Co-formed golf club head

Abstract

A golf club head comprising a face plate, a body, a bonding material, and at least one retainer, wherein the bonding material and the at least one retainer are the only medium for joining the face plate and the body.

Description

Technical Field

[0001] Priority of Cross-References This application claims the benefit of U.S. Provisional Application No. 63 / 364,873, filed May 17, 2022, and U.S. Provisional Application No. 63 / 370,485, filed Aug. 4, 2022, the contents of which are hereby incorporated by reference in their entirety.

[0002] The present disclosure generally relates to golf equipment, and more particularly to golf heads. In particular, the present invention relates to a co-molded golf club head.

Background Art

[0003] The golf club head includes a face plate and a body. Conventionally, the face plate and the body are welded. However, in order to enable welding, the face plate and the body must be formed of compatible materials such as materials having substantially the same hardness, density, and rigidity. As a result, when it is desired that the face plate and the body have different characteristics, the design of the golf club head is restricted. For example, it may be desirable for the face plate to be harder than the body in order to improve the weakness of the face plate against wear and the reactivity against the impact of a golf ball. Further, it may be desirable to lighten the face plate without sacrificing durability. That is, when the face plate is light, the weight moves from the center of the club head toward the outer edge of the club head, thereby increasing the moment of inertia (MOI) of the entire club head. Further, when the face plate is light, the structural mass is reduced, so that a large discretionary mass can be provided. In conventional club heads, a flexible polymer material has been introduced between the body and the striking plate in an attempt to improve at least one of sound at impact, feel at impact, or flexibility, but face plates and bodies having different material characteristics could not be used. Further, in conventional club heads, an attempt has been made to increase ball speed by thinning the face and providing structural support to the face plate with a flexible polymer, but there is a lower limit to how thin the face plate can be considering the amount of support provided by the soft polymer and the weld resistance of the face plate.

Summary of the Invention

[0004] Therefore, there is a need to provide a golf club head having a face plate and a body with different material characteristics in order to improve at least one of sound at impact, feel at impact, MOI, ball speed, or flexibility without sacrificing durability.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0035] Other aspects of the disclosure will become apparent by considering the detailed description and the accompanying drawings. For the sake of brevity and clarity of the description, the drawings show aspects of a general structure, and well-known features and techniques may be omitted in order to avoid unnecessarily obscuring the disclosure. Further, the elements in the drawings are not necessarily drawn to scale. For example, in order to make it easier to understand the embodiments of the disclosure, the dimensions of some elements in the drawings may be exaggerated relative to other elements. The same reference numerals in different drawings refer to the same elements.

[0036] This specification describes a golf club head comprising a face plate, a body, and a bonding material disposed between the face plate and the body. The face plate and the body are bonded only by the bonding material (i.e., the face plate and the body are co-molded). The face plate or the body further comprises at least one retainer disposed within the club head, and the bonding material surrounds at least one retainer such that the face plate and the body are firmly bonded without welding. By bonding the body and the face plate only by the bonding material, the constraints of welding are eliminated even if the materials of the face plate and the body are different.

[0037] The face plate and the body have different material properties. For example, the face plate comprises a material having a lower density than the material of the body. When the face plate has a low density, the weight distribution changes so as to improve the weighting of the outer edge portion, thereby increasing the MOI and enabling more discretionary mass to be provided.

[0038] Furthermore, since the bonding material provides structural support to the face plate, structural concerns of the face plate such as durability, bending stress, flexibility, etc. are alleviated. For example, the face plate can be made thinner and harder compared to the case without the bonding material. In some embodiments, the bonding material may have a void located behind the face plate to facilitate increasing the ball speed with the face plate. If the body and the face plate are welded without being bonded by the bonding material and the retainer, the above advantages will not be obtained.

[0039] Definition As used herein, the term "face plate" refers to a plate attached to the golf club body and contacting the golf ball during a swing. The face plate may extend to form part of the topline, part of the sole, or part of the toe.

[0040] As used herein, the term "body" refers to the portion of the golf club head that extends behind the face plate.

[0041] As used herein, the term "striking face" refers to the combined coplanar portion of the face plate and the body that forms the surface intended to strike the golf ball.

[0042] As used herein, the term "bonding material" refers to a material disposed between the face plate and the body to bond them together.

[0043] In this specification and the claims, when terms such as "first", "second", "third", "fourth", etc. are used, they are used to distinguish similar elements and are not necessarily used to describe a specific order or chronological order. Words used in this way are interchangeable under appropriate circumstances, and it should be understood that the embodiments described in this specification can operate in an order other than the order illustrated or otherwise described in this specification. Further, "comprising", "having", and their variations are intended to cover non-exclusive inclusion, and a process, method, system, article, device, or apparatus having a listing of elements is not necessarily limited to those elements and may include other elements not expressly listed or other elements inherent to such a process, method, system, article, device, or apparatus.

[0044] As used herein, the term "iron" may, in some embodiments, refer to an iron-type golf club head having a loft angle of less than about 60 degrees, less than about 58 degrees, less than about 56 degrees, less than about 54 degrees, less than about 52 degrees, less than about 50 degrees, less than about 49 degrees, less than about 48 degrees, less than about 47 degrees, less than about 46 degrees, less than about 45 degrees, less than about 44 degrees, less than about 43 degrees, less than about 42 degrees, less than about 41 degrees, or less than about 40 degrees. Further, in many embodiments, the loft angle of the club head is 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, greater than about 25 degrees, greater than about 30 degrees, greater than about 35 degrees, greater than about 40 degrees, greater than about 45 degrees, greater than about 50 degrees, greater than about 55 degrees, or greater than about 60 degrees.

[0045] In this specification and the claims, when terms such as "left", "right", "front", "back", "up", "down", "above", "below", etc. are used, they are for illustrative purposes and are not necessarily used to describe permanent relative positions. Terms used in this way are interchangeable under appropriate circumstances, and it should be understood that the embodiments of the devices, methods, and / or manufactured articles described in this specification can operate in orientations other than those described herein or in other ways.

[0046] The "XYZ" coordinate system of the golf club head used in this specification is based on the geometric center of the face plate. The dimensions of the golf club head described in this specification can be measured based on the coordinate system defined below. The geometric center of the face plate defines a coordinate system having an origin located at the geometric center of the face plate. The coordinate system defines an X-axis, a Y-axis, and a Z-axis. The X-axis extends through the geometric center of the face plate in a direction from the heel to the toe of a fairway-type club head. The Y-axis extends through the geometric center of the face plate in a direction from the top rail to the sole of the golf club head. The Y-axis is perpendicular to the X-axis. The Z-axis extends through the geometric center of the face plate in a direction from the front end to the rear end of the golf club head. The Z-axis is perpendicular to both the X-axis and the Y-axis.

[0047] The terms and phrases "center of gravity position" and "CG position" may refer to the center of gravity (CG) position of the club head with respect to the XYZ coordinate system, and the CG position is defined by positions along the X-axis, Y-axis, and Z-axis. The term "CGx" may refer to the CG position along the X-axis measured from the origin. The term "CG height" may refer to the CG position along the Y-axis measured from the origin. The term "CGy" may be synonymous with CG height. The term "CG depth" may refer to the CG position along the Z-axis measured from the origin. The term "CGz" may be synonymous with CG depth.

[0048] The terms and phrases "CG projection" and "CG projection point" often refer to the position where CG is projected onto the face plate, and the projection is taken in the normal direction with respect to the loft surface.

[0049] The XYZ coordinate system of the golf club head in this specification defines an XY plane that extends through the X and Y axes. The coordinate system defines an XZ plane that extends through the X and Z axes. The coordinate system further defines a YZ plane that extends through the Y and Z axes. The XY plane, XZ plane, and YZ plane are all perpendicular to each other and intersect at the origin of the coordinate system located at the geometric center of the face plate. In these or other embodiments, when viewing the face plate from a direction perpendicular to the XY plane, the golf club head may be viewed from the front. Further, in these or other embodiments, when viewing the heel from a direction perpendicular to the YZ plane, the golf club head may be viewed in a side view or side cross-sectional view.

[0050] The golf club head further includes a coordinate system centered on the center of gravity. This coordinate system includes an X'-axis, a Y'-axis, and a Z'-axis. The X'-axis extends in the direction from the heel to the toe. The X'-axis is positive toward the heel and negative toward the toe. The Y'-axis extends in the direction from the sole to the top rail and is perpendicular to both the Z'-axis and the X'-axis. The Y'-axis is positive toward the top rail and negative toward the sole. The Z'-axis extends front to back, is parallel to the ground, and is perpendicular to both the X'-axis and the Y'-axis. The Z'-axis is positive toward the face plate and negative toward the rear.

[0051] The term or phrase "moment of inertia" (hereinafter referred to as "MOI") may refer to a value derived using the center of gravity (CG) position. The MOI can be calculated assuming the club head includes a body and a hosel structure. The term "MOIxx" or "Ixx" may refer to the MOI measured about the X' axis. The term "MOIyy" or "Iyy" may refer to the MOI measured about the Y' axis. The term "MOIzz" or "Izz" may refer to the MOI measured about the Z' axis. The values of MOI, MOIxx, MOIyy, and MOIzz determine the tolerance of the club head when the golf ball impacts off-center.

[0052] Before any embodiment of the present disclosure is described in detail, it is to be understood that the application of the present disclosure is not limited to the details of construction and the arrangement of components set forth in the following description or shown in the following drawings. The present disclosure is capable of other embodiments and of being practiced or carried out in various ways.

[0053] Detailed Description The golf club head described herein has features that improve sound at impact, feel, MOI, CG position, and ball speed, while maintaining at least durability. The golf club head may comprise a face plate, a body, and a bonding material, and the body and the face plate are co-molded via the bonding material and at least one retainer. That is, the face plate is not welded to the body. The at least one retainer is used through the face plate or the body and engages with the bonding material to firmly bond the body and the face plate. Further, the outer edge of the face plate and the inner side of the body are engaged via the bonding material. The face plate does not contact the body. The face plate contacts only the bonding material, and the body contacts only the bonding material. A lip is formed along the outer edge of the face plate. The lip comprises the bonding material and defines the boundary between the face plate and the body.

[0054] The faceplate is not welded to the body. Since it is not welded, there are no welding-related constraints such as material compatibility. Therefore, the faceplate and the body may include materials that are very difficult to weld. When the faceplate and the body include dissimilar materials, if an attempt is made to weld the faceplate to the body, each material will melt independently and cool without bonding to the other material. Thus, it is often very difficult to weld dissimilar materials.

[0055] The degree of freedom obtained by fixing the faceplate to the body via a bonding material and at least one retainer enables combinations of club head materials that were not achievable with conventional club heads. For example, the materials may be selected such that the faceplate has a lower density than the density of the body. The low-density faceplate may be obtained by a unique material selection or by manufacturing the faceplate in a different manner from the body (e.g., heat treatment). By reducing the density of the faceplate, mass is removed from the center of the club head, increasing the MOI of the club head. Further, by reducing the mass from the center of the club head, it is possible to provide a discretionary mass that can be redistributed preferably to the outer edge of the club head including the rear portion and the sole, improving the MOI and the CG position.

[0056] Also, the faceplate may have a sufficiently high hardness, improving the durability of the faceplate. High durability of the faceplate is particularly important for club heads such as wedges. This is because spin is generated by the groove design, and changes during spin generation can have a dramatic impact on performance. When the club head repeatedly hits a golf ball, the grooves of the club head deteriorate, reducing the spin imparted to the golf ball. Therefore, a harder faceplate can provide grooves with higher durability that maintain their shape even after repeated impacts, enabling the spin speed to be maintained.

[0057] Furthermore, the binder not only holds the club head together but also structurally supports the face plate. Different from conventional club heads that utilize soft polymers, the presence of the binder provides substantial structural support to the face plate. Therefore, the face plate can be made significantly thinner than the face plate of a conventional club head. When the face plate is thin, the mass between the outer edges of the club head decreases, resulting in a larger MOI. Additionally, when the face plate is thin, the structural mass decreases, allowing the MOI and CG to be improved by discretionary mass. In contrast, in a conventional club head where the face plate is not substantially supported by the binder, it would not be possible to achieve a thin face plate like that of the present invention. That is, in a conventional club head, the face plate has to be relatively thick to avoid breakage due to bending stress. Furthermore, a conventional welded club head needs to have a face plate thick enough to withstand welding. Therefore, the club head of the present invention can typically achieve simultaneously advantageous performance features that are usually contradictory. For example, the club head can be provided with a lightweight face plate that increases ball speed and MOI and minimizes groove wear while having durability.

[0058] Specifically, the binder supports the face plate by taking on most of the bending stress applied to the club head. Thus, the rear body, including the top rail and sole, hardly deflects. Since the rear body does not bend during impact with the golf ball, the edges of the face plate near the top rail and sole are restricted. Therefore, since the bending of the face plate is restricted, the face plate can be made thinner compared to a conventional welded face plate.

[0059] Regarding ball speed, in embodiments where the bonding material engages continuously with the face plate and the body, even if the strike is off-center, the ball speed is improved, thus promoting the consistency of ball speed. That is, when the bonding material continuously supports the face plate, a thin face plate with a large MOI can be realized by reducing the structural mass between the outer edges of the club head. When the MOI is large, the ball speed of an off-center strike is improved. Therefore, the present invention can increase the ball speed of an off-center strike compared to a golf club head of the same design that requires welding.

[0060] To further improve the ball speed, the bonding material may have individual voids adjacent to the face plate. These individual, discrete voids allow the face plate to flex locally. Further, these voids can be used to increase the characteristic time (hereinafter "CT"). CT depends on the position on the face plate. Generally, there are "hot" spots and "cold" spots of CT on the face plate. Therefore, the voids may be placed behind the "cold" spots to increase CT, and the bonding material may support the face plate behind the "hot" spots. This structure makes CT constant across the entire face plate. Therefore, this non - continuous bonding of the face plate and the body can normalize the ball speed across the entire face. For example, by placing individual voids near the top and bottom of the face plate, the ball speed for both high and low strikes may increase. Further, the individual voids encourage local flexure near the center of the face plate and can increase the ball speed at the top end.

[0061] A club head with a bonding material improves the hitting sound and feel compared to conventional designs. To improve the hitting sound and feel, the bonding material may continuously engage with the face plate and the body, or may discontinuously engage with the face plate and the body. Specifically, the bonding material attenuates the sound generated when hitting the ball. Further, the bonding material reduces the vibration transmitted to the club head when hitting the ball, and particularly improves the feel of off-center hits. Further, instead of being welded to the body as is done in conventional club heads, the internal weight may be embedded in the bonding material. Accordingly, the bonding material may counter the movement or rattling of the internal weight. Thus, the embodiments described in more detail below provide overall feel, performance, and structural advantages over conventional club heads with a flexible filler between a welded face plate and body.

[0062] Referring to FIGS. 1-3, club head 100 may include a face plate 102, a body 101, a hosel 105, and a bonding material 115 that bridges the face plate 102 to the body 101. The face plate 102 may include a striking face 112 and a back face 113. The body 101 may include a heel end 104, a toe end 103, a topline 109, a sole 111, a rear end 110, and a frame 119. The frame 119 defines a continuous boundary (hereinafter, body opening 129) around the front end of the body 101. The body opening 129 is configured to receive the face plate 102. The face plate 102 is sized such that a gap or offset 1030 remains between the face plate 102 and the frame 119. The face plate and the body 101 may be engaged by filling the gap 1030 with the bonding material 115. Specifically, the bonding material 115 may include a lip 126 that extends between the outer edge of the face plate and the frame 119.

[0063] The club head 100 may further include at least one retainer 120, and the bonding material 115 engages with the retainer 120 to firmly bond the face plate 102 and the body 101. Further, the bonding material 115 may include a protrusion or projection 125 that engages with the retainer 120. Specifically, the face plate 102 includes at least one retainer 120, and the body 101 includes at least one retainer 122. The interaction between the bonding material 115, the face plate 102, and the body 101 provides unique performance advantages. That is, the club head 100 can obtain improved hitting sound, feel, MOI, CG, ball speed, and durability. In contrast, the prior art is limited to obtaining only some of these advantages, and usually the remaining advantages are lost.

[0064] These performance advantages are made possible because the face plate 102 is not welded to the body 101. Instead, the face plate 102 and the body 101 are co-molded via the bonding material 115 and at least one retainer 120.

[0065] Therefore, since the face plate 102 is not welded to the body 101, the material compatibility of welding is not relevant. Therefore, the face plate 102 and the body 101 may be made of different materials. Therefore, the materials can be uniquely selected to obtain the desired performance advantages.

[0066] The face plate 102 may be made of a material that cannot generally be welded to the body 101. For example, the face plate 102 may be made of titanium. Titanium face plates are commonly used in wooden golf clubs, but for incorporation into an iron club with a steel body, usually, adhesion with an adhesive or mechanical fastening is required. However, such conventional options for engaging a titanium face plate to a steel body may be very costly or cumbersome to manufacture. In contrast, the present invention can successfully incorporate a titanium face using a binder. Since titanium is lighter than steel, it is desirable to incorporate a titanium face plate. For example, the density of a face plate made of a titanium alloy is about 4 g / cm 3 whereas the density of steel is about 7.8 g / cm 3 . In fact, by incorporating a titanium face plate using a binder, the density of the face plate becomes about half that of a conventional welded face plate. Accordingly, in the club head 100, the structural mass between the outer edges of the club head is small and the MOI is large. Also, in the club head 100, since there is a large amount of discretionary mass, the moment of inertia can be further increased and the center of gravity can be moved further rearward and downward.

[0067] Furthermore, the face plate 102 may be made of a metal matrix composite material such as a magnesium matrix composite material. The magnesium matrix composite material includes a magnesium alloy as a base and may be reinforced with fibers. For example, carbon fibers may be used to reinforce the magnesium alloy. As a result, the face plate 102 made of a magnesium matrix composite material has a very low density, such as 1.8 g / cm 3 . In contrast, a conventional steel face plate has a density of about 8 g / cm 3has a density. However, magnesium is merely an example of a metal used to form a metal matrix. Among others, matrices may be formed by various metals such as titanium, steel, copper, cobalt, nickel, and aluminum. Further, carbon fiber is merely an example of a reinforcing material in a metal matrix composite. Among others, various reinforcing materials may be used. Generally, a metal matrix can be reinforced by ceramics such as silicon carbide, alumina, and glass fiber. Further, a metal matrix may be reinforced by another metal such as titanium, steel, aluminum, copper, cobalt, nickel, and magnesium. Further, the reinforcing material may be provided in the form of discontinuous fibers, continuous fibers, or both.

[0068] Specifically, each of the face plate 102 and the body 101 has an elastic modulus. Since the face plate 102 and the body 101 are not welded to each other and are joined by a binder and a retainer, the face plate 102 and the body 101 can have different elastic moduli.

[0069] For example, the elastic modulus of the face plate 102 may be greater than the elastic modulus of the body 101 (i.e., the material of the face plate 102 is less flexible than the material of the body 101). When the bending of the face plate 102 is restricted by the binder 115, since the hardness of the face plate 102 may be prioritized over flexibility, it is preferable to have a relatively hard face plate 102.

[0070] Alternatively, the elastic modulus of the face plate 102 may be smaller than the elastic modulus of the body 101 (i.e., the face plate 102 is more flexible than the body 101). When the face plate 102 is not continuously supported by the binder 115, it is preferable to have a relatively flexible face plate 102. For example, referring to FIGS. 9A to 9D in which the club head has individual gaps 709A to 709D between the face plates 702A to 702D and the binders 715A to 715D, the improvement of the ball speed is promoted by the flexible face plates 712A to 712D.

[0071] Specifically, the elastic modulus of the face plate 102 may be 60 GPa to 140 GPa. In some embodiments, the elastic modulus of the face plate may be 60 GPa to 70 GPa, 70 GPa to 80 GPa, 80 GPa to 90 GPa, 90 GPa to 100 GPa, 100 GPa to 110 GPa, 110 GPa to 120 GPa, 120 GPa to 130 GPa, or 130 GPa to 140 GPa.

[0072] Furthermore, the elastic modulus of the body 101 may be 40 GPa to 300 GPa. In some embodiments, the elastic modulus of the body may be 40 GPa to 100 GPa, 100 GPa to 150 GPa, 150 GPa to 200 GPa, 200 GPa to 220 GPa, 220 GPa to 240 GPa, 240 GPa to 260 GPa, 260 GPa to 280 GPa, or 280 GPa to 300 GPa.

[0073] Furthermore, the face plate 102 has a face plate density, and the body 101 has a body density. The face plate density may be 1.5 g / cm 3 ~18 g / cm 3 . In some embodiments, the face plate density may be 1.5 g / cm 3 ~9 g / cm 3 , or 1.5 g / cm 3 ~4 g / cm 3 . Furthermore, the face plate density may be 1.5 g / cm 3 ~3.0 g / cm 3 , or 3.0 g / cm 3 ~4.5 g / cm 3 , or 4.5 g / cm 3 ~6.0 g / cm 3 , or 6.0 g / cm 3 ~7.5 g / cm 3 , or 7.5 g / cm 3 ~9.0 g / cm 3 . Specifically, the face plate density may be 1.5 g / cm 3 , 2.0 g / cm 3, 2.5 g / cm 3 , 3.0 g / cm 3 , 3.5 g / cm 3 , 4.0 g / cm 3 , 4.5 g / cm 3 , 5.0 g / cm 3 , 5.5 g / cm 3 , 6.0 g / cm 3 , 6.5 g / cm 3 , 7.0 g / cm 3 , 7.5 g / cm 3 , 8.0 g / cm 3 , 8.5 g / cm 3 , or 9.0 g / cm 3 may be. The body density may be 6 g / cm 3 ~ 10 g / cm 3 may be. In some embodiments, the body density may be 7 g / cm 3 ~ 9 g / cm 3 , or 7.5 g / cm 3 ~ 8.5 g / cm 3 may be. Further, the body density may be 6 g / cm 3 ~ 7 g / cm 3 , or 7 g / cm 3 ~ 8 g / cm 3 , or 8 g / cm 3 ~ 9 g / cm 3 , or 9 g / cm 3 ~ 10 g / cm 3 may be. Specifically, the body density may be 6.0 g / cm 3 , 6.25 g / cm 3 , 6.5 g / cm 3 , 6.75 g / cm 3 , 7.0 g / cm 3 , 7.25 g / cm 3 , 7.5 g / cm 3 , 7.75 g / cm 3 , 8.0 g / cm 3 , 8.25 g / cm 3 , 8.5 g / cm 3 , 8.75 g / cm 3 , 9.0 g / cm 3 , 9.25 g / cm 3 , 9.5 g / cm 3 , 9.75 g / cm 3or 10.0 g / cm 3 may be.

[0074] Furthermore, in some embodiments, the body and the faceplate have similar densities. For example, a thin steel faceplate may be coupled to a steel body via a binder and a retainer. That is, since the binder and the retainer hold the club head together instead of welding, a very thin faceplate can be incorporated without melting the faceplate. In contrast, in a conventional welded club head, the faceplate needs to have a thickness sufficient to withstand the heat applied to the part during welding. Also, since the binder structurally supports the faceplate, a very thin faceplate can be incorporated while maintaining durability. In contrast, the flexible polymers used in conventional filled irons do not limit face deflection enough to incorporate a faceplate that is thin enough without sacrificing durability.

[0075] In other embodiments, the body and the faceplate have different densities. For example, if the faceplate and the body are made of different materials, there may be a difference between the body density and the faceplate density. In contrast, in a conventional welded golf club, since different materials cannot be easily welded, the face density and the body density are substantially the same. For example, steel and titanium cannot be easily welded.

[0076] In some embodiments, the body density may be greater than the face plate density. For example, the club head may comprise a steel body and a titanium face plate. The steel body is a conventional one. In contrast, in a conventional iron, welding is required and steel and titanium cannot be easily welded, so the combination of a steel body and a relatively low-density titanium face plate is unique. Further, the relatively low-density face plate has less structural mass between the outer edges of the club head than a conventional welded iron. Therefore, by co-molding a low-density titanium face plate and a steel body, the MOI is improved.

[0077] Specifically, the club head 100 further has a density ratio, which is the ratio of the body density to the face plate density. The density ratio may be from 0.33 to 6.66. In some embodiments, the density ratio may be from 1 to 6.66, or from 3 to 6.66, or from 5 to 6.66. In some embodiments, the density ratio may be from 1 to 2, or from 2 to 3, or from 3 to 4, or from 4 to 5, or from 5 to 6. Specifically, the density ratio is at least 0.33, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, or 6.5.

[0078] Furthermore, the faceplate may have a relatively high hardness and enhanced durability. Specifically, high durability can be regarded as an improvement in the deterioration of the grooves. This high durability can be achieved by incorporating a faceplate made of a high-hardness material. For example, the faceplate may be made of a metal matrix composite material. In contrast, when a high-hardness faceplate is incorporated into a conventional club head, the body needs to be formed from a material of substantially the same hardness. However, since the body does not impact the golf ball, a high-hardness body may not be preferable. Therefore, the high-hardness body required for welding a high-hardness face to a conventional club head may unnecessarily limit deflection and increase the structural mass without any advantage. However, in the present invention, since there is no need to weld the faceplate to the body, a very hard faceplate can be combined with a body made of another soft material.

[0079] High durability can also delay the deterioration of the grooves and result in more consistent spin. When the grooves of the club head wear or deteriorate, the spin of the golf ball decreases and the ball speed increases. When the groove wear is significant, usually, the player's score increases. That is, a decrease in spin causes the shot to roll off the green, and an increase in ball speed causes the player to overshoot the intended landing zone.

[0080] For example, in a conventional wedge, the spin speed decreases by approximately 100 RPM every 500 strikes. Therefore, the player may need to replace the wedge within two years. Of course, the higher the practice frequency and the more regular the practice, the higher the replacement frequency. However, when the hardness of the faceplate is high, the deterioration rate of the grooves decreases, and the decrease in spin speed can be delayed.

[0081] Specifically, each of the faceplate and the body has hardness. In some embodiments, the hardness of the faceplate is greater than the hardness of the body. In some embodiments, the hardness of the faceplate is between 35 HRC and 62 HRC. In some embodiments, the faceplate hardness may be 35 HRC - 40 HRC, 40 HRC - 45 HRC, 45 HRC - 50 HRC, 50 HRC - 55 HRC, or 55 HRC - 62 HRC.

[0082] In some embodiments, the faceplate and the body may have substantially the same hardness. For example, a thin steel faceplate may be bonded to a steel body via a bonding material and a retainer. The faceplate and the body have the same hardness, but the thin faceplate reduces the structural mass and improves the MOI. Further, in embodiments where the bonding material and the faceplate form individual voids behind the faceplate (e.g., FIGS. 9A - 9D), the thin face can improve ball speed. In contrast, in a conventional club head, since it is welded, the faceplate needs to be thick enough to withstand the welding temperature. Thus, even when the faceplate and the body have substantially the same hardness, the present invention can provide a thinner faceplate compared to a conventional welded club head.

[0083] In other embodiments, the faceplate and the body have different hardnesses. For example, a faceplate made of a metal matrix composite material may be bonded to a steel body via a bonding material and a retainer. In contrast, a conventional welded club head must have a faceplate and a body that can be easily welded. A faceplate made of a metal matrix composite material and a steel body cannot be easily welded. Therefore, the present invention does not require an unnecessarily hard body and can provide a high - hardness face to improve groove deterioration. In contrast, in a conventional club head, to incorporate a high - hardness faceplate, a body with similar material properties, i.e., a body with a similar hardness, is required.

[0084] Specifically, the club head may have a hardness ratio that is the ratio of the face plate hardness to the body hardness. The hardness ratio may be from 1 to 3. In some embodiments, the hardness ratio may be from 1 to 1.5, or from 1.5 to 2, or from 2 to 2.5, or from 2.5 to 3. The high hardness ratio is unique to the present invention. That is, in conventional club heads, since the face plate and the body are welded together, the hardness ratio is limited. In contrast, in the present invention, a high-hardness face plate can be coupled to a relatively soft body via a binder and a retainer. Therefore, a high hardness ratio indicates that the present invention does not require an unnecessarily hard body and can protect against groove wear.

[0085] Since the face plate is not welded to the body, it is possible to incorporate a thin, low-density, and high-hardness face plate. Therefore, the face plate and the body may be made of materials that cannot be welded to each other. That is, the face plate and the body are coupled to each other by a binder and a retainer. Specifically, the binder engages the face plate and the body via the retainer.

[0086] Generally, the retainer 120 provides a surface area for engagement with the binder 115. Specifically, the binder 115 includes protrusions 125 that engage with the retainer. The retainer 120 is characterized by its cross-sectional shape. The cross-section of the retainer may have various shapes including, but not limited to, a circle, an "L-shaped" bracket or hook, a slot, a rectangle, an ellipse, and a semi-circle as shown in FIGS. 7A-7H. The shape of the protrusion is determined by the shape of the retainer. FIG. 7A shows a faceplate retainer 420A having circular holes continuously distributed in a groove along the outer edge of the faceplate. FIG. 7B shows a faceplate retainer 420B having circular holes or oval voids discretely arranged in a groove along the outer edge of the faceplate. FIG. 7C shows a faceplate retainer 420C having two D-flanges further including circular holes. FIG. 7D shows a faceplate retainer 420D having an outward-facing "L-shaped" bracket. FIG. 7E shows a faceplate retainer 420E having a groove partially along the outer edge of the faceplate, the groove having circular holes or oval voids discretely arranged. FIG. 7F shows a faceplate retainer 420F having an outward-facing "L-shaped" bracket, the outward-facing "L-shaped" bracket having circular holes or oval voids discretely arranged. FIG. 7G shows a faceplate retainer 420G having an inward-facing "L-shaped" bracket, the inward-facing "L-shaped" bracket having circular holes or oval voids discretely arranged. FIG. 7H shows a faceplate retainer 420H having an inward-facing "L-shaped" bracket.

[0087] Referring to FIGS. 2 and 5A, the retainer 120 may be proximate to the top rail 109 and the sole 111. Also referring to FIG. 5B, the retainer 120 may be proximate to the heel end 104 and the toe end 103. Continuing to refer to both FIGS. 5A and 5B, the body 101 may also include one or more retainers 122. The one or more body retainers may be disposed at the heel end 104, the toe end 103, the top rail 109, or the sole 111. In some embodiments, the one or more body retainers 122 may be characterized by an undercut. In other embodiments, the one or more body retainers 122 may be similar in shape to the face plate retainers described above.

[0088] The face plate 102 and the body 101 are also engaged by a lip 126 in addition to at least one retainer, and the lip 126 is the region between the outer edge of the face plate 102 and the frame 119 in the bonding material 115. That is, the lip 126 may be adjacent to the sole 111, the heel end 104, the toe end 103, or the top rail 109. Further, the lip 126 may form a part of the sole 111, the toe 103, or the top rail 109.

[0089] In some embodiments, the lip is adjacent to the top rail, the sole, the heel, and the toe. Further, in such embodiments, the lip does not form any part of the sole, the top rail, or the toe. For example, as shown in FIG. 1, the lip 115 surrounds the striking face 112.

[0090] In other embodiments, the lip forms part of the top rail 109, part of the sole 111, or part of the toe 103. That is, the faceplate 102 may form part of the sole 111, part of the toe 103, or part of the top rail 109. Thus, in these embodiments, the lip is visible in the sole 111, the toe 103, or the top rail 109. In such embodiments where the faceplate 102 forms part of the sole 111, part of the toe 103, or part of the top rail 109, the ball speed can be significantly improved. For example, the faceplate 102 may extend to form part of the top rail 109. Further, the club head may include individual voids (e.g., FIGS. 9A-9D) adjacent to the sole 111 formed by the bonding material 115 and the faceplate 102. By the faceplate 102 extending to part of the top rail 109, the distance between the individual voids adjacent to the sole 111 and the upper edge of the faceplate is longer compared to embodiments where the faceplate does not form part of the top rail. Thus, when the ball is struck near the individual voids, the face deflects more greatly near the individual voids, increasing the ball speed.

[0091] Specifically, in some embodiments, the lip is adjacent to the heel end 104, the toe end 103, and the top rail 109 and forms part of the sole 111. In further embodiments, the lip is adjacent to the heel end 104, the toe end 103, and the sole 111 and forms part of the top rail 109. In further embodiments, the lip is adjacent to the heel end 104, the sole 111, and the top rail 109 and forms part of the toe end 103. In some embodiments, the lip is adjacent to the heel end 104 and the toe end 103 and forms part of the top rail 109 and part of the sole 111. In further embodiments, the lip is adjacent to the heel end 104 and the sole 111 and forms part of the top rail 109 and part of the toe end 103. In further embodiments, the lip is adjacent to the heel end 104 and the top rail 109 and forms part of the sole 111 and part of the toe end 103. In some embodiments, the lip is adjacent to the heel end 104 and forms part of the top rail 109, part of the sole 111, and part of the toe end 103.

[0092] The club head 100 may further include a face surface 1015 and an offset 1030. The face surface 1015 is parallel to and in the same plane as the face plate 102. The offset 1030 is the distance between the face plate 102 and the body 101 measured along the face surface 1015. The offset 1030 may be constant or vary across the entire face plate 102. Further, the offset 1030 defines the lip. The offset distance may be from 0.001 inches to 0.125 inches. Considering aesthetic appeal, the offset distance is preferably minimal.

[0093] The retainer and the lip facilitate a secure connection between the bonding material 115, the face plate 102, and the body 101 in all of their variations. However, the bonding material 115 is also a high-strength component. Thus, the bonding material 115 provides substantial structural support.

[0094] Thus, due to the structural support provided by the binder 115, a very thin faceplate 102 that promotes improvement in MOI and ball speed is made possible. Specifically, the faceplate 102 has a thickness, which is measured orthogonal to the face surface. Further, the faceplate 102 may have a thickness change profile. For example, the faceplate 102 may have a maximum thickness in the central region and a minimum thickness in the outer edge region of the faceplate 102. The thickness change profile can improve the characteristic time or the ball speed.

[0095] Compared to the technology in the art, the faceplate 102 of the present invention may be thin. Specifically, the thickness of the faceplate may be from 0.02 inches to 0.125 inches. In an exemplary embodiment, the thickness of the faceplate is 0.04 inches.

[0096] When the faceplate is thin, the structural weight between the outer edges of the club head is reduced. Thus, when the faceplate is thin, not only is the MOI fundamentally increased, but also more discretionary mass is provided to further increase the MOI and improve the center of gravity. On the other hand, a conventional welded club head needs to have a face thickness sufficient to withstand the welding temperature. Even a conventional cavity-back iron has limitations in making the faceplate thin. That is, in a conventional cavity-back iron, since it is filled with a softer material than the present invention, the face can flex but does not provide the same degree of structural support. Further, in a conventional cavity-back iron, the faceplate and the body need to be welded. Thus, compared to a conventional welded club head, the present invention can include a very thin faceplate supported by a binder and improving the MOI. Further, since the faceplate is very thin, in the present invention, the CG can be placed at a more rearward and lower position compared to a conventional welded club head.

[0097] By improving the MOI, the thin faceplate also improves the ball speed of off-center strikes. Specifically, the greater the MOI of the clubhead, the more consistent the ball speed. Further, when the individual voids formed by the binder and the faceplate are combined with the thin faceplate, the ball speed can be further improved. Specifically, due to the increased flexibility and contact time of the thin faceplate, the ball speed increases compared to conventional welded clubheads where the faceplate must withstand the welding temperature and cannot be made thin.

[0098] That is, as detailed below, the binder supports the faceplate. However, the binder 115 does not necessarily continuously support the faceplate 102. For example, referring to FIGS. 9A - 9D, clubheads 700A - D may include at least one individual void 714A - D between faceplates 702A - D and binders 715A - D. The binders 715A - D and the retainer also hold the clubheads 700A - D together here, and the binder also supports the faceplates 702A - D here. On the other hand, at least one individual void 714A - D allows the faceplate 702A - D to locally flex and may be aligned with dead spots on the face.

[0099] In some embodiments such as FIG. 9C, the clubhead 700C includes discrete voids 714C located near the heel and toe ends, away from the center of the faceplate 702C. By promoting local flexing of the faceplate 702C near the heel and toe ends, the speed of the ball struck near the heel and toe ends increases. In another embodiment, the clubhead includes a single individual void located near the toe end and the top rail. By promoting local flexing in the high - toe region, the speed of the ball struck near the high - toe region is improved. Specifically, at least one individual void may be located near the heel end, near the toe end, near the top rail, or near the sole, or any combination thereof.

[0100] The advantages of MOI and ball speed associated with a light and thin face are obtained by the substantial support provided by the binder. Specifically, the binder has sufficient compressive strength and thickness. For example, in some embodiments, the binder has a compressive strength of 80 Ksi. Further, since the binder extends between the face plate and the body, it is thick enough in the direction of impact. Thus, the binder has high compressive strength when viewed over the entire component.

[0101] As a result, the binder affects the bending stress. Therefore, when the binder directly supports the face, the bending of the face plate is restricted. Since the deflection of the face plate is restricted by direct contact with the binder, a thin face plate can be incorporated without sacrificing the durability of the club head.

[0102] Specifically, the binder may include a thermoplastic resin and a plurality of discontinuous fibers. Suitable thermoplastic resins may include thermoplastic polyamides (e.g., PA6 or PA66), which may be filled with short carbon fibers (i.e., carbon-filled polyamide). Other resins include certain polyimides, polyamide-imides, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polycarbonate, engineering polyurethane, and / or other similar materials. Other preferred resins include nylon 11 (PA-11), nylon 12 (PA-12), polycarbonate (PC), polyetherimide (PEI), polyethyleneimine (PEI), thermoplastic polyurethane (TPU), polymethylpentene (TPX), polyvinylidene fluoride (PVDF), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyethylene (PE), polyoxymethylene (POM), polypropylene (PP), polystyrene (PS), and polymethyl methacrylate (PMMA).

[0103] The resin is reinforced with fibers. The fibers, discontinuous fibers / short fibers, may include, for example, carbon short fibers or glass short fibers, which are embedded in the resin before molding the front body 12. Regarding possible material configurations, which will be further described later, in one configuration, the polymeric material may be a "long fiber thermoplastic" in which discontinuous fibers are embedded in a thermoplastic resin and each fiber has a fiber length designed to be from about 3 mm to about 25 mm. In an exemplary embodiment, 12.7 mm fibers are used. In another configuration, the polymeric material may be a "short fiber thermoplastic" in which discontinuous fibers are embedded in a thermoplastic resin and each fiber has a fiber length designed to be from about 0.01 mm to about 3 mm. In any case, these lengths are the lengths before mixing, and it should be noted that some of the fibers may actually end up shorter than the described range due to breakage during the molding process. In some configurations, the discontinuous short fibers may be characterized by an aspect ratio (e.g., fiber length / diameter) greater than about 10, more preferably greater than about 50 and less than about 1500. Regardless of the type of discontinuous short fibers used, in a particular configuration, the material may have a fiber length from about 0.01 mm to about 12 mm and a resin content from about 40 wt% to about 90 wt%, more preferably from about 55 wt% to about 70 wt%.

[0104] In some embodiments, the discontinuous fibers occupy 5% to 50% of the volume of the binder. The binder may include, by volume, 5% to 20%, or 20% to 35%, or 35% to 50% of the fibers. Specifically, the binder may include, by volume, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50% of the fibers. In an exemplary embodiment, the binder may include a TPU resin reinforced with carbon fibers 12.7 mm in length, and the binder is, by volume, 40% carbon fibers and 60% TPU.

[0105] Although it will be described in more detail along with the manufacturing process, by co - molding the face plate and the body using a binder and a retainer, a higher fiber concentration can be achieved than in conventional filled irons. Specifically, in a conventional filled iron, it is usually necessary to inject a polymer into the cavity of the club head after welding the face plate and the body. In contrast, in the present invention, the face plate and the body are co - molded. In the co - molding process, before curing, excess binder can pass through the offset between the face plate and the body. Specifically, the offset 1030 may function as a strainer that allows the resin to pass through easily but does not allow the fibers to pass through. Alternatively, the club head may be provided with slits that allow the resin to pass through the club head, whereby the fiber concentration can be increased. Therefore, the present invention can have a very high fiber concentration, that is, it can have a very high strength compared to conventional welded club heads.

[0106] In some embodiments, the binder may include continuous fibers having an aspect ratio greater than 1500. Generally, continuous fibers can increase strength compared to discontinuous fibers. However, continuous fibers are not very suitable for forming intricate geometric shapes or geometries with tight curvatures. Therefore, in some embodiments, both discontinuous fibers and continuous fibers may be used. For example, discontinuous fibers may be used around narrow corners, and continuous fibers may be used in relatively uniform portions.

[0107] Furthermore, the binder has a sufficiently high compressive strength. Specifically, the binder may have a compressive strength of 10 ksi to 100 ksi. Preferably, the binder has a compressive strength of 50 to 100 ksi. In some embodiments, the compressive strength of the binder is 50 to 60 ksi, or 60 to 70 ksi, or 70 to 80 ksi, or 80 to 90 ksi, or 90 to 100 ksi. Since the compressive strength of the binder is sufficiently high, even if the area of the binder is thin, the durability of the club head is guaranteed. For example, referring to FIG. 5A, the binder 115 is quite thin near the bottom of the retainer 120. In this thin region, there is less binder 115 supporting the face plate 102, so it is more likely to break than other parts of the binder 115. However, since the compressive strength of the binder 115 is high, it is guaranteed that such a thin region will not break even when repeatedly subjected to dynamic loads.

[0108] In addition to the compressive strength of the base material, since the binder 115 occupies a significant portion of the volume of the club head, it resists compression as a finished part. Specifically, since the binder 115 extends between the face plate 102 and the body 101, it has a sufficient thickness in the direction of impact. In some embodiments, the binder 115 has a minimum thickness of 0.025 inches to 0.050 inches and a maximum thickness of 0.25 inches to 0.5 inches.

[0109] Typically, the binder may occupy about 20% to 35% of the volume of the club head. However, the volume of the club head includes the body, the face plate, and the binder. Therefore, the binder may occupy all of the empty volume between the rear body and the face plate. For example, referring to FIGS. 2 and 5, the binder 115 fills the entire cavity between the body 101 and the face plate 102.

[0110] Alternatively, the club head may include discrete voids, in which case the binder does not fill the entire cavity. Instead, the binder and the face plate form individual voids behind the face plate. For example, referring to FIGS. 9A - D, there are individual voids 709A - D inside the club heads 700A - D, and the binders 715A - D are spaced apart from the face plates 702A - D.

[0111] The binder has a sufficiently high compressive strength to reduce the bending stress on the body including the top rail and the sole. By reducing the bending stress on the body, the structural requirements for the body can be reduced. Therefore, compared with the conventional welded club head, the body can be made significantly thinner. For example, the thickness of the top rail 109 and the back surface 110 of the body may be 0.03 inches. In contrast, the thickness of the top rail and the back surface of the conventional welded club head is about 0.05 inches.

[0112] Furthermore, due to the rigidity of the club head body, the deflection of the face plate is restricted. Therefore, the stress on the face plate is also minimized, improving durability. Ultimately, due to the high compressive strength of the binder, very different face plate materials and body materials can be integrally combined with good durability, improving the performance of the club head. For example, since the binder absorbs most of the bending stress applied to the club head, the face plate can be made significantly thinner than the conventional welded club and at least maintain durability.

[0113] Such unique and advantageous faceplate characteristics are promoted by the high compressive strength and toughness of the binder, and the binder also contributes to performance improvement on its own. That is, since the binder is surrounded by the body, it may have a considerably lower density compared to the metal that conventionally fills the inside of the club head. Specifically, since the binder is surrounded by the body of the club head, it is hardly subjected to tensile stress. Therefore, the binder mainly deals with only compressive force. Since the binder does not need to be so tough against tension and compression, it can have sufficient durability and can also achieve a significant weight reduction. The low-density binder reduces the structural mass between the outer edges of the club head. Therefore, the MOI is fundamentally increased compared to a similar club head that is forged or cast. Furthermore, the lower the density of the binder in the club head, the more discretionary mass there is to further improve the MOI and CG.

[0114] Specifically, the density of the binder is 0.85 g / cm 3 ~1.75 g / cm 3 That is. In contrast, the density of steel is about 8 g / cm 3 and the density of aluminum is about 2.7 g / cm 3 In some embodiments, the density of the binder is 1 g / cm 3 ~1.60 g / cm 3 or 1.15 g / cm 3 ~1.45 g / cm 3 It may be. Furthermore, the binder is 0.85 g / cm 3 ~1.0 g / cm 3 or 1.0 g / cm 3 ~1.15 g / cm 3 or 1.15 g / cm 3 ~1.3 g / cm 3 or 1.3 g / cm 3 ~1.45 g / cm 3 or 1.45 g / cm 3 ~1.6 g / cm 3 or 1.6 g / cm 3 ~1.75 g / cm 3 That is. Specifically, the density of the binder is 0.85 g / cm 3, 0.9 g / cm 3 , 0.95 g / cm 3 , 1.0 g / cm 3 , 1.05 g / cm 3 , 1.10 g / cm 3 , 1.15 g / cm 3 , 1.20 g / cm 3 , 1.25 g / cm 3 , 1.3 g / cm 3 , 1.35 g / cm 3 , 1.4 g / cm 3 , 1.45 g / cm 3 , 1.5 g / cm 3 , 1.55 g / cm 3 , 1.60 g / cm 3 , 1.65 g / cm 3 , 1.7 g / cm 3 , 1.75 g / cm 3 , 1.8 g / cm 3 , or 1.85 g / cm 3 is. In combination with the discretionary mass obtained from the low-density thin faceplate, the density of the binder provides a discretionary mass that can increase the MOI of the clubhead and selectively position the CG of the clubhead.

[0115] As described above, using a binder instead of welding to join the clubhead together provides unique performance advantages. As discussed separately, the structural support provided by the binder also provides unique performance advantages. However, these unique advantages are not mutually exclusive. Rather, both features complement each other.

[0116] Specifically, a low-density and thin faceplate reduces the structural mass between the outer edges of the club head. Also, a low-density binder further reduces the structural mass between the outer edges of the club head. When the low-density and thin faceplate and the low-density binder are combined, the discretionary mass increases. That is, the faceplate and the internal cavity are close to the center of the club head. Therefore, when each mass is reduced, the mass at the center of the club head is reduced. For example, instead of steel, a titanium faceplate and a binder made of a thermoplastic material may be used. The density of steel is about 8 g / cm 3 whereas the density of titanium is about 4 g / cm 3 and the density of the binder made of a thermoplastic material can be about 2 g / cm 3 Accordingly, the MOI is fundamentally improved. For example, a club head having a titanium faceplate and a binder made of a thermoplastic material can have an MOI that is about 15% larger than that of a similar conventional welded steel club head. Further, the discretionary mass increases. To improve the MOI and CG, the discretionary mass may be moved to other locations of the club. For example, the discretionary mass may be disposed in at least one of the weighting features described below.

[0117] In addition to the binder, retainer, faceplate, and body, the club head may further include a discretionary weight system. Referring to FIG. 8A, the club head 500 may include at least one weighting feature. The weighting feature may be disposed within the binder 515 as an internal weight 516 or may be disposed within the toe end of the club head 500. Different from a conventional polymer-filled iron, the internal weight 516 is not removable to provide a port for injecting the polymer. Specifically, in the present invention, the faceplate 502 and the body 501 are co-molded. In contrast, a conventional filled iron includes a welded faceplate and body and a polymer injected into a cavity formed by the welded faceplate and body.

[0118] In some embodiments, the club head 500 includes one or more internal weights 516 embedded within the binder 515, and the one or more internal weights 516 are included in the volume of the club head. Referring to FIG. 8B, an exemplary embodiment of a golf club head 600 including one or more internal weights 616 is depicted. The golf club head 600 includes a face plate 602, a retainer 620, a body 601, an internal cavity 606, and a top rail 609. In this embodiment, the one or more internal weights are disposed in an intermediate portion of the internal cavity 616 that is close to the rear portion and the sole of the club head. The one or more internal weights 616 may be disposed on the heel end side, the toe end side, or both the heel end side and the toe end side of the internal cavity. Thus, depending on the arrangement of the one or more internal weights 616, the MOI characteristics and CG characteristics of the club head 600 change.

[0119] The one or more internal weights 516 or 616 may be made of a high-density material such as tungsten. In some embodiments, the one or more internal weights 516 or 616 contact the inner portion of the body 501 or 601 but do not contact the face plate 502 or 602.

[0120] One or more internal weights 516 or 616 may further include weight retainers 520 or 620 for securely engaging with the binder 515 or 615. By embedding the one or more internal weights 516 or 616 within the binder 515 or 615, some of the limitations that may otherwise be imposed on the one or more internal weights 516 or 616 are eliminated. For example, in some embodiments, the one or more internal weights 516 or 616 are not welded to the body 501 or 601. Further, internal weights typically require an exact fit for a secure and durable attachment, but the one or more internal weights 516 or 616 of the present invention may be formed roughly since they are embedded within the binder 515 or 615. The rough formation of the internal weights and the minimal direct attachment to the body 501 or 601 can reduce manufacturing time and the mass of the club head, while maintaining durability due to the reinforcement provided by the binder 515 or 615.

[0121] Further, embedding the one or more internal weights 516 or 616 within the binder reduces rattling that can cause undesirable sounds. Specifically, the movement of the one or more internal weights 516 or 616 is sufficiently restricted by the binder and the body 501 or 601.

[0122] The internal weights 516 or 616 may be arranged and sized to improve tolerance. For example, internal weights 516 or 616 located at a low position on the toe side may significantly lower the center of gravity of the club head and shift the center of gravity towards the toe side. In this case, it is known in the art that the MOI of the club head is improved. The one or more internal weights 516 or 616 may have a mass of 10 grams to 40 grams.

[0123] The internal cavity 506 or 606 may comprise one or more internal weights 516. In some embodiments, there may be one internal weight, two internal weights, three internal weights, four internal weights, or five or more internal weights. One or more internal weights 516 or 616 may be equally spaced from each other within the bonding material 515 or 615. One or more internal weights 516 or 616 do not contact the faceplate 502 or 602. One or more internal weights 516 or 616 may contact the body 501 or 601 at either the toe end, heel end, or rear end 510 or 610.

[0124] One or more internal weights 516 or 616 may have a generally triangular cross-sectional shape. In other embodiments, the cross-section of one or more internal weights may be rectangular, circular, semi-circular, polygonal, or any other suitable shape. That is, since one or more internal weights 516 or 616 are embedded within the bonding material 515 or 615 and do not need to be welded in place, the shape of the internal weights 516 or 616 is not structurally critical. Instead, various shapes may be used to achieve the desired CG position and improvement in MOI. In contrast, the internal weights of conventional welded clubs are limited to shapes having sufficient surface area for welding.

[0125] In a further embodiment, the golf club head may comprise a toe screw weight disposed within a toe screw weight port. The toe screw weight port may comprise a cylindrical recess having an external opening and a cylindrical sidewall. The toe screw weight port may further comprise a groove provided in at least a portion of the cylindrical sidewall, the groove configured to receive the threads of the toe screw weight and to secure the toe screw weight in a predetermined position.

[0126] In some embodiments, the toe screw weight has a mass of about 1 to 20 grams. In some embodiments, the mass of the toe screw weight may be about 1 to 2 grams, about 2 to 3 grams, about 3 to 4 grams, about 4 to 5 grams, about 5 to 6 grams, about 6 to 7 grams, about 7 to 8 grams, about 8 to 9 grams, about 9 to 10 grams, about 10 to 11 grams, about 11 to 12 grams, about 12 to 13 grams, about 13 to 14 grams, about 14 to 15 grams, about 15 to 16 grams, about 16 to 17 grams, about 17 to 18 grams, about 18 to 19 grams, or about 19 to 20 grams.

[0127] As described above, by combining the face plate, the bonding material, the retainer, and the body, it becomes easier to obtain a desired CG position and a discretionary weight that improves the MOI. That is, generally, a rear low-position CG is desirable.

[0128] Specifically, the CG depth may be 0.080 to 0.110 inches. The CG depth is measured from the origin of the XYZ coordinate system 1035 located at the geometric center of the striking face. The CG depth may be 0.080 inches, 0.082 inches, 0.084 inches, 0.086 inches, 0.088 inches, 0.090 inches, 0.092 inches, 0.094 inches, 0.096 inches, 0.098 inches, 0.100 inches, 0.105 inches, or 0.110 inches.

[0129] Furthermore, the sole-top rail CG height can be defined as the vertical distance between the origin of the XYZ coordinate system 1035 and the CG. The sole-top rail CG height may be 0.450 to 0.600 inches. The CG height may be less than 0.600 inches, less than 0.590 inches, less than 0.580 inches, less than 0.570 inches, less than 0.560 inches, less than 0.550 inches, less than 0.545 inches, less than 0.540 inches, less than 0.535 inches, less than 0.530 inches, less than 0.525 inches, less than 0.520 inches, less than 0.515 inches, less than 0.510 inches, less than 0.505 inches, less than 0.500 inches, or less than 0.450 inches.

[0130] Furthermore, there are moments of inertia Ixx about the x-axis (i.e., the moment of inertia from the top rail to the sole), Iyy about the y-axis (i.e., the moment of inertia from the heel to the toe), and the moment of inertia about the z-axis (i.e., the moment of inertia from the striking face to the rear). In many embodiments, the golf club head has a top rail-sole moment of inertia Ixx of 95 g in 2 ~150 g in 2 In many embodiments, the golf club head has a top rail-sole moment of inertia Ixx of about 95 g in 2 greater than, about 98 g in 2 greater than, about 100 g in 2 greater than, about 102 g in 2 greater than, about 103 g in 2 greater than, about 104 g in 2 greater than, about 105 g in 2 greater than, about 106 g in 2 greater than, about 110 g in 2 greater than, about 115 g in 2 greater than, about 120 g in 2 greater than, about 125 g in 2 greater than, about 130 g in 2 greater than, about 135 g in 2 greater than, about 140 g in 2 greater than, about 145 g in 2 greater than, or about 150 g in 2 greater than.

[0131] Furthermore, in many embodiments, the golf club head has a heel-toe moment of inertia Iyy, which may be greater than about 350 g in 2 greater than, about 360 g in 2 greater than, about 370 g in 2 greater than, about 380 g in 2 greater than, about 390 g in2 May be greater than, about 400 g in 2 May be greater than, about 410 g in 2 May be greater than, about 420 g in 2 May be greater than, about 430 g in 2 May be greater than, about 440 g in 2 May be greater than, about 450 g in 2 May be greater than, about 460 g in 2 May be greater than, about 470 g in 2 May be greater than, about 480 g in 2 May be greater than, or about 490 g in 2 May be greater than. In many embodiments, the golf club head is 420 g in 2 ~490 g in 2 and has a heel-toe moment of inertia Iyy of

[0132] Furthermore, the club head has a face-back moment of inertia Izz, and this moment of inertia is about 400 g in 2 May be greater than, about 410 g in 2 May be greater than, about 420 g in 2 May be greater than, about 430 g in 2 May be greater than, about 440 g in 2 May be greater than, about 450 g in 2 May be greater than, about 460 g in 2 May be greater than, about 470 g in 2 May be greater than, or about 480 g in 2 May be greater than. In many embodiments, the golf club head may have a face-back moment of inertia Izz of 400 g in 2 ~450 g in 2

[0133] ​Combining the described features (e.g., thin, low density, hard faceplate) is made possible by a unique co - molding manufacturing process. Specifically, in conventional clubs, it is necessary to weld the faceplate and the body, but the present invention can be formed by co - molding the faceplate and the body via a binder and a retainer. Even in conventional polymer - filled irons, it is necessary to weld the faceplate and the body and then inject the polymer from a port.

[0134] Therefore, in order to be well - constructed, the club head may include gates, flow - guiding parts, and voids that facilitate guiding the binder. That is, in a molding process such as injection molding, the embedded fibers tend to align in the direction in which the polymer flows. Depending on the specific fibers and resins, they tend to align more completely near the mold wall or the edge of the molded product. By arranging gates, flow - guiding parts, and voids within the mold design, the flow can be directed to control the fiber orientation more intricately. By doing so, non - uniform fiber orientations such as curving / arching, converging, diverging / spreading fan - like are possible. For example, the flow - guiding part may direct the flow towards the retainer.

[0135] Referring to FIG. 18, the faceplate may include a flow guiding portion 930. In some embodiments, the faceplate includes one or more flow guiding portions 930. The flow guiding portion 930 facilitates the flow of the binder 915 in the co - molding process. In some embodiments, the flow guiding portion 930 ensures that the fibers of the binder 915 are aligned in a specific direction. The required fiber direction is due to the stress distribution within the binder 915. The direction may be horizontal, vertical, or oblique at an angle of 0 - 90 degrees with respect to the ground. The flow guiding portion 930 is recessed into the faceplate 902 and may form a channel. In other embodiments, one or more flow guiding portions 930 are located along the outer edge of the faceplate 902. In some embodiments, the faceplate 902 includes six flow guiding portions 930 spaced equidistantly along the outer edge of the faceplate 902. In other embodiments, the faceplate includes four flow guiding portions 930. Specifically, the first flow guiding portion may be located at the toe portion of the outer edge of the faceplate, the second flow guiding portion may be located at the top portion of the outer edge of the faceplate, the third flow guiding portion may be located at the heel portion of the outer edge of the faceplate, and the fourth flow guiding portion may be located at the sole portion of the outer edge of the faceplate.

[0136] The flow guiding portion 930 has a width, a depth, and a length. The width may be from 0.1 inch to 2 inches. The depth may be from 0.1 inch to 1 inch. The length may be from 0.1 inch to 2 inches. The flow guiding portion may have various shapes including polygons, rectangular parallelepipeds, semi - cylindrical shapes, rectangular parallelepipeds with rounded corners, and similar shapes. The various shapes are advantageous for dispersing the filler throughout the club head in various applications.

[0137] As shown in FIG. 6, the gate 140 may be located in the central region on the rear surface of the body 101, recessed toward the face plate 102 but not in contact with the face plate 102. In other embodiments, the gate 140 may be located at the heel end 104 or the toe end 103. In a preferred embodiment, one gate 140 is centrally disposed. In a further embodiment, one or more gates (not shown) may be disposed on the rear surface of the body 101.

[0138] The gate 140 generally has a circular shape. In other embodiments, the gate 140 may have a rectangular, triangular, polygonal, or any other suitable shape. The gate 140 has a diameter. In some embodiments, the diameter of the gate may be from 0.15 inches to 0.35 inches. In some embodiments, the diameter of the gate may be from 0.15 inches to 0.17 inches, from 0.17 inches to 0.19 inches, from 0.19 inches to 0.21 inches, from 0.21 inches to 0.23 inches, from 0.23 inches to 0.25 inches, from 0.25 inches to 0.27 inches, from 0.27 inches to 0.29 inches, from 0.29 inches to 0.31 inches, from 0.31 inches to 0.33 inches, or from 0.33 inches to 0.35 inches. In an exemplary embodiment, the diameter of the gate is 0.25 inches.

[0139] The gate 140 may be recessed from the rear surface by from 0.38 inches to 0.52 inches. In some embodiments, the recess distance of the gate may be from 0.38 inches to 0.40 inches, from 0.40 inches to 0.42 inches, from 0.42 inches to 0.44 inches, from 0.44 inches to 0.46 inches, from 0.46 inches to 0.48 inches, from 0.48 inches to 0.50 inches, or from 0.50 inches to 0.52 inches. In an exemplary embodiment, the recess distance of the gate is 0.42 inches.

[0140] The gate 140 further includes a gate interface surface 142, a gate recess outer peripheral surface 144, and a gate opening 146. These features are used in the manufacturing process, more specifically in the injection molding process described below.

[0141] The body 101 may further include a protruding recess 150. The protruding recess 150 further includes a protruding interface surface 152 and an outer peripheral portion 154 of the protruding recess. These features are used in the manufacturing process, more specifically, the injection molding process described below.

[0142] Manufacturing Method In addition to the performance advantages disclosed above, the golf club head of the present invention may be uniquely manufactured to provide unique advantages with respect to manufacturing time and quality. That is, without welding between the face plate and the body, the completed club head can be inserted into the mold without being damaged, so several steps can be omitted from the conventional manufacturing method, and higher manufacturing quality can be guaranteed.

[0143] The club head may first be manufactured by separately forming the face plate and the body using conventional techniques established in the art. Further, the face plate and the body are heat-treated separately. Subsequently, the body is inserted into the mold and the face plate is held separately from the body. In some embodiments, the mold is a silicon-lined mold. Further, a bonding material is inserted between the face plate and the body. The completed club head is removed from the mold, and the face plate and the body are bonded only by the bonding material.

[0144] Referring to FIG. 10, the manufacturing process is shown step by step. Further, referring to FIG. 11, an exploded view of the injection molding assembly 970 is shown. The manufacturing process can be divided into three different manufacturing steps. Each of the three steps includes a subset of steps. These three different steps include the manufacturing of the body 901, the manufacturing of the face plate 902, and the manufacturing of the club head 900.

[0145] Steps 1a to 1e show a subset of steps for manufacturing a body 901 similar to the above-described bodies 101 and 501. In step 1a, the body 901 is formed by a known manufacturing method such as casting, forging, or milling. In step 1b, the body 901 is roughly cleaned. By the rough cleaning, excess material is removed and a rough shape is imparted to the body 901. In step 1c, the body 901 is heat-treated. In step 1d, the body 901 is finished by grinding, polishing, or machining. In an optional step 1e, the body 901 may be chrome-plated. The body 901 formed by steps 1a to 1e does not require additional finishing such as polishing, grinding, or plating.

[0146] Steps 2a to 2d include manufacturing a face plate 902 similar to the above-described face plates 102 and 502. In step 2a, the overall shape of the face plate 902 is formed by casting, forging, or milling. In step 2b, retainers 920 similar to 120 and 520 are formed in the face plate 902. In step 2c, the face plate 902 is heat-treated. In step 2d, grooves and face flats may be formed in the face plate 902.

[0147] Steps 3a to 3f include manufacturing a golf club head 900 by injection molding. Referring to FIGS. 11 to 17, the injection molding assembly 970 includes a side A portion 980 and a side B portion 990. The side A portion 980 includes a gate 981. The gate 981 further includes an opening 984, a body interface surface 982, and a club complementary shape 983. The opening 984 is concentric with the gate opening 946. The opening 984 provides a passage through which the binder 915 flows during the injection molding process. The body interface surface 982 forms a seal with the gate interface surface 942. This seal prevents the binder 915 from flowing out of the internal cavity (not shown similar to 106). The club complementary shape 983 is complementary to the outer peripheral portion of the gate recess 944.

[0148] The A-side portion 980 may further include a body recess 988 and a protrusion 985. The body recess 988 is complementary to the shape of the body 901. The protrusion 985 is complementary to the protruding recess 950. The protrusion 985 includes a top interface surface 986 and an outer peripheral surface 987. The top interface surface 986 has a shape complementary to the outer peripheral portion 954 of the protruding recess. The top interface surface 986 transmits a force to the body 901 via the protrusion interface surface 952. Due to this force, the body 901 is held in a predetermined position during the injection molding process. The outer peripheral surface 987 and the body recess 988 prevent the body 902 from rotating during the injection process.

[0149] In step 3a, the face plate 902 and the body 901 are arranged on the B-side portion 990. The B-side portion 990 includes a fence 991. The fence 991 positions the face plate 902 and the body 901 in their final positions before the injection molding process of step 3b begins. The face plate 902 is arranged inside the fence 991. The fence 991 includes a face plate interface surface 993. The face plate interface surface 993 extends along the outer edge of the face plate 902 and seals the space between the face plate 902 and the B-side portion 980. The seal between the face plate 902 and the B-side portion 990 serves as a barrier for the bonding material 915 when the bonding material 915 is injected into the internal cavity (not shown similar to 106). The fence 991 includes a club interface surface corresponding to the fence opening of the body 901 (not shown similar to the fence opening 129). The fence 991 prevents the face plate 902 and the body 901 from rotating during the injection molding process.

[0150] The fence 991 may further have a fence height 992 and a fence width 997. The fence height 992 may be from 0.005 inches to 0.125 inches. The fence width 997 may be from 0.001 inches to 0.125 inches. The fence height 992 and the fence width 997 may be configured to minimize the size of the above-described lip while accommodating the bonding material 915 within an internal cavity (not shown similar to 106 and 506).

[0151] The B-side portion 990 may further include a top surface 995 that defines a B-side surface 999. The face plate is placed in the same plane as the B-side surface 999. Further, the top interface surface 986, the body interface surface 982, the gate interface surface 142, and the protrusion interface surface 152 are parallel to the B-side surface 999. By these surfaces being parallel to the B-side surface 999, force is smoothly transmitted between the injection molding assembly 970 and the body 901.

[0152] When the body 901 is disposed on the A-side portion 980 and the face plate 902 is disposed on the B-side portion 990, the injection molding assembly 970 is closed and step 3b is started. The bonding material 915 is injected into the injection molding assembly 970 through the gate 981. In step 3c, the excess bonding material 915 outside the internal cavity is removed. The excess bonding material 915 to be removed includes the gate 981 and burrs.

[0153] In step 3d, the club head 900 is masked except for the impact area. The impact area is the area designed to hit the golf ball. Next, the impact area is media blasted. By media blasting, a texture is imparted to the golf ball and the glare of the club head 900 is reduced in the impact area. From the injection molding process, a groove is left by the fence 991, and this groove may be filled with a suitable material such as polyurethane. When steps 1a - 1e, 2a - 2d, and 3a - 3e are completed, the finished golf club head 900 is obtained. The finished golf club head 900 does not require additional manufacturing processes such as grinding, polishing, or milling.

[0154] Furthermore, several examples are detailed below.

[0155] Example Example 1 - Reference Performance In the first example, an embodiment of the present invention was compared with an existing player's iron. The purpose of this test was to demonstrate that the performance would not degrade when co - molding the face plate and the body instead of welding. Specifically, the motivation for this test was that if a co - molded iron made of stainless steel could exhibit the same performance as a welded iron made of stainless steel, then by leveraging the unique advantages of co - molded irons such as a variety of material selections, thinning of the face plate, thinning of the body, and weight embedding, it might be possible to improve the performance from the criteria along the lines of the performance of conventional club heads.

[0156] Generally, in this example, two clubheads having similar face thicknesses and face materials were compared. One clubhead had a binder, while the other had a solid, uniform body, and the face plate and the body were welded. Specifically, the tested embodiment had a face made of stainless steel, and the thickness of the face plate was about 0.07 inches. Similarly, the tested conventional clubhead also had a stainless steel face plate with a thickness of about 0.07 inches. Further, the binder had a density of about 1.42 g / cm 3 and was made of a thermoplastic composite material. Specifically, the binder consisted of a TPU resin reinforced with carbon fibers 12.7 mm in length, and by volume, 40% was carbon fiber and 60% was TPU.

[0157] Furthermore, the tests included player tests in which players with handicaps of -4 to 12 used the clubheads. The results are summarized in the following table. Table 1 Changes in Reference Performance [Table 1]

[0158] Generally, in this first example, it was revealed that the performance was similar between the tested embodiment of the present invention and the control group's player irons. Specifically, in the tests, it was revealed that there was a slight difference in MOI. The MOI of the conventional welded clubhead was about 434 g in 2 and the MOI of the exemplary clubhead was about 424 g in 2It was. Furthermore, in this test, it was revealed that there was a difference of approximately 0.5 miles per hour in the average ball speed and a difference of approximately 0.4 degrees in the launch angle. Ultimately, it was revealed that in the test, even when introducing a bonding material instead of welding, the performance of the club head did not decline. Therefore, by leveraging the unique advantages of the present invention such as the selection of various materials, thinning of the face plate, thinning of the body, and embedding of weights, it would be possible to improve the performance from the performance criteria along the lines of existing player irons. Therefore, this example demonstrates that by incorporating unique materials and components such as a low-density and thin face plate, more unique performance is provided compared to conventional welded club heads so that the bonding material is promoted.

[0159] Example 2 - Standard durability Furthermore, an air cannon durability test was conducted on the embodiment of the first example. That is, the club head was subjected to thousands of high-energy collisions with a golf ball. The purpose of this test was to demonstrate that the durability would not decline even when co-molding the face plate and the body instead of welding.

[0160] The club head exhibited almost the same durable characteristics as the player iron tested in the first example. Specifically, the exemplary club head withstood at least 3500 strikes. Therefore, this example demonstrates that the durability does not decline even when using a bonding material instead of conventional welding.

[0161] Example 3 - Low-density face plate (made of titanium) In the third example, the embodiment of the present invention included a face plate made of titanium and a body made of steel, and the face plate and the body were co-molded using a bonding material and a retainer. The purpose of this test was to demonstrate that it was possible to co-mold a face plate and a body formed from different materials. This test also aimed to demonstrate that using a titanium face plate improved the MOI.

[0162] Titanium faceplates have been used in wooden golf clubs but not in iron clubs made of steel. Generally, to bond titanium and steel, bonding with adhesives or mechanical fixing is required. Such mechanisms can be heavy, costly, and may cause significant delays in manufacturing and lack of consistency. However, in this example, the titanium faceplate was integrated with the steel body via a binder and a retainer.

[0163] Specifically, the thickness of the faceplate was about 0.07 inches, similar to the exemplary embodiments tested in Example 1 and Example 2. On the other hand, the density of the faceplate was about 4.0 g / cm 3 while that of steel is about 8 g / cm 3 Thus, the density of the faceplate was about 50% lower than that of the faceplate of the clubhead in the first example.

[0164] As a result, the MOI increased compared to the clubhead in the first example. That is, despite having approximately the same faceplate thickness and clubhead mass, the MOI was about 4.5% greater than that of the clubhead in the first example. Specifically, the MOI of the exemplary clubhead with a titanium faceplate was about 440 g in 2

[0165] Example 4 - Thin Faceplate In the fourth example, an embodiment of the present invention is compared with the same player's iron as in the first example. However, in this example, the faceplate of the embodiment of the present invention is about 28% thinner than that in the first example. Specifically, the exemplary clubhead has a faceplate thickness of about 0.04 inches.

[0166] ​As described above, incorporating such a thin faceplate is facilitated by the unique structure of the present invention in which the bonding material engages the faceplate and the body. By providing support to the faceplate and eliminating the need for welding, the faceplate can be made very thin without sacrificing durability.

[0167] By incorporating a sufficiently thin faceplate, the MOI is increased compared to the club head of the first example. Specifically, the MOI is approximately 10% greater.

[0168] Thus, this example shows that the unique structure of the present invention provides a platform into which desirable structural changes can be incorporated. For example, it is known to incorporate a thin club face to improve performance, but durability has been a limiting factor. However, the present invention has desirable structural elements such as a very thin face without sacrificing durability.

[0169] Example 5 - Low - density faceplate (made of metal matrix composite material) In the fifth example, an embodiment of the present invention includes a low - density faceplate to maximize the moment of inertia. That is, the faceplate includes a metal matrix, a magnesium matrix, or a composite material. The density of the faceplate is about 1.8 g / cm 3 and the thickness of the faceplate is about 0.07 inches. In particular, the density of the faceplate is approximately 77% lower than the density of the faceplate of the first example. As a result, the MOI is increased compared to the club head of the first example, even though it has approximately the same faceplate thickness and club head mass. Specifically, the MOI is approximately 15% greater.

[0170] Example 6 - High - hardness faceplate In the sixth example, a club head like the club head of the first example is provided with a face plate having a sufficiently high hardness. That is, the club head includes a face plate made of D2 tool steel having a Rockwell hardness of about 60 HRC. The club is a wedge-type golf club. This face plate is about 1.5 to 2.5 times harder than a typical stainless-steel face plate such as the face plate used in the club head of the first example. By incorporating a sufficiently hard face plate, a significant improvement in the durability of the club head is expected. Specifically, the reduction rate of the spin speed is expected to be improved by about 35 to 65 RPM per 500 hits. That is, assuming that the exemplary club and the control club produce the same reference spin speed, the exemplary club head will produce a spin speed that is about 35 to 65 RPM faster than the control club after 500 hits. Considering that the spin speed typically decreases by about 100 RPM every 500 hits, the exemplary club head shows a reduction in spin speed that is about 35% to 65% less than that of a typical wedge.

[0171] Example 7 - Tungsten Weight In the seventh example, the club head includes a first weight and a second weight inside the club head volume. Both the first weight and the second weight are formed from tungsten. Further, the weights are not welded to either the face plate or the body. Instead, the weights are embedded inside the club head via a bonding material. Further, the first weight is located near the sole and heel, and the second weight is located near the sole and toe. Both weights are about 20 grams. Further, the exemplary club head includes a face plate made of titanium. Specifically, the thickness of the face plate is about 0.07 inches. The density of the face plate is about 4.0 g / cm 3 is.

[0172] Accordingly, the MOI of the club head is increased as compared to the club head of the control group of the first example. Specifically, even though having substantially the same face plate thickness and club head mass, the MOI is about 15% - 20% larger. Substantially, since the low-density binder holds the club head together, the structural mass of the club head is less. Thus, in such an exemplary club head, etc., discretionary mass can be assigned to improve the MOI.

[0173] Replacing one or more of the claimed elements is a reconstruction, not a repair. Further, with respect to particular embodiments, benefits, other advantages, and solutions to problems have been described. However, a benefit, advantage, solution to a problem, and one or more elements that may cause or make more prominent such a benefit, advantage, or solution are not to be construed as important, necessary, or essential features or elements of any or all of the claims unless such benefit, advantage, solution, or element is expressly recited in such claims.

[0174] Since the rules of golf can change from time to time (e.g., new rules may be adopted or old rules may be abolished or modified by golf standardization organizations and / or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St. Andrews (R&A), etc.), the golf equipment related to the devices, methods, and articles of manufacture described herein may or may not conform to the rules of golf at any given point in time. Accordingly, the golf articles related to the devices, methods, and articles of manufacture described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf articles. The devices, methods, and articles of manufacture described herein are not limited in this regard.

[0175] The above examples may be described in connection with iron-type golf clubs, but the devices, methods, and articles of manufacture described herein may be applicable to other types of golf clubs such as driver wood-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. Alternatively, the devices, methods, and articles of manufacture described herein may be applicable to other types of sports equipment such as hockey sticks, tennis rackets, fishing rods, ski poles, and the like.

[0176] Furthermore, the embodiments and limitations disclosed herein are not provided to the public based on the doctrine of equivalents where the embodiments and / or limitations are (1) not expressly recited in the claims and (2) are equivalent to, or potentially equivalent to, the expressly recited elements and / or limitations in the claims.

[0177] Item Item 1 An iron-type golf club head, comprising a face plate, a body, and a bonding material, the body comprising a sole and a topline, the bonding material being disposed substantially between the face plate and the body, the bonding material bridging the face plate to the body, the face plate not being welded to the body, the face plate comprising at least one retainer disposed within the volume of the golf club head, the bonding material engaging both at least one body lock shape and at least one retainer, the face plate further comprising a face plate density, the body further comprising a body density, the club head further comprising a density ratio, the density ratio being the ratio of the body density to the face plate density, An iron-type golf club head with a density ratio greater than 1.

[0178] Item 2 The iron-type golf club head according to item 1, wherein at least one retainer has at least one circular hole.

[0179] Item 3 Further comprising a face surface and an offset, The face surface is parallel to the face plate, The face surface is on the same plane as the face plate, The offset is the distance between the face plate and the body measured along the face surface, The offset is substantially constant across the face plate. The iron-type golf club head according to item 1.

[0180] Item 4 The iron-type golf club head according to item 3, wherein the offset is from 0.001 inches to 0.125 inches.

[0181] Item 5 The iron-type golf club head according to item 1, wherein the density ratio is greater than 3.

[0182] Item 6 The iron-type golf club head according to item 1, wherein the density ratio is greater than 4.

[0183] Item 7 The iron-type golf club head according to item 1, wherein the hardness of the face plate is greater than 35 HRC.

[0184] Item 8 The iron-type golf club head according to item 1, wherein the hardness of the face plate is greater than 50 HRC.

[0185] Item 9 The iron-type golf club head according to claim 1, wherein the bonding material contains a resin selected from the group consisting of a thermoplastic composite material (TPC) and a thermoplastic polyurethane (TPU).

[0186] Claim 10 An iron-type golf club head, comprising a face plate, a body, and a bonding material, wherein the body includes a sole and a topline, the bonding material is disposed substantially between the face plate and the body, the bonding material crosslinks the face plate to the body, the face plate is not welded to the body, the face plate includes at least one face plate retainer disposed within the volume of the golf club head, the body includes at least one body retainer disposed within the volume of the golf club head, the bonding material engages both at least one body retainer and at least one face plate retainer, the bonding material and the face plate form at least one individual void behind the face plate, the face plate further includes a face plate density, the body further includes a body density, the club head further includes a density ratio, the density ratio is the ratio of the body density to the face plate density, An iron-type golf club head, wherein the density ratio is greater than 1.

[0187] Claim 11 The iron-type golf club head according to claim 10, wherein at least one individual void is proximate to at least one of the topline and the sole.

[0188] Claim 12 the face plate includes a face plate modulus of elasticity, the body includes a body modulus of elasticity, The iron-type golf club head according to item 10, wherein the body elastic modulus is smaller than the face plate elastic modulus.

[0189] Item 13 An iron-type golf club head comprising a face plate, a body, and a binder, the body comprising a sole and a topline, the binder being disposed substantially between the face plate and the body, the binder cross-linking the face plate to the body, the face plate and the body not being welded to each other, the face plate comprising a retainer disposed within the volume of the golf club head, the retainer comprising a groove along the outer edge of the face plate, the binder engaging the retainer, the face plate further comprising a face plate density, the body further comprising a body density, the club head further comprising a density ratio, the density ratio being the ratio of the body density to the face plate density, the iron-type golf club head, wherein the density ratio is greater than 1.

[0190] Item 14 The iron-type golf club head according to item 13, wherein the density ratio is greater than 3.

[0191] Item 15 The iron-type golf club head according to item 13, wherein the density ratio is greater than 4.

[0192] Item 16 The iron-type golf club head according to item 13, wherein the hardness of the face plate is greater than 35 HRA.

[0193] Item 17 The iron-type golf club head according to item 13, wherein the hardness of the face plate is greater than 50 HRC.

[0194] Item 18 The iron-type golf club head according to item 13, wherein the binder contains a resin selected from the group consisting of a thermoplastic composite material (TPC) and a thermoplastic polyurethane (TPU).

[0195] Item 19 The iron-type golf club head according to item 18, wherein the resin is reinforced with carbon fibers.

[0196] Item 20 The face plate is formed of titanium, The iron-type golf club head according to item 13, wherein the body is formed of steel.

[0197] Item 21 An iron-type golf club head that defines a club head internal volume, Comprising a sole, a top rail, and a body opening, a body having a body density, A face plate, A striking face disposed within the body opening, the striking face being sized to form a gap between the striking face and the body opening, At least one retainer disposed within the head internal volume, A face plate comprising a face plate density, A binder disposed between the face plate and the body, At least one protrusion that mechanically engages with at least one retainer to couple the face plate to the body, A binder comprising a front lip that closes the gap, An iron-type golf club head, wherein the density ratio of the club head, which is the body density with respect to the face plate density, is greater than 1.

[0198] Item 22 The iron-type golf club head according to claim 21, wherein the binder is visible from the outside.

[0199] Claim 23 The iron-type golf club head according to claim 21, wherein at least one retainer forms a groove.

[0200] Claim 24 The iron-type golf club head according to claim 23, wherein the groove comprises a plurality of circular notches.

[0201] Claim 25 The iron-type golf club head according to claim 21, wherein the thickness of the gap measured between the striking face and the body opening is from 0.001 inches to 0.125 inches.

[0202] Claim 26 The iron-type golf club head according to claim 21, wherein the density ratio is greater than 3.

[0203] Claim 27 The iron-type golf club head according to claim 21, wherein the density ratio is greater than 4.

[0204] Claim 28 The iron-type golf club head according to claim 21, wherein the face plate has a hardness greater than 35 HRC.

[0205] Claim 29 The iron-type golf club head according to claim 21, wherein the face plate has a hardness greater than 50 HRC.

[0206] Claim 30 The iron-type golf club head according to claim 21, wherein the binder contains a resin selected from the group consisting of a thermoplastic composite (TPC) and a thermoplastic polyurethane (TPU).

[0207] Claim 31 An iron-type golf club head defining an internal volume of the club head, A body having a sole, a top rail, and a body opening, and having a body density and a body hardness, A face plate, A striking face disposed within the body opening, the striking face being sized to form a gap between the striking face and the body opening, At least one retainer disposed within the head internal volume, A face plate having a face plate density and a face plate hardness, An adhesive disposed between the face plate and the body, At least one protrusion that mechanically engages with the at least one retainer to couple the face plate to the body, An adhesive comprising a front lip that closes the gap, The density ratio of the club head, which is the body density relative to the face plate density, is greater than 1, An iron-type golf club head in which the hardness ratio of the club head, which is the face plate hardness relative to the body hardness, is greater than 1.

[0208] Item 32 The iron-type golf club head according to item 31, wherein the club head has a loft of at least 47 degrees.

[0209] Item 33 The iron-type golf club head according to item 31, wherein the face plate hardness is at least 45 HRC.

[0210] Item 34 The iron-type golf club head according to item 31, wherein the face plate hardness is at least 50 HRC.

[0211] Item 35 The iron-type golf club head according to item 31, wherein the face plate hardness is at least 55 HRC.

[0212] Item 36 The iron-type golf club head according to item 31, wherein the face plate has a hardness of at least 60 HRC.

[0213] Item 37 The iron-type golf club head according to item 31, wherein the binder has a compressive strength of at least 80 Ksi.

[0214] Item 38 The binder consists of a resin and a fiber, The iron-type golf club head according to item 31, wherein the resin contains a material selected from thermoplastic polyurethane (TPU) and thermoplastic composite material (TPC).

[0215] Item 39 The iron-type golf club head according to item 38, wherein the fiber has a length of 0.01 mm to 12 mm.

[0216] Item 40 The iron-type golf club head according to item 38, wherein the binder contains both continuous fibers and discontinuous fibers.

[0217] Item 41 An iron-type golf club head that defines the internal volume of the club head, Comprising a sole, a top rail, a body opening, an outer surface, and an inner surface, a body having a body density and a body hardness, wherein the inner surface of the body forms a frame, the body, A face plate, At least one retainer disposed in the internal volume of the head, Having a face plate density and a face plate hardness, A gap is formed between the face plate and the frame, The face plate forms at least a part of at least one of the sole or the top rail, the face plate, A binder disposed between the face plate and the body, At least one protrusion that mechanically engages with at least one retainer to couple the face plate to the body a bonding material comprising a front lip for closing the gap An iron-type golf club head in which the density ratio of the club head, which is the body density with respect to the face plate density, is greater than 1.

[0218] Item 42 The iron-type golf club head according to Item 41, wherein the face plate and the bonding material form at least one individual gap behind the face plate.

[0219] Item 43 The iron-type golf club head according to Item 42, wherein at least one individual gap is close to the top rail.

[0220] Item 44 The iron-type golf club head according to Item 42, wherein at least one individual gap is close to the sole.

[0221] Item 45 The iron-type golf club head according to Item 41, wherein the face plate and the bonding material form a plurality of gaps behind the face plate.

[0222] Item 46 at least one of the plurality of gaps is close to the toe, The iron-type golf club head according to Item 45, wherein another one of the plurality of gaps is close to the heel.

[0223] Item 47 The iron-type golf club head according to Item 41, wherein the bonding material contains a thermoplastic resin reinforced by a plurality of carbon fibers.

[0224] Item 48 The iron-type golf club head according to Item 42, wherein the plurality of carbon fibers have a length of 0.01 mm to 12 mm.

[0225] Item 49 The face is formed of a metal matrix composite material, The iron-type golf club head according to item 41, wherein the body is made of steel.

[0226] Item 50 An iron-type golf club head comprising a face plate, a body, and a bonding material, the body comprising a heel end, a toe end, a sole, and a topline, the bonding material being disposed substantially between the face plate and the body, the bonding material bridging the face plate to the body, the face plate not being welded to the body, the face plate comprising at least one face plate retainer disposed within the volume of the golf club head, the body comprising two or more body retainers disposed within the volume of the golf club head, the bonding material engaging both two or more body retainers and at least one face plate retainer, the bonding material and the face plate forming two separate voids behind the face plate, the face plate further comprising a face plate density, the body further comprising a body density, the club head further comprising a density ratio, the density ratio being the ratio of the body density to the face plate density, An iron-type golf club head, wherein the density ratio is greater than 1.

[0227] Item 51 The first separate void is disposed proximate to the topline, The iron-type golf club head according to item 50, wherein the second separate void is disposed proximate to the heel end.

[0228] Item 52 The first separate void is disposed proximate to the topline, The iron-type golf club head according to claim 50, wherein a second individual gap is disposed adjacent to the toe end.

[0229] Claim 53 A first individual gap is disposed adjacent to the sole, The iron-type golf club head according to claim 50, wherein a second individual gap is disposed adjacent to the heel end.

[0230] Claim 54 A first individual gap is disposed adjacent to the sole, The iron-type golf club head according to claim 50, wherein a second individual gap is disposed adjacent to the toe end.

[0231] Claim 55 A first individual gap is disposed adjacent to the heel end, The iron-type golf club head according to claim 50, wherein a second individual gap is disposed adjacent to the toe end.

[0232] Claim 56 The iron-type golf club head according to claim 51, wherein the thickness of the face plate is 0.04 inches.

[0233] Claim 57 A first body retainer is disposed adjacent to the top rail, The iron-type golf club head according to claim 50, wherein a second body retainer is disposed adjacent to the sole.

[0234] Claim 58 A first body retainer is disposed adjacent to the heel end, The iron-type golf club head according to claim 50, wherein a second body retainer is disposed adjacent to the toe end.

[0235] Claim 59 The iron-type golf club head according to claim 50, wherein at least one face plate retainer is adjacent to at least one of the top rail and the sole.

[0236] Item 60 The iron-type golf club head according to item 50, wherein the binder includes at least one internal weight.

Claims

1. It is an iron-type golf club head, It comprises a faceplate, a body, and a connecting material. The aforementioned body comprises a sole and a top rail, The bonding material is substantially positioned between the faceplate and the body. The aforementioned bonding material cross-links the faceplate to the body, The faceplate is not welded to the body. The face plate comprises at least one retainer positioned within the volume of the iron-type golf club head. The connector engages with both at least one body lock shape and at least one retainer, The aforementioned faceplate further comprises a faceplate density, The aforementioned body further possesses body density, The aforementioned iron-type golf club head further features a density ratio, The density ratio is the ratio of the body density to the faceplate density. An iron-type golf club head with a density ratio greater than 3.

2. The iron-type golf club head according to claim 1, wherein the at least one retainer comprises at least one circular hole.

3. The face and offset are further enhanced. The face surface is parallel to the face plate, The aforementioned face surface is on the same plane as the face plate, The offset is the distance between the faceplate and the body, measured along the face surface. The iron-type golf club head according to claim 1, wherein the offset is substantially constant across the faceplate.

4. The iron-type golf club head according to claim 3, wherein the offset is 0.001 inches to 0.125 inches.

5. The iron-type golf club head according to claim 1, wherein the density ratio is greater than 4.

6. The iron-type golf club head according to claim 1, wherein the hardness of the faceplate is greater than 35 HRC.

7. The iron-type golf club head according to claim 1, wherein the hardness of the face plate is greater than 50 HRC.

8. The iron-type golf club head according to claim 1, wherein the binder comprises a resin selected from the group consisting of thermoplastic composite materials (TPC) and thermoplastic polyurethane (TPU).

9. It is an iron-type golf club head, It comprises a faceplate, a body, and a connecting material. The aforementioned body comprises a sole and a top rail, The bonding material is substantially positioned between the faceplate and the body. The aforementioned bonding material cross-links the faceplate to the body, The faceplate is not welded to the body. The face plate comprises at least one face plate retainer positioned within the volume of the iron-type golf club head. The body comprises at least one body retainer positioned within the volume of the iron-type golf club head. The connector engages with both the at least one body retainer and the at least one faceplate retainer. The bonding material and the face plate form at least one separate void behind the face plate. The aforementioned faceplate further comprises a faceplate density, The aforementioned body further possesses body density, The aforementioned iron-type golf club head further features a density ratio, The density ratio is the ratio of the body density to the faceplate density. The density ratio is greater than 1. The faceplate has a faceplate elastic modulus, The body has a body elastic modulus, An iron-type golf club head in which the body elastic modulus is smaller than the face plate elastic modulus.

10. The iron-type golf club head according to claim 9, wherein the at least one individual void is in proximity to at least one of the top rail and the sole.

11. It is an iron-type golf club head, It comprises a faceplate, a body, and a connecting material. The aforementioned body comprises a sole and a top rail, The bonding material is substantially positioned between the faceplate and the body. The aforementioned bonding material cross-links the faceplate to the body, The faceplate and the body are not welded to each other. The face plate comprises a retainer positioned within the volume of the iron-type golf club head. The retainer has a groove along the outer edge of the faceplate, The bonding material engages with the retainer, The aforementioned faceplate further comprises a faceplate density, The aforementioned body further possesses body density, The aforementioned iron-type golf club head further features a density ratio, The density ratio is the ratio of the body density to the faceplate density. An iron-type golf club head with a density ratio greater than 3.

12. The iron-type golf club head according to claim 11, wherein the density ratio is greater than 4.

13. The iron-type golf club head according to claim 11, wherein the hardness of the face plate is greater than 35 HRA.

14. The iron-type golf club head according to claim 11, wherein the hardness of the face plate is greater than 50 HRC.

15. The iron-type golf club head according to claim 11, wherein the binder comprises a resin selected from the group consisting of thermoplastic composite materials (TPC) and thermoplastic polyurethane (TPU).

16. The iron-type golf club head according to claim 15, wherein the resin is reinforced with carbon fiber.

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