 104 is the sum of the mass of the strike face 120 and the mass of the surrounding frame 136. Depending on the material from which the forward body 104 is made, the mass of the forward body 104 can range from 40 grams to 140 grams. In most embodiments, the mass of the forward body 104 does not exceed 140 grams. In some embodiments, the mass of the forward body 104 can range from 40 to 50 grams, 50 to 60 grams, 60 to 70 grams, 70 to 80 grams, 80 to 90 grams, 90 to 100 grams, 100 to 110 grams, 110 to 120 grams, 120 to 130 grams, or 130 to 140 grams.

[0023] a. Strike surface 5, 6, and 9, the front body 104 of the golf club head 100 includes a strike face 120 positioned to strike a golf ball. The strike face 120 includes a center point 160, a loft plane 164, and a neutral plane 168. The center point 160 is equidistant from the crown 112 and the sole 116 of the club head 100 and is equidistant from the edge of the face closest to the toe region 128 and the edge of the strike face 120 closest to the heel region 124. The loft plane 164 is tangent to the center point 160 of the strike face 120 of the club head 100. The loft plane 164 intersects with the ground plane 180.

[0024] The strike face 120 of the club head 100 includes a thickness measured as the distance between the strike face 120 and the inner surface 170 of the front body 104. The thickness of the strike face 120 varies at different locations defining a variable face thickness (VFT) or variable thickness profile 196. The variable thickness profile 196 has a central region 192 and a peripheral region 188. In many embodiments, the central region 192 of the variable thickness profile 196 includes an elliptical, oval, oval, or oval-like shape. The central region 192 is generally oval and extends from a portion of the strike face 120 near the sole 116 and heel region 124 to a portion of the strike face 120 near the toe region 128 and crown 112.

[0025] Referring to FIG. 6 , the central region 192 is positioned such that the center point 160 of the strike face 120 is located within the central region 192, or spans or is near the center point 160 of the strike face 120. The central region 192 comprises the maximum thickness of the strike face 120. In many embodiments, the thickness of the central region 192 is substantially constant. The peripheral region 188 is disposed around the perimeter 140 of the strike face 120 and comprises the minimum thickness of the strike face 120. In many embodiments, the thickness of the peripheral region 188 is substantially constant. The thickness of the strike face 120 in the central region 192 is greater than the thickness of the strike face 120 in the peripheral region 188. The transition region 190 is disposed between the central region 192 and the peripheral region 188. The transition region 190 comprises a varying thickness that forms a transition between the central region 192 and the peripheral region 188.

[0026] Additionally, strike face 120 generally includes a major axis 184 that extends in a direction from heel 124 to toe 128. Major axis 184 intersects center point 160 and forms an angle β with the ground plane. In many embodiments, major axis 184 reflects the oval shape of central region 192.

[0027] The major axis 184 forms an angle of approximately 20 degrees with the ground plane 180. For example, the angle formed between the major axis 184 of the central region 192 and the ground plane 180 can vary from 0 degrees to 60 degrees. In some embodiments, the angle formed between the major axis 184 of the central region 192 and the ground plane 180 can vary from 2 to 20 degrees, 2 to 30 degrees, 5 to 40 degrees, 10 to 50 degrees, or 15 to 60 degrees. In other embodiments, the major axis 184 may form an angle of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, or 60 degrees with respect to the contact patch 180. Positioning the central region 192 at an angle further allows the elongated portion of the oval shape to extend upward toward the toe of the strike face 120, where a higher CT value exists, resulting in improved ball speed.

[0028] The elliptical, oval, or oval shape, along with the angle of the central region 192 of the variable thickness profile 196, allows thicker regions of the strike face 120 to be located in areas having essentially high CT and thinner regions of the strike face 120 to be located in areas having essentially low CT, thus decreasing the areas of the surface having essentially high CT and increasing the areas of the surface having essentially low CT, resulting in a normalized CT across the strike face 120. In many embodiments, the variable thickness profile 196 results in a characteristic time range of less than 115 microseconds (μs), less than 110 μs, less than 105 μs, less than 100 μs, less than 95 μs, less than 90 μs, or less than 85 μs. Additionally, in many embodiments, the variable thickness profile 40 results in an average characteristic time of greater than 230 μs, greater than 235 μs, or greater than 240 μs. For example, in many embodiments, the average CT of the face plate 20 may be between 230 μs and 240 μs, between 235 μs and 240 μs, or between 240 μs and 245 μs.

[0029] Additionally, because the angled VFT is designed to position the thicker portion of the strike face 120 in areas where it is needed, the strike face 120 can receive a weight reduction compared to a strike face without the variable thickness profile 196 described herein. Any excess weight can be reintroduced to other areas of the club head to manipulate the club head's center of gravity location, increase the club head's moment of inertia, and further improve club head performance. In the illustrated embodiment, the club head 100 with the variable thickness profile 196 as described herein saves 2.1 grams of weight compared to a similar club head lacking the variable thickness profile 196.

[0030] b.Hosel The front body 104 of the golf club head 100 includes a hosel 144. The hosel 144 includes a hosel axis 176 that extends along the center of the bore of the hosel 144. Referring to FIGS. 3 and 6, in this example, the hosel coupling mechanism of the golf club head 100 includes the hosel 144 and a shaft sleeve (not shown), which can be coupled to the end of a golf shaft (not shown). The shaft sleeve can be coupled to the hosel 144 in multiple configurations, thereby securing the golf shaft to the hosel 144 at multiple angles relative to the hosel axis 176. However, there may be other examples in which the shaft can be non-adjustably secured to the hosel 144. In the illustrated embodiment, the hosel axis 176 is at an angle α relative to the ground plane 12 in a front view of the golf club head 10 (FIG. 1). While the illustrated angle α is approximately 60 degrees, in other configurations, the angle α may be approximately 40 to 80 degrees (e.g., approximately 40 degrees, approximately 45 degrees, approximately 50 degrees, approximately 55 degrees, approximately 60 degrees, approximately 65 degrees, approximately 70 degrees, approximately 75 degrees, or approximately 80 degrees).

[0031] Additionally, the hosel axis 176 and the main axis 184 form an angle Θ. In many embodiments, the angle Θ formed between the hosel axis 176 and the main axis 184 can be in the range of 60 to 140 degrees. In most examples, the minimum angle Θ formed between the hosel axis 176 and the main axis 184 is approximately 60 degrees. In some embodiments, the angle Θ formed between the hosel axis 176 and the main axis 184 can be in the range of 60 to 70 degrees, 70 to 80 degrees, 80 to 90 degrees, 90 to 100 degrees, 100 to 110 degrees, 110 to 120 degrees, 120 to 130 degrees, or 130 to 140 degrees. In one embodiment, the angle Θ formed between the hosel axis 176 and the main axis 184 can be in the range of 80 to 90 degrees.

[0032] c. Surrounding frame The front body 104 of the golf club head 100 includes a perimeter frame 136 that extends rearwardly from the entire perimeter 140 of the striking face 120. The perimeter frame 136 further includes a flange 174 that operates to connect the front body 104 and the rear body 108.

[0033] The flange 174 provides a surface for achieving a lap joint onto which the aft body 108 can be attached. The flange 174 extends rearward from the entire perimeter frame 136, forming a step-type structure downward from the outer surface 172 of the perimeter frame 136. In many embodiments, the flange 174 of the forward body 104 allows the aft body to lap over the flange 174 and be joined to the forward body 104 by epoxy, adhesive, welding, bonding, laser-assisted metal-to-plastic welding, brazing, or any other suitable attachment method. The lap joint style flange 174 also allows the forward body 104 and aft body 108 to fit securely together without the use of any mechanical fasteners.

[0034] Additionally, the perimeter frame 136 includes an outer surface 172 and an inner surface 170 on which additional aerodynamic features can be positioned to improve the overall speed of the golf club head. The perimeter frame 136 of the front body 104 of the golf club head 100 can include additional aerodynamic features, such as turbulence wings 200. The turbulence wings 200 can be used to reduce club head drag and increase club 100 speed. These turbulence wings 200 are further described in U.S. Patent No. 9,555,294, which is incorporated by reference in its entirety.

[0035] II. Rear body 4 and 8-13, the rear body 108 of the club head 100 includes a crown member 204, a sole member 208, and a weight pad 212. The crown member 204 and the sole member 208 are coupled to each other to form a portion of the crown 112 and the sole 116 of the golf club head 100. When the front body 104 and the rear body 108 are joined, the outer surface 172 of the front body 104, the crown member 204, and the sole member 208 form the entire crown 112 and the sole 116 of the golf club head 100. The sole member 208 of the rear body 108 may further include a composite elastic layer 152, a composite structural layer 156, and a metal weight pad 212.

[0036] In the present design, the rear body 108 can include a blend of molded thermoplastic materials (e.g., injection-molded thermoplastic materials) and fiber-reinforced thermoplastic composite materials. As used herein, a molded thermoplastic material is one that relies on the polymer itself to provide structure and rigidity to the final component. A molded thermoplastic material is one that is readily adapted to molding techniques, such as injection molding, whereby the material is freely flowable when heated to a temperature above the melting point of the polymer. A molded thermoplastic material blended with a filler material is referred to as a filled thermoplastic (FT) material. A filled thermoplastic material is freely flowable when in a heated / molten state. To promote flow characteristics, the filler material generally includes discrete particles with a maximum dimension of less than about 25 mm, or more commonly less than about 12 mm. For example, the filler material can include discrete 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 the present design can include, for example, glass beads or discontinuous reinforcing fibers formed from carbon, glass, or aramid polymers.

[0037] In contrast to molded and filled thermoplastic materials, fiber-reinforced composite (FRC) materials generally contain one or more layers of unidirectional or multidirectional fiber fabrics that extend across a larger portion of the polymer. Unlike the reinforcing fibers that may be used in FT materials, the maximum dimensions of the fibers used in FRC may be substantially larger / longer than those used in FT materials and may have sufficient size and properties so that they can be provided as a continuous fabric separate from the polymer. When formed with thermoplastic polymers, the continuous fibers contained therein are generally not flowable, even if the polymer is freely flowable when melted.

[0038] FRC materials are generally formed by arranging fibers in a desired configuration and then impregnating the fiber material with a sufficient amount of polymer material to provide rigidity. In this manner, FRC materials can have a resin content greater than about 45% by volume, or more preferably greater than about 55% by volume, while FRC materials desirably have a resin content less than about 45% by volume, or more preferably less than about 35% by volume. FRC materials traditionally use two-part thermosetting epoxies as the polymer matrix, but it is also possible to use thermoplastic polymers as the matrix. Often, FRC materials are pre-prepared before final manufacturing; such intermediate materials are often referred to as prepregs. When thermosetting polymers are used, the prepregs are partially cured in an intermediate form, with final curing occurring once the prepregs are formed into their final shape. When thermoplastic polymers are used, the prepregs may include a cooled thermoplastic matrix, which can then be heated and molded into their final shape. This technique allows for the creation of complex, lightweight shapes, such as the rear body 108, without sacrificing strength.

[0039] a. Crown member 4 and 9 , the crown member 204 includes an outer surface 206 such that, when the rear body 108 and the front body 104 are joined, the outer surface 206 of the crown member 204 and the outer surface 172 of the perimeter frame 136 form the entire crown 112 of the golf club head 100. The outer surface 206 of the crown member 204 includes a generally curved shape that is concave relative to the ground contact surface 180. The generally curved shape of the crown member 204 allows the rear body 208 to be seamlessly joined to the front body 104, as the crown member is positioned completely over the flange 174 of the front body 104.

[0040] In many embodiments, the crown member 204 is made of woven carbon fiber, but not any layer of a composite ply or unidirectional composite ply. In one embodiment, the crown member 204 may be formed substantially from a formed fiber-reinforced composite material, including woven glass or carbon fiber reinforced layers embedded in a polymer matrix. In such an embodiment, the polymer matrix is ​​preferably a thermoplastic material, such as, for example, polyphenylene sulfide (PPS), polyetheretherketone (PEEK), or a polyamide, such as PA6 or PA66. In other embodiments, the crown member 204 may instead be formed from a filled thermoplastic material, including, for example, glass beads or discontinuous glass, carbon, or aramid polymer fiber fillers embedded throughout a thermoplastic material, such as, for example, polyphenylene sulfide (PPS), polyetheretherketone (PEEK), or a polyamide. In yet other embodiments, the crown member 204 may have a mixed-material construction, including both a filled thermoplastic material and a formed fiber-reinforced composite material.

[0041] b. Sole material 4 and 9, the sole member 208 includes a structural layer 156 and a resilient layer 152, providing a lightweight yet strong sole 116 for the golf club head 100. Referring to the ground contact surface 180, the resilient layer 152 is positioned adjacent to the ground contact surface, and the structural layer 156 is positioned within the golf club head 100 on top of the resilient layer 152.

[0042] In one embodiment, the sole member 208 has a mixed material construction including both a fiber reinforced thermoplastic composite elastic layer 152 and a molded thermoplastic structural layer 156. In a preferred embodiment, the molded thermoplastic structural layer 156 may be formed from a filled thermoplastic material including, for example, glass beads or discontinuous glass, carbon, or aramid polymer fiber fillers embedded throughout a thermoplastic material such as polyphenylene sulfide (PPS), polyetheretherketone (PEEK), or a polyamide such as PA6 or PA66. The elastic layer 152 may then include a woven glass, carbon fiber, or aramid polymer fiber reinforced layer embedded in a thermoplastic polymer matrix including, for example, polyphenylene sulfide (PPS), polyetheretherketone (PEEK), or a polyamide such as PA6 or PA66. In one particular embodiment, the crown member 202 and the resilient layer 152 may each comprise a woven carbon fiber fabric embedded in polyphenylene sulfide (PPS), and the structural layer 156 may comprise a filled polyphenylene sulfide (PPS) polymer.

[0043] The structural layer 156 may generally include a forward portion 236 and a peripheral portion 240 that define the perimeter of the sole member 208. In the assembled club head 100, the forward portion 236 is coupled to the metal front body 104, and the peripheral portion 240 is coupled to the crown member 204. The structural layer 156 defines a plurality of openings 244 that extend through the thickness of the structural layer 156 and are located within the perimeter. Additionally, the structural layer 156 may include one or more structural members 248 that extend from the forward portion 236 and between at least two of the plurality of openings 244. Additionally, as described below, the structural layer 156 may be configured to include a metal weight pad 212 and a metal weight 220.

[0044] The resilient layer 152 may be bonded to the structural layer 156 so as to directly abut or overlap the forward portion 236, the peripheral portion 240, and at least a portion of the plurality of structural members 248. In doing so, the resilient layer 152 may completely cover each of the plurality of openings 244 when viewed from the outside of the club head 100. Similarly, the one or more structural members 248 may act as selective reinforcement for an interior portion of the resilient layer 244, similar to a reinforcing rib or gusset.

[0045] With regard to the polymeric structures of both the crown member 204 and the sole member 208, any filled thermoplastic or fiber-reinforced thermoplastic composite material should preferably incorporate one or more engineering polymers with sufficiently high material strength and / or strength-to-weight ratio properties to withstand typical use while providing weight-saving benefits to the design. Specifically, it is important that the material of the golf club head 100 efficiently withstands the stresses imparted during impact between the striking face 120 and a golf ball while not contributing substantially to the overall weight of the golf club head 100. Generally, preferred polymers can be characterized by a tensile strength at yield greater than about 60 MPa (neat), and when filled, can have a tensile strength at yield greater than about 110 MPa, or more preferably greater than about 180 MPa, and even more preferably greater than about 220 MPa. In some embodiments, suitable filled thermoplastic polymers may have a tensile strength at yield between about 60 MPa and about 350 MPa. In some embodiments, these polymers, either filled or unfilled, may have a density of about 1.15 to about 2.02, and may preferably have a melting point greater than about 210°C, or more preferably greater than about 250°C.

[0046] c. Weight pad 4 and 9-11, in many embodiments, the structural layer 156 can include a weight pad 212. The weight pad 212 includes a cavity 216 adapted to receive a metal weight 220. In some embodiments, the weight pad 212 is generally positioned toward the rearmost point on the club head 100 and, therefore, may be integral with and / or directly coupled to the rear portion 132 of the structural layer 156. In some embodiments, a hole or opening 252 can be provided in the resilient layer 152 through which a portion of the weight pad 212 can extend. In some embodiments, the opening 250 is spaced a minimum distance from the front body 104 of at least 25 mm, or at least 30 mm, or at least 35 mm (i.e., measured along the outer surface of the club head). As shown in FIG. 9, when assembled, the outer surface of the weight pad 212 can lie flush with the outer surfaces of the immediately adjacent sole member 208 and / or resilient layer 152. In this manner, a portion of the weight pad 212 can form part of the outer sole 116 of the golf club head 100. Additionally, in some embodiments, the inner surface of the weight pad 212 may be exposed to the interior of the club head. The weight pad 212 functions to provide a high density rear mass to improve the overall MOI of the golf club head. The weight pad 212 and weight 220 provide an area in which to place a high density of optional mass, as substantial weight savings are achieved by forming a composite rear body 108.

[0047] The weight pad 212 may include any desired shape to position as much mass as possible toward the perimeter of the rear portion 132 of the golf club head 100. The shape of the weight pad 212 may be any one of the following shapes: circular, triangular, square, rectangular, trapezoidal, pentagonal, curved, spade-shaped, or any other polygon or shape having at least one curved side. In one embodiment, the weight pad 212 may be approximately trapezoidal in shape. In another embodiment, the weight pad 212 may be approximately rectangular in shape. In yet another embodiment, the weight pad 212 may be approximately circular in shape. In yet another embodiment, the weight pad 212 may be approximately triangular in shape.

[0048] In most embodiments, the weight pad 212 may be made from a metallic material to provide a high-density rear portion to improve the overall MOI of the golf club head 100. In some embodiments, the weight pad 212 may be formed from stainless steel, titanium, aluminum, a steel alloy (e.g., 455 steel, 475 steel, 431 steel, 17-4 stainless steel, maraging steel), a titanium alloy (e.g., Ti 7-4, Ti 6-4, T-9S), an aluminum alloy, or a composite material. In one embodiment, the weight pad 212 may be made from stainless steel. The weight pad 212 may be forged or cast before being secured within the sole member 208 of the rear body 108.

[0049] The weight pad 212 can be secured within the opening 250 of the elastic layer 152 by one or more techniques operable to provide a robust structural bond. Due to differences in material types / surface energies and the relatively high ratio of component mass to contact surface area, conventional adhesives alone may have difficulty withstanding the forces experienced during golf club impact with a ball. Therefore, it may be desirable to integrate at least a portion of the weight pad with the structural layer 156 and / or the elastic layer 152 by encapsulating at least a portion of the weight pad. In doing so, the material strength of the encapsulation layer can act to provide a more durable bond than the use of a surface adhesive alone. With reference to FIGS. 9 and 13 , examples of suitable encapsulation include structural tape 261 extending over the edge 252 of the weight pad 212, direct encapsulation of at least a portion of the weight pad 212 by the structural layer 156, or encapsulation of a portion of the weight pad between adjacent plies of the elastic layer 152. These techniques may be used instead of or in addition to the use of a chemical adhesive provided between the weight pad and the sole member 208.

[0050] In one configuration, the weight pad 212 can be attached to the sole member 208 without the use of mechanical fasteners. In one embodiment, the weight pad 212 is cast, and then the structural layer 156 may be molded around at least the edges 252 of the weight pad 212, for example, by insert injection molding or co-molding techniques. As discussed above, the filled thermoplastic structure of the structural layer 156 is particularly well-suited to receive the weight pad 212 due to its ability to form complex geometries and extend around edges in a structurally stable manner. Depending on the weight pad geometry, such bonding techniques may be more difficult with tape or FRC due to their more uniform profile.

[0051] The cavity 216 of the weight pad 212 extends inward from the weight pad 212. In the illustrated embodiment, the cavity 216 comprises a circular shape. In other embodiments, the cavity 216 can comprise any shape. For example, the shape of the cavity 216 can comprise a circle, an oval, a triangle, a rectangle, an octagon, or any other polygon or shape having at least one curved surface. The cavity 216 provides a recess for securing a metal weight 220 therein. The metal weight 220 further adds optional weight to the golf club head 100, thus further improving the MOI and CG of the golf club head 100. Furthermore, the cavity 216 and the metal weight 220 allow for the overall weight of the golf club head 100 to be modified by removably attaching different metal weights with different densities.

[0052] Cavity 212 includes a depth measured from a bottom 224 of cavity 212 to the contour of sole member 208 in a direction generally perpendicular to bottom 224. In many embodiments, cavity 212 has a depth between 0.10 inches and 0.50 inches. In some embodiments, cavity 212 has a depth less than 0.50 inches, less than 0.45 inches, less than 0.40 inches, less than 0.35 inches, less than 0.30 inches, less than 0.25 inches, less than 0.20 inches, or less than 0.15 inches.

[0053] Additionally, cavity 212 includes an opening 228 at its bottom 224. Opening 228 extends inward from bottom 224 of cavity 212 toward crown 112 of golf club head 100. In some embodiments, opening 228 may include threads that mate with threads on fastener 230 to secure metal weight 220 within cavity 216. In other embodiments, opening 228 may omit threads for use with self-tapping or self-drilling fasteners.

[0054] Metal weight 220 is configured to be positioned with cavity 216 of weight pad 212. In the illustrated embodiment, weight 220 is circular in shape to correspond to the shape of cavity 212. In other embodiments, weight 220 can include any geometric shape that corresponds to the shape of cavity 212 (e.g., circle, oval, triangle, rectangle, trapezoid, octagon, or any other polygonal shape or form having at least one curved side).

[0055] Metal weight 220 further includes an opening 232 that extends completely through weight 220. Opening 232 is substantially the same size as opening 228 in cavity 212, and opening 232 in weight 220 aligns with opening 228 in cavity 212 when the weight is placed in cavity 212. In most embodiments, opening 232 lacks threads, allowing fastener 230 to pass through weight 220 and be secured to opening 228 in weight pad 212 via the threads. Additionally, in some embodiments, washer 214 can be placed in cavity 212 before placing metal weight 220 in cavity 212.

[0056] d. Assembly 14 illustrates an embodiment of a method 300 for manufacturing a golf club head 100 having an integrally bonded resilient layer 152, structural layer 156, and metal weight pad 220 of a sole member 208. The method 300 includes, at step 310, thermoforming a fiber-reinforced thermoplastic composite material into the exterior shell portion of the club head 100. The thermoforming process may include, for example, preheating a thermoplastic prepreg to a molding temperature that is at least above the glass transition temperature of the thermoplastic polymer, molding the prepreg into the shape of the shell portion, and then trimming the molded part to size.

[0057] Once the composite shell portion is properly shaped, a filled polymer support structure can be injection molded into direct contact with the shell in step 320. This process is commonly referred to as insert molding. In this process, the shell is placed directly into a heated mold with a gated cavity exposed to a portion of the shell. Molten polymer is forced into the cavity, where it either directly mixes with the molten polymer of the heated composite shell or locally bonds with the softened shell. When the mold cools, the polymers of the composite shell and support structure harden together in a fused relationship. The bond is strengthened if the polymer of the shell portion and the polymer of the support structure are compatible, and is further strengthened if the two components contain a common thermoplastic resin component. While insert molding is the preferred technique for forming the structure, other molding techniques, such as compression molding, can also be used.

[0058] 14 , once the sole member 208 has been formed via steps 310 and 320, the FRC crown member 204 may be bonded to the sole member 208 to substantially complete the structure of the rear body 108 (step 330). In a preferred embodiment, the crown member 204 may be formed from a thermoplastic FRC material that is formed using a thermoforming technique similar to that described with respect to step 310. By forming the crown member 204 from a thermoplastic composite material, the crown member 204 may be bonded to the sole member 208 using local welding techniques. Such welding techniques may include, for example, laser welding, ultrasonic welding, or potentially electrical resistance welding if the polymer is electrically conductive. Alternatively, if the crown member 204 is formed using a thermosetting polymer, the crown member 204 may be coupled to the sole member 208 using, for example, adhesives or mechanical attachment techniques (such as studs, screws, posts, mechanical interference engagements, etc.).

[0059] The rear body 108, including the secured crown and sole members 204, 208, may then be adhesively bonded to the metal front body 104 in step 340. While adhesives bond easily to most metals, the process of bonding to polymers may require the use of one or more adhesion promoters or surface treatments to strengthen the bond between the adhesive and the polymer of the rear body 108.

[0060] III. Advantages By utilizing a mixed-material rear body construction, structural weight can be significantly reduced while providing a robust means for reintroducing optional mass without sacrificing design flexibility. While such designs may be formed entirely from filled thermoplastics such as polyphenylene sulfide (PPS), as noted above, the use of fiber-reinforced composites provides a stronger, lighter structure across the entire exterior surface. Conversely, all-FRC designs cannot easily incorporate weight-receiving structures and therefore cannot easily utilize optional added mass.

[0061] Metal weight pads are advantageous over mixed-material golf club heads because they allow for the distribution and interchangeability of metal weights while providing durability and a fixed location for the metal weights. Compared to golf club heads without metal weight pads, metal weight pads reliably withstand the torque applied to the weight pad when the weights are attached. Furthermore, metal weight pads allow manufacturers to replace metal weights, adjust manufacturing tolerances (i.e., change the desired swing weight of the entire club head from 206 grams to 209 grams), or adjust customer specifications (i.e., a golfer wants their club head heavier, from 206 grams to 209 grams).

[0062] The substitution of one or more claimed elements constitutes a rearrangement, not a repair. Furthermore, advantages, other benefits, and solutions have been described with respect to particular embodiments. However, no element or group of elements that provides or further enhances any advantage, benefit, or solution, or any and all of the advantages, benefits, or solutions, should be construed as an essential, required, or essential feature or element of any or all of those claims.

[0063] Because the Rules of golf may change from time to time (e.g., new Rules may be adopted, or old Rules may be eliminated or modified by golf standards organizations and / or governing bodies, such as the United States Golf Association (USGA) or the Royal and Ancient Golf Club of St. Andrews (R&A)), golf equipment related to the apparatus, methods, and articles of manufacture described herein may or may not conform to the Rules of Golf at any particular time. Accordingly, golf equipment related to the apparatus, methods, and products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The apparatus, methods, and products described herein are not limited in this respect.

[0064] The above examples may be described in relation to wood-type golf clubs, and the apparatus, methods, and articles of manufacture described herein may alternatively be applicable to other types of sports equipment, such as hockey sticks, tennis rackets, fishing poles, ski poles, etc.

[0065] Furthermore, the embodiments and limitations disclosed herein are not claimed to the public under the doctrine of equivalents if the embodiments and / or limitations (1) are not expressly recited in the claims and (2) are or could be equivalent to the elements and / or limitations in the claims under the doctrine of equivalents.

[0066] Various features and advantages of the disclosure are described in the following sections.

[0067] (Item 1) A golf club head a metal front body including a strike surface and a perimeter frame extending rearward from a perimeter of the strike surface, the strike surface having a center point, a loft plane along the strike surface and tangent to the center point, and an intermediate plane extending from heel to toe through the center point and perpendicular to the loft plane; a rear body connected to the metal front body, the rear body and the front body forming a substantially hollow structure with a cavity therebetween; Equipped with the rear body includes a crown member and a sole member; the sole member is connected to the crown member; The sole member is a structural layer formed from a filled thermoplastic material and including a plurality of openings extending along a thickness of the structural layer; an elastic layer coupled to an outer surface of the structural layer, the elastic layer extending across each of the plurality of openings, the elastic layer being formed from a fiber-reinforced thermoplastic composite material and defining an opening; a metal weight pad extending at least partially through the opening in the elastic layer and bonded to the structural layer, the metal weight pad including an opening for attaching a metal weight; and Including, the structural layer and the elastic layer each comprise a common thermoplastic resin element; The structural layer is bonded directly to the elastic layer without an intermediate adhesive. Golf club head.

[0068] (Item 2) the metal front body further includes a flange recessed inwardly from an outer surface of the perimeter frame; the structural layer of the sole member is adhesively bonded to the flange; Item 2. The golf club head according to item 1, wherein the outer surface of the elastic layer of the sole member is flush with the outer surface of the peripheral frame.

[0069] (Item 3) the metal front body further includes an extension wall connecting the perimeter frame to the flange; the structural layer of the sole member includes a structural member extending from the weight pad toward the metal front body; 3. The golf club head of claim 2, wherein the structural member operates to transfer dynamic loads between the weight pad and the extension wall during impact between the striking surface and a golf ball.

[0070] (Item 4) 4. The golf club head according to any one of items 1 to 3, having a head center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the mid-plane, measured in a direction perpendicular to the mid-plane, and the head CG depth is greater than 1.7 inches.

[0071] (Item 5) the metal front body further comprising a strike face insert and a receiving frame; 5. The golf club head of any one of items 1 to 4, wherein the receiving frame has a greater density than the strike face insert.

[0072] (Item 6) 6. The golf club head of any one of items 1 to 5, wherein the mass of the front body does not exceed 140 g and the total mass of the golf club head does not exceed 210 g.

[0073] (Item 7) a mechanical fastener secures the metal weight within the opening in the metal weight pad; the opening in the metal weight pad of the structural layer includes a threaded portion; 7. The golf club head according to any one of items 1 to 6, wherein the metal weight does not include threading.

[0074] (Item 8) 8. The golf club head according to any one of items 1 to 7, wherein the metal weight has a mass in the range of 5 grams to 30 grams.

[0075] (Item 9) A golf club head, a metal front body including a strike surface and a perimeter frame extending rearward from a perimeter of the strike surface, the strike surface having a center point, a loft plane tangent to the center point along the strike surface, and an intermediate plane extending through the center point from heel to toe and perpendicular to the loft plane; a rear body connected to the metal front body, the rear body and the front body forming a substantially hollow structure with a cavity therebetween; the rear body includes a crown member and a sole member; the sole member is connected 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 along a thickness of the structural layer; a resilient layer bonded to an outer surface of the structural layer without an intermediate adhesive, the resilient layer abutting the metal front body and extending across each of the plurality of openings; Including, the structural layer is formed from a first material comprising a first plurality of fibers disposed in a first thermoplastic polymer; the elastic layer is formed from a second material comprising a second plurality of fibers disposed in a second thermoplastic polymer; the amount of the first thermoplastic polymer in the first material by volume is greater than the amount of the second thermoplastic polymer in the second material by volume; the structural layer and the elastic layer each contain a common thermoplastic resin component; the structural layer is bonded directly to the elastic layer without an intermediate adhesive; the structural layer of the sole member includes a metal weight pad; The metal weight pad includes an opening for attaching a metal weight. Golf club head.

[0076] (Item 10) the metal front body further includes a flange recessed inwardly from an outer surface of the perimeter frame; the structural layer of the sole member is adhesively bonded to the flange; Item 10. The golf club head according to item 9, wherein the outer surface of the elastic layer of the sole member is flush with the outer surface of the perimeter frame.

[0077] (Item 11) the metal front body further includes an extension wall connecting the perimeter frame to the mating flange; the structural layer of the sole member includes a structural member extending from the weight pad toward the metal front body; Item 11. The golf club head of item 9 or 10, wherein the structural member operates to transfer dynamic loads between the weight pad and the extension wall during impact between the striking surface and a golf ball.

[0078] (Item 12) Item 12. The golf club head of any one of items 9 to 11, wherein the first thermoplastic polymer is directly bonded to the second thermoplastic polymer.

[0079] (Item 13) the first plurality of fibers comprises a plurality of discontinuous fibers; Item 13. The golf club head of any one of items 9 to 12, wherein the first plurality of fibers each have a maximum dimension of less than 0.43 inches.

[0080] (Item 14) Item 14. The golf club head of any one of items 9 to 13, wherein the second plurality of fibers comprises a plurality of continuous fibers woven together as a fabric.

[0081] (Item 15) Item 15. The golf club head according to any one of items 9 to 14, wherein the first thermoplastic polymer is the same as the second thermoplastic polymer.

[0082] (Item 16) 16. The golf club head of any one of items 9 to 15, wherein the mass of the front body does not exceed 140 g and the total mass of the golf club head does not exceed 210 g.

[0083] (Item 17) 17. The golf club head according to any one of items 9 to 16, having a head center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the mid-plane, measured in a direction perpendicular to the mid-plane, and the head CG depth is greater than 1.7 inches.

[0084] (Item 18) the metal front body further comprising a strike face insert and a receiving frame; Item 18. The golf club head of any one of items 9 to 17, wherein the receiving frame has a greater density than the strike face insert.

[0085] (Item 19) a mechanical fastener secures the metal weight within the opening in the metal weight pad; the opening in the metal weight pad of the structural layer includes a threaded portion; 19. The golf club head according to any one of items 9 to 18, wherein the metal weight does not include threading.

[0086] (Item 20) 20. The golf club head according to any one of items 9 to 19, wherein the metal weight has a mass in the range of 5 grams to 30 grams.

Claims

1. A golf club head a metal front body including a strike surface and a perimeter frame extending rearward from a perimeter of the strike surface, the strike surface having a center point, a loft plane along the strike surface and tangent to the center point, and an intermediate plane extending from heel to toe through the center point and perpendicular to the loft plane; a rear body connected to the metal front body, the rear body and the front body forming a substantially hollow structure with a cavity therebetween; Equipped with the rear body includes a crown member and a sole member; the sole member is connected to the crown member; The sole member is a structural layer formed from a filled thermoplastic material and including a plurality of openings extending along a thickness of the structural layer; an elastic layer coupled to an outer surface of the structural layer, the elastic layer extending across each of the plurality of openings, the elastic layer being formed from a fiber-reinforced thermoplastic composite material and defining an opening; a metal weight pad extending at least partially through the opening in the elastic layer and bonded to the structural layer, the metal weight pad including an opening for attaching a metal weight; and Including, the structural layer and the elastic layer each comprise a common thermoplastic resin element; The structural layer is bonded directly to the elastic layer without an intermediate adhesive. Golf club head.

2. the metal front body further includes a flange recessed inwardly from an outer surface of the perimeter frame; the structural layer of the sole member is adhesively bonded to the flange; The golf club head of claim 1 , wherein the outer surface of the resilient layer of the sole member is flush with the outer surface of the perimeter frame.

3. the metal front body further includes an extension wall connecting the perimeter frame to the flange; the structural layer of the sole member includes a structural member extending from the weight pad toward the metal front body; The golf club head of claim 2 , wherein the structural member operates to transfer dynamic loads between the weight pad and the extension wall during impact between the striking face and a golf ball.

4. 2. The golf club head of claim 1, wherein the head has a center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the intermediate plane, measured in a direction perpendicular to the intermediate plane, and the head CG depth is greater than 1.7 inches.

5. the metal front body further comprising a strike face insert and a receiving frame; The golf club head of claim 1 , wherein the receiving frame has a greater density than the strike face insert.

6. The golf club head of claim 1 , wherein the mass of the front body does not exceed 140 g and the total mass of the golf club head does not exceed 210 g.

7. a mechanical fastener secures the metal weight within the opening in the metal weight pad; the opening in the metal weight pad of the structural layer includes a threaded portion; The golf club head of claim 1 , wherein the metal weight does not include threading.

8. 2. The golf club head of claim 1, wherein the metal weight has a mass in the range of 5 grams to 30 grams.

9. A golf club head, a metal front body including a strike surface and a perimeter frame extending rearward from a perimeter of the strike surface, the strike surface having a center point, a loft plane tangent to the center point along the strike surface, and an intermediate plane extending through the center point from heel to toe and perpendicular to the loft plane; a rear body connected to the metal front body, the rear body and the front body forming a substantially hollow structure with a cavity therebetween; the rear body includes a crown member and a sole member; the sole member is connected 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 along a thickness of the structural layer; a resilient layer bonded to an outer surface of the structural layer without an intermediate adhesive, the resilient layer abutting the metal front body and extending across each of the plurality of openings; Including, the structural layer is formed from a first material comprising a first plurality of fibers disposed in a first thermoplastic polymer; the elastic layer is formed from a second material comprising a second plurality of fibers disposed in a second thermoplastic polymer; the amount of the first thermoplastic polymer in the first material by volume is greater than the amount of the second thermoplastic polymer in the second material by volume; the structural layer and the elastic layer each contain a common thermoplastic resin component; the structural layer is bonded directly to the elastic layer without an intermediate adhesive; the structural layer of the sole member includes a metal weight pad; The metal weight pad includes an opening for attaching a metal weight. Golf club head.

10. the metal front body further includes a flange recessed inwardly from an outer surface of the perimeter frame; the structural layer of the sole member is adhesively bonded to the flange; The golf club head of claim 9 , wherein the outer surface of the resilient layer of the sole member is flush with the outer surface of the perimeter frame.

11. the metal front body further includes an extension wall connecting the perimeter frame to the mating flange; the structural layer of the sole member includes a structural member extending from the weight pad toward the metal front body; The golf club head of claim 9 , wherein the structural member operates to transfer dynamic loads between the weight pad and the extension wall during impact between the striking face and a golf ball.

12. The golf club head of claim 9 , wherein the first thermoplastic polymer is directly bonded to the second thermoplastic polymer.

13. the first plurality of fibers comprises a plurality of discontinuous fibers; The golf club head of claim 9 , wherein the first plurality of fibers each have a maximum dimension of less than 0.43 inches.

14. The golf club head of claim 9 , wherein the second plurality of fibers comprises a plurality of continuous fibers woven together as a fabric.

15. The golf club head of claim 9 , wherein the first thermoplastic polymer is the same as the second thermoplastic polymer.

16. The golf club head of claim 9 , wherein the mass of the front body does not exceed 140 g and the total mass of the golf club head does not exceed 210 g.

17. 10. The golf club head of claim 9, wherein the head has a center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the intermediate plane, measured in a direction perpendicular to the intermediate plane, and the head CG depth is greater than 1.7 inches.

18. the metal front body further comprising a strike face insert and a receiving frame; The golf club head of claim 9 , wherein the receiving frame has a greater density than the strike face insert.

19. a mechanical fastener secures the metal weight within the opening in the metal weight pad; the opening in the metal weight pad of the structural layer includes a threaded portion; The golf club head of claim 9 , wherein the metal weight does not include threading.

20. 10. The golf club head of claim 9, wherein the metal weight has a mass in the range of 5 grams to 30 grams.

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