Iron-type golf club head with a flexible structure

Abstract

We provide iron-type golf club heads with flex structures, face reinforcement structures, and modified face thicknesses to improve the durability of the club head while increasing the flex of the face elements. [Solution] The club head comprises a face element for striking a golf ball. The face element is integrally formed with a flex structure. The flex structure comprises a curved profile (e.g., S-shaped or sinusoidal) that acts like a spring to support the face element upon impact with the golf ball. The face reinforcement structure comprises annular ribs that provide support around the center of the face element. Variable face thickness includes thickened and thinned areas to increase or support further flex of the face element.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 821,962, filed Mar. 21, 2019, and U.S. Provisional Patent Application No. 62 / 745,176, filed Oct. 12, 2018, and the entire contents of all of the disclosures described above are hereby incorporated by reference in their entirety.

[0002] The present invention generally relates to an iron - type club head having a structure for reinforcing a face element.

Background Art

[0003] Various characteristics of a golf club can affect the performance of the golf club. For example, the center of gravity, moment of inertia, and coefficient of restitution of the club head of a golf club are characteristics of the golf club that can each affect performance.

[0004] The center of gravity and moment of inertia of the club head of a golf club are functions of the distribution of the mass of the club head. In particular, focusing the mass of the club head closer to the sole of the club head, farther from the face of the club head, and / or closer to the toe and heel ends of the club head can change the center of gravity and / or moment of inertia of the club head. For example, distributing the mass of the club head closer to the sole of the club head and / or farther from the face of the club head can increase the flight angle of the golf ball due to the strike by the club head. On the other hand, increasing the flight angle of the golf ball can increase the distance the golf ball travels. Further, distributing the mass of the club head closer to the toe end and / or heel end of the club head can affect the moment of inertia of the club head, thereby increasing the forgiveness of the golf club.

[0005] Furthermore, the coefficient of restitution of a golf club head can be a function of at least the flexibility of the club head face. On the other hand, the flexibility of the club head face can be a function of the face's geometry (e.g., height, width, and / or thickness) and / or the face's material properties (e.g., Young's modulus). That is, the flexibility of the face can be increased by maximizing the face's height and / or width, and / or minimizing the face's thickness and / or Young's modulus. As a result, the coefficient of restitution of the club head can be increased. Increasing the coefficient of restitution of a golf club head, which is essentially a measure of the efficiency of energy transfer from the club head to the golf ball, can increase the distance the golf ball travels after impact, decrease the amount of spin the golf ball has, and / or increase the ball speed of the golf ball. [Overview of the project] [Problems that the invention aims to solve]

[0006] However, while thinning the clubhead face allows for the redistribution of mass from the face to other parts of the clubhead, making the face more flexible, this can result in increased flex within the face, potentially leading to buckling and breakage. Therefore, the art requires clubheads that increase face flex while maintaining or improving face durability. [Brief explanation of the drawing]

[0007] [Figure 1] This is a front perspective view of an iron-type club head according to an embodiment. [Figure 2] Figure 1 is a rear view of an iron-type club head. [Figure 3] This is a side cross-sectional view of the iron-type club head shown in Figure 1, cut along line 3-3 in Figure 2. [Figure 4]This is a side cross-sectional view of the iron-type club head shown in Figure 1, cut along line 3-3 in Figure 2. [Figure 5] Figure 1 is a rear perspective view of an iron-type club head. [Figure 6] Figure 1 is a top view of an iron-type club head. [Figure 7] Figure 1 is a cross-sectional view of the flex structure of an iron-type club head. [Figure 8] This is a cross-sectional view of a flexible structure according to an embodiment. [Figure 9] This is a cross-sectional view of a flexible structure according to an embodiment. [Figure 10] This is a rear view of an iron-type club head according to another embodiment. [Figure 11] This is a cross-sectional view of the iron-type club head shown in Figure 10, cut along line 11-11 in Figure 10. [Figure 12] This is a rear perspective view of an iron-type club head in a different embodiment. [Figure 13] This is a rear perspective view of an iron-type club head according to another embodiment. [Modes for carrying out the invention]

[0008] For the sake of clarity and simplicity, the figures illustrate schematic aspects of the configuration, and well-known features and technical descriptions and details may be omitted to avoid unnecessarily obscuring the disclosure. Furthermore, elements in the figures are not necessarily drawn to actual size. For example, to aid in the understanding of embodiments of the disclosure, some dimensions of elements in the figures may be exaggerated relative to others. The same reference numeral in different figures indicates the same element.

[0009] The embodiment described below relates to an iron-type club head having a structure that supports a face element. The club head comprises a face element for striking a golf ball. The face element is formed integrally with a flex structure. The flex structure has a curved profile (e.g., S-shaped or sinusoidal) that bends or flexes like a spring and supports the face element upon impact with the golf ball. To withstand the stress generated when the face element bends, the club head further comprises a face reinforcement structure and various face element thicknesses. The face reinforcement structure is formed integrally with the face element and the flex structure and supports the face element. The face reinforcement structure comprises annular ribs that support near the geometric center of the face element. The face reinforcement structure allows for intentionally and partially changing the thickness of the face element. In one example, the thickness of the face element is made thinner at the geometric center within the face reinforcement structure, thicker around the geometric center, and thicker outside the face reinforcement structure near the heel end or toe end of the club head. The combination of a flexible structure, a face reinforcement structure, and modified face element thickness increases the flex of the face elements, thereby increasing ball speed. Furthermore, this allows a large amount of stress to be transferred away from the face elements and into the face reinforcement structure upon impact with the golf ball. Transferring this large amount of stress into the face reinforcement structure improves the durability of the club head. In addition, iron-type club heads with a flexible structure, a face reinforcement structure, and modified face element thickness can have a thinner overall face element compared to face elements with a configuration that does not have a flexible structure and / or face reinforcement structure. Club heads with a combination of a flexible structure, a face reinforcement structure, and modified face element thickness can increase internal energy by 3.7 lbf·in compared to club heads without a flexible structure, a face reinforcement structure, and modified face element thickness. An increase of 3.7 lbf·in in internal energy is equivalent to an increase in ball speed of approximately 0.5 mph and an increase in distance of approximately 4 to 7 yards.

[0010] The terms “first,” “second,” “third,” “fourth,” etc., used in this description and claims are used to distinguish between similar elements, where present, and not necessarily to describe a particular order or chronological sequence. It should be understood that the terms used in this manner are interchangeable under appropriate circumstances so that the embodiments described herein may operate in an order other than, for example, those illustrated or otherwise described herein. Furthermore, the terms “includes” and “has” and any inflections thereof are intended to cover non-exclusive inclusion, thereby meaning that a process, method, system, object, device, or apparatus containing a list of elements is not necessarily limited to these elements, may include other elements not expressly listed, or are inherent to such process, method, system, object, device, or apparatus.

[0011] The terms “left,” “right,” “front,” “rear,” “top,” “bottom,” “up,” and “down” used in this description and claims are used for descriptive purposes, where present, and not necessarily to describe permanent relative positions. It should be understood that the terms used in this manner are interchangeable under appropriate circumstances so that embodiments of the apparatus, methods, and products described herein may operate in orientations other than those illustrated or otherwise described herein.

[0012] In this specification, the golf club term "loft" or "loft angle" refers to the angle formed between the clubface and the shaft, as measured by any suitable loft and drive angle measuring device.

[0013] Embodiments of golf club heads are described herein, and golf club heads may comprise iron-type club heads. More specifically, iron-type club heads may be muscle-back iron-type club heads, cavity-back iron-type club heads, blade-type iron-type club heads, hollow-bodied iron-type club heads, cavity-muscle-back iron-type club heads, high-MOI iron-type club heads, or any other type of iron-type club head. Iron-type club heads include a loft angle. The loft angle refers to the angle formed between the clubface and the shaft. More specifically, the loft angle is measured from a vertical plane extending from the hosel / shaft central axis to the clubface. The loft angle is measured backward from the vertical plane toward the clubface of the iron-type club head.

[0014] For example, in some embodiments, an iron-type club head may have a loft angle of less than approximately 60 degrees. Iron-type club heads may have loft angles of less than approximately 59 degrees, less than approximately 58 degrees, less than approximately 57 degrees, less than approximately 56 degrees, less than approximately 55 degrees, less than approximately 54 degrees, less than approximately 53 degrees, less than approximately 52 degrees, less than approximately 51 degrees, less than approximately 50 degrees, less than approximately 49 degrees, less than approximately 48 degrees, less than approximately 47 degrees, less than approximately 46 degrees, less than approximately 45 degrees, less than approximately 44 degrees, less than approximately 43 degrees, less than approximately 42 degrees, less than approximately 41 degrees, less than approximately 40 degrees, and less than approximately 39 degrees. It can have a loft angle of less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, less than approximately 30 degrees, less than approximately 29 degrees, less than approximately 28 degrees, less than approximately 27 degrees, less than approximately 26 degrees, less than approximately 25 degrees, less than approximately 24 degrees, less than approximately 23 degrees, less than approximately 22 degrees, less than approximately 21 degrees, less than approximately 20 degrees, less than approximately 19 degrees, and less than approximately 18 degrees.

[0015] Furthermore, in some embodiments, the loft angle of the iron-type club head is about 17 degrees or more, about 18 degrees or more, about 19 degrees or more, about 20 degrees or more, about 21 degrees or more, about 22 degrees or more, about 23 degrees or more, about 24 degrees or more, about 25 degrees or more, about 26 degrees or more, about 27 degrees or more, about 28 degrees or more, about 29 degrees or more, about 30 degrees or more, about 31 degrees or more, about 32 degrees or more, about 33 degrees or more, about 34 degrees or more, about 35 degrees or more, about 36 degrees or more, about 37 degrees or more, about 38 degrees or more, about 39 degrees or more, about 40 degrees or more, about 41 degrees or more, about 42 degrees or more, about 43 degrees or more, about 44 degrees or more, about 45 degrees or more, about 46 degrees or more, about 47 degrees or more, about 48 degrees or more, about 49 degrees or more, about 50 degrees or more, about 51 degrees or more, about 52 degrees or more, about 53 degrees or more, about 54 degrees or more, about 55 degrees or more, about 56 degrees or more, about 57 degrees or more, about 58 degrees or more, about 59 degrees or more, about 60 degrees or more.

[0016] Furthermore, in some embodiments, the loft angle of the iron-type club head may be 60 degrees, 59 degrees, 58 degrees, 57 degrees, 56 degrees, 55 degrees, 54 degrees, 53 degrees, 52 degrees, 51 degrees, 50 degrees, 49 degrees, 48 degrees, 47 degrees, 46 degrees, 45 degrees, 44 degrees, 43 degrees, 42 degrees, 41 degrees, 40 degrees, 39 degrees, 38 degrees, 37 degrees, 36 degrees, 35 degrees, 34 degrees, 33 degrees, 32 degrees, 31 degrees, 30 degrees, 29 degrees, 28 degrees, 27 degrees, 26 degrees, 25 degrees, 24 degrees, 23 degrees, 22 degrees, 21 degrees, 20 degrees, 19 degrees, 18 degrees, or 17 degrees.

[0017] Furthermore, in some embodiments, the loft angle of the iron-type club head may be set between 17 degrees and 60 degrees. In another embodiment, the loft angle of the iron-type club head may be set between 17 degrees and 60 degrees. In another embodiment, the loft angle of the iron-type club head may be set between 17 degrees and 40 degrees, or between 40 degrees and 60 degrees. In another embodiment, the loft angle of the iron-type club head may be set between 17 degrees and 35 degrees, between 25 degrees and 40 degrees, between 30 degrees and 45 degrees, between 35 degrees and 50 degrees, between 40 degrees and 55 degrees, between 45 degrees and 60 degrees. In another embodiment, the loft angle of the iron-type club head may be set between 17 degrees and 30 degrees, between 30 degrees and 40 degrees, between 40 degrees and 50 degrees, between 50 degrees and 60 degrees.

[0018] Other features and aspects will become apparent by considering the following detailed description and the accompanying drawings. Before explaining embodiments of the present disclosure in detail, it is to be understood that the present disclosure is not limited in its application to the details or embodiments and component arrangements described in the following description or shown in the drawings. The present disclosure can support other embodiments and can be practiced or implemented in various ways. It is to be understood that the description of specific embodiments is not intended to limit the present disclosure from covering all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. Also, it is to be understood that the expressions and terms used herein are for the purpose of description and should not be regarded as limiting.

[0019] (Iron-type club head with a flex structure) The present technology generally relates to an iron-type club head that increases the flex of a face element while improving the durability of the club head. These advantages can be achieved by a club head having an integrated body including a flex structure, a face reinforcement structure, and a face element thickness change. The flex structure is integrally formed with the face reinforcement structure and the rear portion of the club head. The flex structure has a curved shape (e.g., S-shaped or sinusoidal) extending between the face element and the rear portion. The flex structure is not connected to the club head except for the connecting portions at the face reinforcement structure and the rear portion. Thereby, the flex structure can bend freely without interfering with the structure of the club head. By the flex structure providing support to the face element, the face element can be made thinner in overall thickness compared to a face element having no flex structure and / or face reinforcement structure.

[0020] The face reinforcement structure includes a closed annular rib formed integrally with the face element. The face reinforcement structure extends around the geometric center of the face element. The face reinforcement structure locally changes the thickness of the face element. This makes the face element stiffer or more rigid at a location around the geometric center of the face element. The face reinforcement structure further includes a fillet that provides a smooth transition between the face element and the face reinforcement structure. The closed annular rib and fillet transfer large stresses away from the face element into the face reinforcement structure. This improves the durability of the face element and the club head.

[0021] The thickness of the face element is intentionally varied in parts, including thickened and thinned areas. The thickened areas provide support to the face element, while the thinned areas increase the flex of the face element. In one example, the face element may have the minimum thickness at its geometric center and include the maximum thickness along the face reinforcement structure. The face element may further include one or more thickness areas near the toe and heel ends of the clubhead, away from the face reinforcement structure. One or more thickness areas provide additional support against impact with the golf ball near the heel and toe areas of the clubhead. The flex structure, face reinforcement structure, and thickness variation of the face element, integrally formed within a single clubhead body, can increase the flex of the face element and ball speed while improving the durability of the clubhead. A clubhead having a combination of flex structure, face reinforcement structure, and thickness variation of the face element can increase internal energy by 3.7 lbf·in compared to a clubhead without flex structure, face reinforcement structure, and thickness variation of the face element. An increase of 3.7 lbf·in in internal energy is equivalent to an increase of approximately 0.5 mph in ball velocity and an increase of approximately 4 to 7 yards in distance. A first embodiment of the technology and performance examples of this disclosure that demonstrate the advantages of the present invention is described below.

[0022] By reference to figures that use the same reference numerals to identify similar or identical components in various figures, Figures 1-6 schematically illustrate a first embodiment of the design of the present invention. In detail, Figure 1 shows a front perspective view of an iron-type club head 100. The club head 100 includes a top rail 104, a sole 108 opposite the top rail 104, a toe end 112, and a heel end 116 opposite the toe end 112.

[0023] As shown in Figures 1 and 2, the club head 100 includes a face element 120. The face element 120 is integrally formed with the top rail 102, sole 108, toe end 112, and heel end 116 of the club head 100. The face element 120 includes a striking surface 124 for striking the golf ball and a rear wall 128 opposite the striking surface 124. The striking surface 124 further defines a face center 132 located at the geometric center or midpoint of the striking surface 124. The face element 120 further defines an outer edge 136 that extends overall around the face element 120 in the vicinity of the top rail 104, heel end 116, sole 108, and toe end 112.

[0024] Referring to Figures 1-3, the face center 132 of the striking surface 124 defines the origin of a coordinate system having x-axis 700, y-axis 800, and z-axis 900. The club head 100 further defines the ground plane 1000 to which the sole 108 is in contact when the club head 100 is in the address position. The x-axis 700 passes through the face center 132 and extends parallel to the ground plane 1000 from the vicinity of the heel end 116 to the vicinity of the toe end 112. The y-axis 800 passes through the face center 132 and extends from the vicinity of the top end 104 to the bottom end 108, in which case the y-axis 800 is perpendicular to the x-axis 700 and the ground plane 1000. The z-axis 900 passes through the face center 132 and extends parallel to the ground plane 1000 behind the face element 120. The z-axis at 900° is perpendicular to the x-axis at 700° and the y-axis at 800°.

[0025] Referring to Figure 3, the club head 100 defines a loft plane 2000, which is in contact with the striking surface 124 and extends toward the top rail 104, sole 108, toe end 112, and heel end 116. The loft plane 2000 is positioned at an acute angle with respect to the y-axis 800, and this acute angle may correspond to the loft angle of the club head 100. The club head 100 further defines a central plane 3000 that passes through the face center 132 and is perpendicular to the loft plane 2000. The central plane 3000 is positioned at an acute angle with respect to the z-axis 900. The central plane 3000 extends from the vicinity of the toe end 112 to the vicinity of the heel end 116 and extends behind the face element 120 or the loft plane 2000. The central plane 3000 intersects the ground plane 1000 at a point separated rearward from the face element 120.

[0026] Referring to Figures 2 and 3, the club head includes a rear section 140. The rear section 140 is integrally formed with the sole 108 and extends toward the top rail 104. The rear section 140 extends from the sole 108 to the top surface 144 of the rear section 140. The rear section 140 is integrally formed with the toe end 112 and heel end 116 of the club head 100. As shown in Figure 2, the rear section 140 can cover a portion of the rear wall 128. The rear section 140 can cover 5% to 25% of the rear wall 128. In some embodiments, the rear section 140 can cover 5% to 15%, or 15% to 25% of the rear wall 128. In other embodiments, the rear section 140 can cover 5% to 10%, 10% to 15%, 15% to 20%, or 20% to 25% of the rear wall 128. For example, the rear portion 140 can cover 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25% of the rear wall 128.

[0027] The club head 100 may further include a bottom inner wall 148 on the opposite side of the sole 108. The bottom wall 148 is integrally formed with the rear wall 128, rear section 140, toe end 112, and heel end 116. The bottom wall 128 integrally connects the rear wall 128, rear section 140, toe end 112, and heel end 116. The rear wall 128, rear section 140, bottom wall 148, toe end 112, and heel end 116 together form a channel 152. The channel 152 extends from the toe end 112 to the heel end 116. The channel 152 defines a space between the rear wall 128 and rear section 140 of the face element 120. In other words, the rear wall 128, rear section 140, bottom wall 148, toe end 112, and heel end 116 together form a rear cavity 152. The rear cavity 152 extends from the toe end 112 to the heel end 116. The rear cavity 152 can define a space between the rear wall 128 and the rear 140 of the face element 120. The rear cavity 152 is not completely closed and can be seen from a point outside the clubhead 100.

[0028] (Flexible structure) As previously mentioned, the club head 100 comprises a flex structure and a face reinforcement structure. The flex structure may comprise a flex structure 156, and the face reinforcement structure may comprise a face reinforcement structure 174. The flex structure 156 generally extends between the rear wall 128 and the rear section 140. The flex structure 156 is integrally formed with the rear wall 128 and the rear section 140. More specifically, the flex structure 156 is integrally formed with the face reinforcement structure 174 and the rear section 140. The club head 100 having an integrated body including the flex structure 156 and the face reinforcement structure 174 allows the face element 120 to flex more while supporting the face element 120 during impact with the golf ball. The flex structure 156 and the face reinforcement structure 174 allow large impact stresses to be transferred away from the face element 120 and into the face reinforcement structure 174. By transferring large impact stresses away from the face element 120 and into the face reinforcement structure 174, the durability of the club head is improved.

[0029] Referring to Figures 3-6, the flex structure 156 can be further defined as having a first end 158 and a second end 160. The first end 158 of the flex structure 156 is integrally formed with the face reinforcement structure 174. More specifically, the first end 158 of the flex structure 156 is integrally formed with the outer circumferential surface 176 of the face reinforcement structure 174. The second end 160 of the flex structure 156 is integrally formed with the rear 140. More specifically, the second end 160 of the flex structure 156 is integrally formed with the top surface 144 of the rear 140. As shown in Figure 6, the second end 160 of the flex structure 156 is attached to or connected to the rear 140. This allows the player to see the flex structure 156 when the club head 100 is in the address position. The flexible structure 156 extends across the channel 152 between the first end 158 and the second end 160. The flexible structure 156 extends across the channel 152 without separating from the channel 152. The flexible structure 156 does not come into contact with the channel 152. In other words, the flexible structure 156 is spaced apart from the bottom wall 148 so as not to come into contact with the bottom wall 148.

[0030] The flex structure 156 can have a parabolic, curved, S-shaped, double curved, double curved, or sinusoidal shape between the first end 158 and the second end 160. In some embodiments, the flex structure 156 may comprise one or more interconnected parabolas. In some embodiments, the flex structure 156 may comprise one or more interconnected curves. The curvature of the flex structure 156 can define a vertex 162 and a bottom point 164. The vertex 162 defines the highest or uppermost part of the flex structure 156 in relation to the top rail 104. The bottom point 164 defines the lowest or bottommost part of the flex structure 156 in relation to the sole 108. The flex structure 156 extends away from the face reinforcement structure 174 in the direction toward the sole 108 to form the bottom point 164. The flex structure 156 then extends higher than the top surface 144 of the rear 140 in the direction from the lowest point 164 toward the top rail 104, forming a vertex 162. The flex structure 156 then extends in the direction from the vertex 162 toward the sole 108, connecting with the rear 144.

[0031] In one configuration, vertex 162 may be located above the top surface 144 of the rear section 140. In another configuration, vertex 162 may be located below the top surface 144 of the rear section 140. The lowest point 164 of the flexible structure 156 is spaced away from the channel 152 so as not to contact the bottom wall 148. However, it will be understood that the curvature of the flexible structure 156 may provide two or more vertices 162 and two or more lowest points 164. In other embodiments, the flexible structure 156 may include one, two, three, four, or five lowest points. In yet another embodiment, the flexible structure 156 may include one, two, three, four, or five vertices.

[0032] Furthermore, the vertices 162 and vertex 164 of the flex structure 156 may be indicated in relation to the structure of the club head 100 or in relation to a plane defined by the club head 100. In one configuration, both the vertex 162 and vertex 164 can be located below the central plane 3000. In another configuration, the vertex 162 can be located above the central plane 3000 and the vertex 164 can be located below the central plane 3000. In yet another configuration, both the vertex 162 and vertex 164 can be located above the central plane 3000. In yet another configuration, the vertex 164 can be located closer to the face element 120 than the vertex 162. In yet another configuration, the vertex 162 can be located closer to the face element 120 than the vertex 164.

[0033] The flexible structure 156 can further define radii of curvature. The flexible structure 156 can define two or more radii of curvature, such as two, three, four, or five radii of curvature. In this first embodiment, the flexible structure 156 defines a radius of curvature at the vertex 162 and a radius of curvature at the lowest point 164. In this first embodiment, the radius of curvature at the vertex 162 and the radius of curvature at the lowest point 164 are approximately equal. The radii of curvature at the vertex 162 and the lowest point 164 can be in the range of 0.25 to 1 inch. In other embodiments, the radii of curvature at the vertex 162 and the lowest point 164 can be in the range of 0.25 to 0.5 inches, or 0.5 to 1 inch. In yet another embodiment, the radius of curvature at vertex 162 and the lowest point 164 can be in the range of 0.25 to 0.5 inches, 0.5 to 0.75 inches, or 0.75 to 1 inch. For example, the radius of curvature at vertex 162 and the lowest point 164 can be 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, or 1 inch. However, in another embodiment, the radius of curvature at vertex 162 and the radius of curvature at the lowest point 164 can be different. In another embodiment, the radius of curvature at vertex 162 can be less than the radius of curvature at the lowest point 164. In yet another embodiment, the radius of curvature at the lowest point 164 can be greater than the radius of curvature at vertex 162.

[0034] The flex structure 156 further defines an upper surface 168 and a lower surface 172. The upper surface 168 of the flex structure 156 faces the top rail 104 of the club head 100. The lower surface 172 of the flex structure faces the sole 108 of the club head 100. The flex structure 156 further defines a thickness measured between the upper surface 168 and the lower surface 172. The thickness of the flex structure 156 is defined as the distance between the upper surface 168 and the lower surface 172, measured in a direction perpendicular to the upper surface 168 or the lower surface 172 of the flex structure 156. In some embodiments, the thickness of the flex structure 156 can be constant between the first end 158 and the second end 160. In other embodiments, a portion of the flex structure 156 may include a tapered thickness. In one example, the first end 158 of the flexible structure 156 may have a tapered thickness, in which case the thickness of the flexible structure 156 is greater at the face reinforcement structure 174 and then decreases towards the bottom point 164. In another example, the second end 160 of the flexible structure 156 may have a tapered thickness, in which case the thickness of the flexible structure 156 is greater at the rear end 140 and then decreases towards the top 162.

[0035] The thickness of the flexible structure 156 can be in the range of 0.04 to 0.2 inches. In some embodiments, the thickness of the flexible structure 156 can be in the range of 0.04 to 0.12 inches, or 0.12 to 0.20 inches. In other embodiments, the thickness of the flexible structure 156 can be in the range of 0.04 to 0.08 inches, 0.08 to 0.12 inches, 0.12 to 0.16 inches, or 0.16 to 0.20 inches. For example, the thickness of the flexible structure 156 can be 0.04, 0.045, 0.05, 0.06, 0.07, 0.075, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, or 0.20 inches. In one example, the thickness of the flexible structure 156 can be 0.075 inches. In another example, the thickness of the flexible structure 156 at the first end 158 can be 0.075 inches, and then it can taper to a thickness of 0.045 inches near the lowest point 164 of the flexible structure 156. In yet another example, the thickness of the flexible structure 156 at the second end 160 can be 0.075 inches, and then it can taper to a thickness of 0.045 inches near the apex 162 of the flexible structure 156.

[0036] The flex structure 156 defines a width. The width of the flex structure 156 is defined as the distance the flex structure 156 extends from the toe end 112 towards the heel end 116. The width of the flex structure 156 can be in the range of 0.1 to 1 inch. In some embodiments, the width of the flex structure 156 can be in the range of 0.1 to 0.5 inches, or 0.5 to 1 inch. In some embodiments, the width of the flex structure 156 can be in the range of 0.1 to 0.4 inches, 0.4 to 0.7 inches, or 0.7 to 1 inch. For example, the width of the flex structure 156 can be 0.1, 0.15, 0.175, 0.18, 0.2, 0.3, 0.35, 0.40, 0.45, 0.50, 0.60, 0.70, 0.80, 0.90, or 1 inch. In one example, the width of the flex structure 156 can be 0.175 inches.

[0037] Referring to Figure 7, the flexible structure 156 has a cross-sectional shape. The cross-sectional shape of the flexible structure 156 can be a rectangle, a triangle, an ellipse, a rectangle with rounded corners, a square with rounded corners, or any other suitable shape. In the first embodiment of this design, as shown in Figure 7, the cross-sectional shape of the flexible structure 156 is rectangular. The rectangular cross-sectional shape of the flexible structure 156 defines dimensions T and W. Dimension T defines the thickness of the flexible structure 156, and dimension W defines the width of the flexible structure 156. In one example, dimension T may be 0.07 inches and dimension W may be 0.18 inches.

[0038] Figures 8 and 9 show two alternative cross-sectional shape configurations. As shown in Figure 8, the cross-sectional shape of the flexible structure 156 can be elliptical. The elliptical cross-sectional shape defines dimension A1 corresponding to the principal axis and dimension A2 corresponding to the secondary axis. Dimension A1 defines the width of the flexible structure 156, and dimension A2 defines the thickness of the flexible structure 156. In one example, dimension A1 can be 0.18 inches and dimension A2 can be 0.08 inches. As shown in Figure 9, the cross-sectional shape of the flexible structure 156 can be rectangular with rounded corners. The rectangular shape with rounded corners defines dimensions R and D. The rectangular shape with rounded corners defines a rectangle and two semicircles. Dimension R defines the radius of the semicircles, and dimension D defines the distance between the centers of the two semicircles. In this embodiment, the thickness of the flex structure 156 is defined as twice the radius R dimension, and the width of the flex structure 156 is defined as twice the radius R dimension and the D dimension. In one example, the radius R dimension may be 0.04 inches, and the D dimension may be 0.10 inches, in which case the thickness of the flex structure 156 is 0.08 inches and the width of the flex structure 156 is 0.18 inches.

[0039] (Face reinforcement structure) As previously mentioned, the club head 100 is equipped with a face reinforcement structure. The face reinforcement structure may include a face reinforcement structure 174. The face reinforcement structure 174 is formed integrally with the face element 120 and extends away from the rear wall 128. The face reinforcement structure 174 supports the face element 120 during impact with the golf ball. In detail, the face reinforcement structure 174 provides localized thickness on the face element 120 near the face center 132, thereby making the face element 120 stiffer and more rigid in the area around the face center 132. Because the face element 120 flexes more due to the flex structure 156 and the change in face thickness, the face element 120 experiences greater stress during impact with the golf ball. The face reinforcement structure 174 transfers or moves this maximum stress away from the face element 120 into the face reinforcement structure 174, thereby improving the durability of the club head.

[0040] The face reinforcement structure 174 may be provided with ribs. More specifically, the face reinforcement structure 174 may be provided with annular ribs, ring ribs, circular annular ribs, or elliptical annular ribs extending around the face center 132. The face reinforcement structure 174 may be provided with a closed annular structure continuous around the face center 132. The closed structure can resist deformation as a result of circumferential (i.e., ring-shaped) stress acting on the face reinforcement structure 174. For example, circumferential stress acting on the face reinforcement structure 174 prevents the opposite sides of the face reinforcement structure 174 from rotating away from each other, thereby stiffening the face element 120. This allows the face element 120 to thin at the face center 132 while directing the stress away from the face element 120. By transmitting the stress within the face reinforcement structure 174 in this way, the durability of the face element 120 and the club head 100 is improved.

[0041] Referring to Figure 4, the face reinforcement structure 174 may comprise an outer circumferential surface 176 and an inner circumferential surface 180. The outer circumferential surface 176 is located at the portion of the face element 120 having the maximum thickness. The outer circumferential surface 176 is located spaced apart from the rear wall 128 and may be substantially parallel to the rear wall 128. The outer circumferential surface 176 extends along the face reinforcement structure 176 around the face center 132. The outer circumferential surface 176 is located adjacent to the inner circumferential surface 180. The inner circumferential surface 180 is located within the face reinforcement structure 176 and extends substantially perpendicular to the rear wall 128. The inner circumferential surface 180 extends along the face reinforcement structure 176 around the face center 132. The inner circumferential surface 180 is located between the rear wall 128 and the outer circumferential surface 176.

[0042] The face reinforcement structure 174 has a fillet in the rear wall 128, which smoothly connects the face reinforcement structure 174 and the rear wall 128. By providing the rear wall 128, the outer circumferential surface 176, and the fillet, impact stress is directed away from the face element 120 within the face reinforcement structure 174. The club head 100 may have a fillet 184 between the outer circumferential surface 176 and the rear wall 128. The fillet 184 may have a radius of 0.012 centimeters or more. In some embodiments, the fillet 184 may be in the range of 0.012 to 2.0 centimeters, 0.50 to 3.0 centimeters, or 1.0 to 4.0 centimeters. In other embodiments, the fillet 184 may be in the range of 0.012 to 1.5 centimeters, 0.5 to 2.0 centimeters, 1.0 to 2.5 centimeters, 1.5 to 3.0 centimeters, 2.0 to 3.5 centimeters, or 2.5 to 4.0 centimeters. For example, fillet 184 can be 0.012, 0.02, 0.05, 0.08, 0.1, 0.2, 0.5, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.2, 2.5, 2.8, 3.0, 3.2, 3.5, 3.8, or 4.0 centimeters.

[0043] The face reinforcement structure 174 can further define a rib span 186. The rib span 186 is located within the face reinforcement structure 174 on the inner surface 180. The rib span 186 refers to the maximum distance from one side of the inner surface 180 to the opposite side. The rib span 186 can refer to the diameter of the inner surface 180 of the face reinforcement structure 174. In embodiments where the annular rib 174 comprises an elliptical annular rib, the rib span 186 refers to the principal axis of the inner surface 180. In embodiments where the annular rib 174 comprises a circular annular rib, the rib span 186 refers to the diameter of the inner surface 180.

[0044] The rib span 186 can be between 0.609 centimeters and 1.88 centimeters. In some embodiments, the rib span 186 can be in the range of 0.609 to 1.2 centimeters, or 1.2 to 1.88 centimeters. In one example, the rib span 186 can be 1.0 centimeter. The rib span 186 is important for directing impact stress away from the face element 120 and into the face reinforcement structure 174. When the rib span 186 is too large (i.e., greater than 1.88 centimeters), the face reinforcement structure 174 is insufficient to reinforce the face element 120 in the vicinity of the face center 132. In the case of a rib span 186 that is too large, the maximum impact stress occurs at the face center 132, thereby destroying or damaging the face element 120 at the face center 132. On the other hand, when the rib span 186 is too small (i.e., less than 0.609 centimeters), the face reinforcement structure 174 is insufficient to reinforce the face element 120 in the vicinity of the face center 132. In the case of a rib span 186 that is too small, the maximum impact stress occurs within and around the face reinforcement structure 174, thereby destroying or damaging the face element 120. When the rib span 186 is between 0.609 centimeters and 1.88 centimeters, the face reinforcement structure 174 reinforces the face element by directing the impact stress away from the face element 120 (i.e., at the face center 132) and into the circular ribs of the face reinforcement structure 174.

[0045] The inner circumferential surface 180 of the face reinforcement structure 174 can further define the rib height 188. The rib height 188 is measured between the rear wall 128 and the outer circumferential surface 176 in a direction perpendicular to the rear wall 128. In some embodiments, the rib height 188 can be greater than 0.30 cm, 0.40 cm, 0.50 cm, or 0.60 cm. In other embodiments, the rib height 188 can be in the range of 0.30 to 0.7 cm. In some embodiments, the rib height 188 can be in the range of 0.30 to 0.50 cm, 0.40 to 0.60 cm, or 0.50 to 0.70 cm. For example, the rib height 188 can be 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, or 0.70 cm.

[0046] (Face elements) As previously mentioned, the face element 120 can have varying thickness. By intentionally varying the thickness of the face element 120 in parts, it can be supported while increasing the flex of the face element. The face element 120 can be thinnest at the face center 132 within the face reinforcement structure 174 and thickest at the outer periphery 176 of the face reinforcement structure 174. The face element 120 can further include one or more thickness regions located away from the face reinforcement structure 174 to support the toe and heel regions of the face element 120. In other embodiments, the face element 120 may not have one or more thickness regions near the toe end 112 and heel end 116 of the club head 100.

[0047] Referring to Figure 4, the thickness of the face element 120 may be varied from the toe end 114 to the heel end 118, from the top rail 104 to the sole 108, or in any combination thereof. The thickness of the face element 120 helps to distribute stress and allows the face element 120 to flex more upon impact with the golf ball. The face element 120 includes a first thickness 190, a second thickness 192, a third thickness 194, and a fourth thickness 196. The first thickness 190 of the face element 120 is measured from the face center 134 to the back wall 120 in a direction perpendicular to the loft plane 2000 or the striking surface 124. The first thickness 190 can be the minimum thickness of the face element 120. The first thickness 190 can be associated with the center thickness of the face element 120. In some embodiments, the first thickness 190 can be in the range of 0.055 inches to 0.085 inches. In other embodiments, the first thickness 190 can be in the range of 0.055 inches to 0.07 inches, or 0.07 to 0.085 inches. For example, the first thickness 190 can be 0.055, 0.06, 0.065, 0.07, 0.075, 0.08, or 0.085 inches. In one example, the first thickness 190 can be 0.075 inches.

[0048] The second thickness 192 of the face element 120 is measured from the striking surface 124 to the outer circumferential surface 176 of the face reinforcement structure 174, in a direction perpendicular to the loft plane 2000 or the striking surface 124. The second thickness 192 can be the maximum thickness of the face element 120. The second thickness 192 can be in the range of 0.10 inches to 0.30 inches. In other embodiments, the second thickness 192 can be in the range of 0.10 inches to 0.20 inches, or 0.20 inches to 0.30 inches. In other embodiments, the second thickness 192 can be in the range of 0.10 to 0.15 inches, 0.15 to 0.20 inches, 0.20 to 0.25 inches, or 0.25 to 0.30 inches. For example, the second thickness 192 can be 0.10, 0.15, 0.16, 0.17, 0.18, 0.188, 0.19, 0.198, 0.20, 0.25, or 0.30 inches. In one example, the second thickness 192 could be 0.198 inches.

[0049] The third thickness 194 of the face element 120 is measured from the striking surface 124 to the rear wall 128, in the loft plane 2000 or in the direction perpendicular to the striking surface 124. The third thickness 194 of the face element 120 is located on the face element 120 that does not have the face reinforcement structure 174 and the thickness region 198. The third thickness 194 can be greater than the first thickness 190. The third thickness 194 can be less than the second thickness 192. In some embodiments, the third thickness 194 can be in the range of 0.05 inches to 0.15 inches. In some embodiments, the third thickness 194 can be in the range of 0.05 inches to 0.15 inches. In other embodiments, the third thickness 194 can be in the range of 0.05 inches to 0.10 inches, or 0.10 inches to 0.15 inches. For example, the third thickness 194 can be 0.05, 0.055, 0.06, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.10, 0.11, 0.12, 0.13, 0.14, or 0.15 inches. In one example, the third thickness 194 could be 0.083 inches.

[0050] The fourth thickness 196 of the face element 120 is measured from the striking surface 124 to the rear wall 128, in the loft plane 2000 or in the direction perpendicular to the striking surface 124. The fourth thickness 192 of the face element 120 is located at the outer edge 130 of the face. The fourth thickness 196 can be related to the perimeter thickness of the face element 120. In some embodiments, the fourth thickness 196 and the third thickness 192 can be equal. In other embodiments, the fourth thickness 196 can be greater than the third thickness 192. In other embodiments, the fourth thickness 196 can be greater than the first thickness 190. In yet another embodiment, the fourth thickness can be greater than the second thickness 192. In some embodiments, the fourth thickness 196 can be in the range of 0.05 inches to 0.15 inches. In other embodiments, the fourth thickness 196 can be in the range of 0.05 inches to 0.10 inches, or 0.10 inches to 0.15 inches. For example, the fourth thickness 196 can be 0.05, 0.055, 0.06, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.10, 0.11, 0.12, 0.13, 0.14, or 0.15 inches. In one example, the fourth thickness 196 could be 0.083 inches.

[0051] Referring back to Figures 2 and 5, the face element 120 may further include one or more thickness regions 198. The thickness region 198 may be a thickened area on the face element 120 in a location where there is no face reinforcement structure 174. The thickness region 198 is located away from or outside the face reinforcement structure 174. The thickness region 198 may be located near the toe end 112 and heel end 116 of the club head 100. The thickness region 198 supports the face element 120 against impact with the golf ball in the vicinity of the toe end 112 and heel end 116.

[0052] The thickness region 198 can have a shape. The thickness region 198 can be semicircular, C-shaped, bean-shaped, or any other suitable shape. The thickness region 198 can be positioned relative to the central plane 3000. In some embodiments, the thickness region 198 can be located above the central plane 3000. In other embodiments, the thickness region 198 can be located below the central plane 3000. In other embodiments, a first thickness region 198 can be located above the central plane 3000, and a second thickness region 198 can be located below the central plane 3000. In other embodiments, a portion of the thickness region 198 can be located above the central plane 3000, and another portion of the thickness region 198 can be located below the central plane 3000. By positioning the thickness region 198 relative to the central plane 3000, the stiffness and rigidity of the face element 120 in the heel and toe regions can be adjusted. The thickness region 198 further supports the face element 120 in the vicinity of the heel and toe regions of the face element 120 against impact with the golf ball.

[0053] The thickness region 198 can be in the range of 0.08 to 0.16 inches. In some embodiments, the thickness region 198 can be in the range of 0.08 to 0.12 inches, or 0.12 to 0.16 inches. In other embodiments, the thickness region 198 can be in the range of 0.08 to 0.10 inches, 0.10 to 0.12 inches, 0.12 to 0.14 inches, or 0.14 to 0.16 inches. For example, the thickness region 198 can be 0.08, 0.09, 0.10, 0.108, 0.11, 0.12, 0.13, 0.14, 0.15, or 0.16 inches. In one example, the thickness region 198 can be 0.108 inches.

[0054] (Additional embodiments) Figures 1-6 illustrate a first embodiment of how this technology can be used, while Figures 11-13 schematically show three alternative configurations. In each embodiment (including the embodiments shown in Figures 1-6), the iron-type club head increases the flex of the face elements while improving the durability of the club head, by including changes in the flex structure, face reinforcement structure, and thickness of the face elements. The iron-type club heads shown in Figures 11-13 may be similar to club head 100 shown in Figures 1-6, but differ in the number of flex structures.

[0055] In one embodiment, as shown in Figures 10 and 11, an iron-type club head may comprise an iron-type club head 200. The club head 200 comprises a first flex structure 256, a second flex structure 256, and a face reinforcement structure 274. In this embodiment, the first flex structure 256 can be integrally formed with the face reinforcement structure 256 and the rear portion 240, and the second flex structure 256 can be integrally formed with the face reinforcement structure 256 and the top rail 204. The first flex structure 256 and the second flex structure 256 may be arranged around the outer circumferential surface of the face reinforcement structure 274 so as to be 180° apart from each other.

[0056] In another embodiment, as shown in Figure 12, an iron-type club head may comprise an iron-type club head 300. The club head 300 comprises a first flex structure 356, a second flex structure 356, a third flex structure, and a face reinforcement structure 374. In this embodiment, the first flex structure 356 is integrally formed with the face reinforcement structure 374 and the rear section 340 near the toe end 312 of the club head 300. The second flex structure 356 may be integrally formed with the face reinforcement structure 374 and the rear section 340 near the heel end 318 of the club head 300. The third flex structure 356 may be integrally formed with the face reinforcement structure 356 and the top rail 304. The first flex structure 152, the second flex structure 152, and the third flex structure 152 can be arranged around the outer perimeter of the face reinforcement structure 374 so that they can be spaced 60° apart from each other.

[0057] In another embodiment, as shown in Figure 13, an iron-type club head may comprise an iron-type club head 400. The club head comprises a first flex structure 456, a second flex structure 456, a third flex structure 456, a fourth flex structure 456, and a face reinforcement structure 474. In this embodiment, the first flex structure 456 may be integrally formed with the face reinforcement structure 474 and the rear section 440 near the toe end 412 of the club head 400. The second flex structure 456 may be integrally formed with the face reinforcement structure 474 and the rear section 440 near the heel end 418 of the club head 400. The third flex structure 456 may be integrally formed with the face reinforcement structure 456 and the top rail 404 near the toe end 412 of the club head 400. The fourth flex structure 456 may be formed integrally with the face reinforcement structure 456 and the top rail 404 near the heel end 416 of the club head 400. The first, second, third, and fourth flex structures 456 may be arranged around the outer perimeter of the face reinforcement structure 474 so that they can be spaced 45° apart from each other.

[0058] (Manufacturing method) A method is provided for manufacturing a club head 100 having a flex structure 156, a face reinforcement structure 174, and a face element 120 having a change in thickness. The method includes providing an integrally formed club head 100. The method includes providing a club head 100 having a top rail 104, a sole 108, a toe end 112, a heel end 116, and a rear section 140. The method includes providing a face element 120 having a striking surface 124 and a rear wall 128. The method further includes providing a flex structure 156 and a face reinforcement structure 174. The flex structure 156 and the face reinforcement structure 174 are integrally formed with the face element 120. The club head 100 may be formed by any suitable manufacturing process that can be used to form an integral body. The club head 100 may be formed from metal using processes such as casting, die casting, co-die casting, additive manufacturing, or metal 3D printing. Examples of metals include, but are not limited to, steel, steel alloys, stainless steel, stainless steel alloys, C300, C350, Ni (nickel)-Co (cobalt)-Cr (chromium)-steel alloys, 8620 alloy steel, S25C steel, 303SS, 17-4SS, carbon steel, maraging steel, 565 steel, AISI 304 type or AISI 630 type stainless steel, titanium alloys, Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti15-3-3-3, Ti15-5-3, Ti185, Ti6-6-2, Ti-7s, Ti-9s, Ti-92, or Ti-8-1-1, titanium alloys, amorphous metal alloys, or other similar metals.

[0059] (benefit) The flex structure 156 and the face reinforcement structure 174 support the face element 120, which in turn allows the entire face element 120 to be thinner, resulting in greater flex of the face element. The face reinforcement structure 174 provides a path for redirecting impact stress from the face element 120 into the outer circumferential surface 176 of the face reinforcement structure 174. By transferring impact stress from the face element 120 into the face reinforcement structure 174, the durability of the face element 120 and the club head 100 is improved. The thickness of the face element 120 within the diameter of the face reinforcement structure 174 and near the face center 132 can be thinner than the thickness of the face element 120 in the outer circumferential surface 176 of the face reinforcement structure 174, in areas without the face reinforcement structure 174, and on the outer edge 136 of the face. The combination of the flex structure 156 and the face reinforcement structure 174 allows for a thinner overall thickness of the face element 120 compared to a face element without the flex structure and / or face reinforcement structure. A club head 100 having the combination of the flex structure 156, the face reinforcement structure 174, and the face element 120 with the thickness modification allows for a 3.7 lbf·in increase in internal energy compared to a club head without the flex structure, face reinforcement structure, and the variable thickness modification of the face element. A 3.7 lbf·in increase in internal energy is equivalent to an increase of approximately 0.5 mph in ball speed and an increase of approximately 4 to 7 yards in distance.

[0060] The face element 120 of the club head 100 can be 5 to 20% thinner compared to a face element or striking surface that does not have a flex structure and / or face reinforcement structure. In some embodiments, the face element 120 can be 5 to 10%, or 10 to 20%, thinner compared to a face element or striking surface that does not have a flex structure and / or face reinforcement structure. In other embodiments, the face element 120 can be 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, or 20% thinner compared to a face element or striking surface that does not have a flex structure and / or face reinforcement structure.

[0061] In exemplary embodiments, but not limited to them, a club head 100 was compared to a control club head. The club head 100 includes a flex structure 156 and a face reinforcement structure 174. The control club head includes a face reinforcement structure similar to the face reinforcement structure 174, but does not have a flex structure 156. The club head 100 includes a first thickness 190 of 0.075 inches, a second thickness 192 of 0.198 inches, a third thickness 194 of 0.083 inches, and a fourth thickness 196 of 0.083 inches (i.e., a perimeter thickness 196). The control club head includes a first thickness of 0.075 inches, a second thickness of 0.188 inches, a third thickness of 0.088 inches, and a fourth thickness of 0.088 inches (i.e., a perimeter thickness 196). The club head 100 can be 5-7% thinner around or near the face element 120 compared to a control club head. The flex structure 156 and face reinforcement structure 174 of the club head 100 can make the overall thickness of the face element 120 thinner compared to a club head without the flex structure 156.

[0062] The clubhead 100 with flex structure 156 offers many improvements compared to known iron-type clubheads. Flex structure 156 reinforces the face element 120 without requiring an insert or backing material. Combined with face reinforcement structure 174, flex structure 156 and face reinforcement structure 174 can absorb impact stress, redirecting it away from the thinned face element 120 and into the face reinforcement structure 174. The face reinforcement structure 174 supports the face element 120, maintaining or improving the durability of the clubhead.

[0063] The flex structure 156, having a curved profile, acts like a spring to support the face element 120 upon impact with the golf ball. As the face element 120 flexes under impact force, the face element 120 and the flex structure 156 flex toward the rear 140. Due to the curved profile of the flex structure 156, the flex structure 156 flexes inward at the lowest point 164 and the apex 162. In this first embodiment, since the lowest point 164 is located closest to the source of the maximum force (i.e., the impact force acting on the face element 120), the flex structure 156 flexes more at the lowest point 164 than at the apex 162. As the face element 120 flexes, the stress within the face element 120 is transmitted toward the face reinforcement structure 174, away from the face center 132 of the face element 120. The stress is transmitted away from the face element 120 and into the outer surface 176 of the face reinforcement structure 174. This stress transmission prevents the face element 120 from breaking under impact force. The stress transmission improves the durability of the face element 120 and the club head 100.

[0064] (Example 1 - Ball speed test of an iron-type club head) An exemplary iron-type club head 100, featuring a face reinforcement structure and a flex structure, was compared to a similar comparative iron-type club head that also features a face reinforcement structure but lacks a flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 includes a face reinforcement structure, a flex structure, and a fourth or perimeter thickness of 0.079 inches. The comparative iron-type club head includes a face reinforcement structure and a perimeter thickness of 0.088 inches.

[0065] A test was conducted to compare golf ball speeds between 100 exemplary iron-type clubheads and control iron-type clubheads. The test used an air cannon to launch golf balls from each clubhead. The distance from each clubhead to the air cannon was kept constant, and each clubhead was held in the address position (i.e., there was no loft adjustment during the test). The test compared the golf ball speed as it left the striking surface over many impacts. The results showed that the average golf ball speed for the 100 exemplary iron-type clubheads was 124.9 mph, while the average golf ball speed for the control iron-type clubheads was 124.5 mph. This result indicates that the ball speed of the 100 exemplary iron-type clubheads was, on average, 0.5 mph faster than that of the control iron-type clubheads. An increase of 0.5 mph in ball speed is roughly equivalent to an increase of 4 to 7 yards in ball distance. The combination of face reinforcement structure, flex structure, and reduced perimeter thickness increases golf ball speed, thereby increasing the golf ball carry distance.

[0066] (Example 2 - Ball spin test of iron-type club heads) An exemplary iron-type club head 100, featuring a face reinforcement structure and a flex structure, was compared to a similar comparative iron-type club head that also features a face reinforcement structure but lacks a flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 includes a face reinforcement structure, a flex structure, and a fourth or perimeter thickness of 0.079 inches. The comparative iron-type club head includes a face reinforcement structure and a perimeter thickness of 0.088 inches.

[0067] A test was conducted to compare the amount of golf ball spin (i.e., backspin) between 100 exemplary iron-type club heads and a control iron-type club head. The test measured the amount of ball spin imparted from the striking surface of each club head while keeping club head dimensions, loft angle, shaft characteristics, and weather conditions constant. The results showed that the exemplary iron-type club heads averaged 6710 rpm of golf ball spin, while the control iron-type club heads averaged 6517 rpm. This indicates that the exemplary iron-type club heads averaged 200 rpm more golf ball spin than the control iron-type club heads. The combination of face reinforcement structure, flex structure, and reduced perimeter thickness can increase ball spin and result in better golf ball control.

[0068] (Example 3 - Stat-area test of iron-type club heads) An exemplary iron-type club head 100, featuring a face reinforcement structure and a flex structure, was compared to a similar comparative iron-type club head that also features a face reinforcement structure but lacks a flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 includes a face reinforcement structure, a flex structure, and a fourth or perimeter thickness of 0.079 inches. The comparative iron-type club head includes a face reinforcement structure and a perimeter thickness of 0.088 inches.

[0069] A test was conducted to compare the stat area (i.e., the standard deviation of the summation of golf ball carry distance multiplied by the standard deviation of the summation of golf ball offline distance) between 100 exemplary iron-type club heads and a control iron-type club head. Golf ball carry distance is the distance a golf ball travels in the air. Golf ball offline distance is the distance a golf ball is offset from the line extending from the player to the desired target. Golf ball offline distance is measured perpendicular to the line extending from the player to the desired target. The stat area determines the accuracy of the grouping or dispersion of the summation of golf ball shots, in which case a denser dispersion indicates a smaller stat area, and a larger dispersion indicates a larger stat area. The test results showed that the stat area of ​​the 100 exemplary iron-type club heads was reduced by an average of 32.8% compared to the control iron-type club heads. The combination of face reinforcement structure, flex structure, and reduced perimeter thickness can result in a desirable smaller stat area, leading to greater accuracy in the dispersion of golf ball shots.

[0070] (Example 4 - Internal energy test of an iron-type club head) An exemplary iron-type club head 100, featuring a face reinforcement structure and a flex structure, was compared to a similar comparative iron-type club head that also features a face reinforcement structure but lacks a flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 includes a face reinforcement structure, a flex structure, and a fourth or perimeter thickness of 0.079 inches. The comparative iron-type club head includes a face reinforcement structure and a perimeter thickness of 0.088 inches.

[0071] A test was conducted to compare the internal energy of 100 exemplary iron-type clubheads with that of a control iron-type clubhead. The test used finite element simulation to measure the internal energy of the clubheads at an impact velocity of 100 mph with a golf ball. The results of this test showed that the peak internal energy of 100 exemplary iron-type clubheads increased by an average of 3.7 lbf·in compared to the control clubheads. An increase of 3.7 lbf·in in internal energy is equivalent to an increase of approximately 0.5 mph in ball velocity. An increase of 0.5 mph in ball velocity is roughly equivalent to an increase of 4 to 7 yards in ball distance. The combination of flex structure and face reinforcement structure supports the face elements while increasing the flex and ball velocity of the face elements.

[0072] The replacement of one or more elements of the claims constitutes a reconstruction, not a restoration. Furthermore, benefits, other advantages, and solutions to problems have been described in relation to specific embodiments. However, benefits, advantages, solutions to problems, and any elements or combinations that give rise to or make more apparent any benefits, advantages, or solutions are not to be construed as any or all important, required, or essential features or elements of the claims.

[0073] Because the rules of golf can change from time to time (for example, new rules may be adopted or old rules may be deleted or modified by the standard organizations and / or governing bodies of golf, such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St. Andrews (R&A), etc.), golf equipment relating to the devices, methods, and products described herein may be conforming to or non-conforming to the rules of golf at any given time. Accordingly, golf equipment relating to the devices, methods, and products described herein may be advertised, marketed, and / or sold as conforming or non-conforming golf equipment. The devices, methods, and products described herein are not limited in this respect.

[0074] Furthermore, the embodiments and limitations disclosed herein are not available to the public under the doctrine of dedication if (1) they are not expressly claimed in the claims, or (2) they are potential equivalents of express elements and / or limitations in the claims under the doctrine of equivalents.

[0075] (Item 1) A golf club head comprising: a top rail, a sole located opposite the top rail, a toe end, a heel end located opposite the toe end, a rear portion connected to the sole and extending toward the top rail, and a face element comprising a striking surface and a rear wall located opposite the striking surface; a reinforcing structure integrally formed with the face element; and a flex structure integrally formed with the face element and the rear portion, wherein the face element defines a face center, the reinforcing structure comprises a circular annular rib extending away from the rear wall and around the face center, and the flex structure comprises a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion.

[0076] (Item 2) The golf club head according to Item 1, further comprising a bottom wall located opposite the sole and integrally connecting the rear wall, the rear portion, the toe end, and the heel end, wherein the rear wall, the rear portion, the toe end, the heel end, and the bottom wall integrally form a channel, and the flex structure extends within the channel without contacting the channel.

[0077] (Item 3) The golf club head according to Item 1, wherein the flex structure has a curved shape, and the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

[0078] (Item 4) The golf club head according to Item 3, wherein the club head further defines a central plane extending toward the toe end and the heel end behind the center of the face, and the lowest point and the apex of the central plane are located below the central plane.

[0079] (Item 5) The golf club head according to Item 1, wherein the face reinforcement structure comprises an inner circumferential surface located within the face reinforcement structure and extending perpendicularly to the rear wall, and an outer circumferential surface located at the portion having the maximum thickness of the face element and adjacent to the inner circumferential surface.

[0080] (Item 6) The golf club head as described in Item 5, wherein the inner circumferential surface defines a rib span of 0.609 centimeters or more and 1.88 centimeters or less.

[0081] (Item 7) The golf club head according to Item 5, wherein the thickness of the face element is variable, and the thickness comprises a first thickness measured perpendicular to the striking surface from the center of the face to the rear wall, a second thickness measured perpendicular to the striking surface from the striking surface to the outer surface of the face reinforcing structure, a third thickness measured perpendicular to the striking surface from the striking surface to the rear wall without the reinforcing element, and a fourth thickness measured perpendicular to the striking surface from the striking surface to the rear wall located on the outer edge of the face, the first thickness being the minimum thickness of the face element, and the second thickness being the maximum thickness of the face element.

[0082] (Item 8) A golf club head comprising: a face element comprising: a top rail; a sole located opposite the top rail; a toe end; a heel end located opposite the toe end; a bottom wall located opposite the sole; a rear portion connected to the sole and extending toward the top rail; and a face element comprising: a striking surface; a rear wall located opposite the striking surface; a reinforcing structure integrally formed with the face element; and a flex structure integrally formed with the face element and the rear portion, wherein the face element defines a face center; the reinforcing structure comprises a circular annular rib extending away from the rear wall and around the face center; and the flex structure comprises: a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion; the rear wall, the rear portion, the toe end, the heel end, and the bottom wall integrally form a channel; and the flex structure extends across the channel without contacting the channel.

[0083] (Item 9) The golf club head according to Item 8, wherein the flex structure has a curved shape, and the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

[0084] (Item 10) The golf club head according to Item 9, wherein the club head further defines a central plane extending toward the toe end and the heel end behind the center of the face, and the lowest point and the apex of the flex structure are located below the central plane.

[0085] (Item 11) The golf club head according to Item 9, wherein the club head further defines a central plane extending toward the toe end and the heel end behind the center of the face, the lowest point of which is located below the central plane, and the apex of which is located above the central plane.

[0086] (Item 12) The golf club head according to Item 8, wherein the face reinforcement structure comprises an inner circumferential surface located within the face reinforcement structure and extending perpendicularly to the rear wall, and an outer circumferential surface located at the portion having the maximum thickness of the face element and adjacent to the inner circumferential surface.

[0087] (Item 13) The golf club head as described in Item 12, wherein the inner circumferential surface defines a rib span of 0.609 centimeters or more and 1.88 centimeters or less.

[0088] (Item 14) The golf club head according to Item 8, wherein the thickness of the face element is variable, and the thickness comprises a first thickness measured perpendicular to the striking surface from the center of the face to the rear wall, a second thickness measured perpendicular to the striking surface from the striking surface to the outer surface of the face reinforcement structure, a third thickness measured perpendicular to the striking surface from the striking surface to the rear wall without the reinforcement element, and a fourth thickness measured perpendicular to the striking surface from the striking surface to the rear wall located on the outer edge of the face, the first thickness being the minimum thickness of the face element, and the second thickness being the maximum thickness of the face element.

[0089] (Item 15) A golf club head comprising: a top rail; a sole located opposite the top rail; a toe end; a heel end located opposite the toe end; a bottom wall located opposite the sole; a rear portion connected to the sole and extending toward the top rail; a face element comprising a striking surface and a rear wall located opposite the striking surface; a reinforcing structure integrally formed with the face element; and a flex structure integrally formed with the face element and the rear portion, wherein the face element defines a face center; the reinforcing structure comprises a circular annular rib extending away from the rear wall around the face center; and the flex structure comprises a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion, and the flex structure has a sinusoidal shape.

[0090] (Item 16) The golf club head according to Item 15, wherein the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

[0091] (Item 17) The golf club head according to Item 16, wherein the flex structure defines a first radius of curvature at the lowest point and a second radius of curvature at the vertex, the first radius of curvature being equal to the second radius of curvature.

[0092] (Item 18) The golf club head according to Item 16, wherein the flex structure defines a first radius of curvature at the lowest point and a second radius of curvature at the apex, the first radius of curvature being different from the second radius of curvature.

[0093] (Item 19) The golf club head according to Item 15, wherein the club head further defines a central plane extending toward the toe end and the heel end behind the center of the face, and the lowest point and the apex of the flex structure are located below the central plane.

[0094] (Item 20) The golf club head according to Item 15, wherein the club head further defines a central plane extending toward the toe end and the heel end behind the center of the face, the lowest point of which is located below the central plane, and the apex of which is located above the central plane.

[0095] The various features and benefits of this disclosure are described below.

Claims

1. Top rail and The sole located on the opposite side of the aforementioned top rail, To end, The heel end located on the opposite side of the toe end, A rear portion connected to the sole and extending toward the top rail, A face element comprising a striking surface and a rear wall located on the opposite side of the striking surface, A reinforcing structure formed integrally with the face element, A flexible structure integrally formed with the face element and the rear portion, Equipped with, The aforementioned face element defines the center of the face, The reinforcing structure comprises a circular annular rib that extends away from the rear wall and around the center of the face, The flex structure comprises a first end formed integrally with the face reinforcing structure and a second end formed integrally with the rear portion, in a golf club head.

2. The club head further comprises a bottom wall located on the opposite side of the sole, which integrally connects the rear wall, the rear portion, the toe end, and the heel end. The rear wall, the rear portion, the toe end, the heel end, and the bottom wall together form a channel. The flexible structure extends within the channel so as not to come into contact with the channel. The golf club head according to claim 1.

3. The aforementioned flexible structure has a curved shape, The golf club head according to claim 1, wherein the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

4. The club head further defines a central plane behind the center of the face, extending toward the toe end and the heel end. The golf club head according to claim 3, wherein the lowest point and the vertex of the central plane are located below the central plane.

5. The aforementioned face reinforcement structure is An inner circumferential surface located within the face reinforcement structure and extending perpendicularly to the rear wall, The outer surface located at the portion having the maximum thickness of the face element and adjacent to the inner surface, A golf club head according to claim 1, comprising:

6. The golf club head according to claim 5, wherein the inner circumferential surface defines a rib span that is 0.609 centimeters or more and 1.88 centimeters or less.

7. The thickness of the aforementioned face element is changeable. The aforementioned thickness is A first thickness measured from the center of the face to the rear wall in a direction perpendicular to the striking surface, A second thickness measured in a direction perpendicular to the striking surface, from the striking surface to the outer peripheral surface of the face reinforcement structure, A third thickness measured perpendicular to the striking surface, from the striking surface to the rear wall without the reinforcing element, It has a fourth thickness measured perpendicular to the striking surface, from the striking surface to the rear wall located on the outer edge of the face, The first thickness is the minimum thickness of the face element, The golf club head according to claim 5, wherein the second thickness is the maximum thickness of the face element.

8. Top rail and The sole located on the opposite side of the aforementioned top rail, To end, The heel end located on the opposite side of the toe end, The bottom wall located on the opposite side of the sole, A rear portion connected to the sole and extending toward the top rail, A face element comprising a striking surface and a rear wall located on the opposite side of the striking surface, A reinforcing structure formed integrally with the face element, A flexible structure integrally formed with the face element and the rear portion, Equipped with, The aforementioned face element defines the center of the face, The reinforcing structure comprises a circular annular rib extending away from the rear wall and around the center of the face, The flexible structure comprises a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion. The rear wall, the rear portion, the toe end, the heel end, and the bottom wall together form a channel. The flex structure is a golf club head that extends across the channel without contacting the channel.

9. The aforementioned flexible structure has a curved shape, The golf club head according to claim 8, wherein the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

10. The club head further defines a central plane behind the center of the face, extending toward the toe end and the heel end. The golf club head according to claim 9, wherein the lowest point and the apex of the flex structure are located below the central plane.

11. The club head further defines a central plane behind the center of the face, extending toward the toe end and the heel end. The lowest point is located below the central plane, The golf club head according to claim 9, wherein the aforementioned vertex is located above the central plane.

12. The aforementioned face reinforcement structure is An inner circumferential surface located within the face reinforcement structure and extending perpendicularly to the rear wall, The golf club head according to claim 8, comprising an outer circumferential surface located at the portion having the maximum thickness of the face element and adjacent to the inner circumferential surface.

13. The golf club head according to claim 12, wherein the inner circumferential surface defines a rib span that is 0.609 centimeters or more and 1.88 centimeters or less.

14. The thickness of the aforementioned face element is changeable. The aforementioned thickness is A first thickness measured from the center of the face to the rear wall in a direction perpendicular to the striking surface, A second thickness measured in a direction perpendicular to the striking surface, from the striking surface to the outer peripheral surface of the face reinforcement structure, A third thickness measured perpendicular to the striking surface, from the striking surface to the rear wall without the reinforcing element, It has a fourth thickness measured perpendicular to the striking surface, from the striking surface to the rear wall located on the outer edge of the face, The first thickness is the minimum thickness of the face element, The golf club head according to claim 8, wherein the second thickness is the maximum thickness of the face element.

15. Top rail and The sole located on the opposite side of the aforementioned top rail, To end, The heel end located on the opposite side of the toe end, The bottom wall located on the opposite side of the sole, A rear portion connected to the sole and extending toward the top rail, A face element comprising a striking surface and a rear wall located on the opposite side of the striking surface, A reinforcing structure formed integrally with the face element, A flexible structure integrally formed with the face element and the rear portion, Equipped with, The aforementioned face element defines the center of the face, The reinforcing structure comprises a circular annular rib extending away from the rear wall and around the center of the face, The flexible structure comprises a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion. The aforementioned flex structure is a golf club head with a sinusoidal curve shape.

16. The golf club head according to claim 15, wherein the flex structure comprises a lowest point defining the lowest part of the flex structure and a vertex defining the uppermost part of the flex structure.

17. The aforementioned flexible structure defines a first radius of curvature at the lowest point and a second radius of curvature at the vertex, The golf club head according to claim 16, wherein the first radius of curvature is equal to the second radius of curvature.

18. The aforementioned flexible structure defines a first radius of curvature at the lowest point and a second radius of curvature at the vertex, The golf club head according to claim 16, wherein the first radius of curvature is different from the second radius of curvature.

19. The club head further defines a central plane behind the center of the face, extending toward the toe end and the heel end. The golf club head according to claim 15, wherein the lowest point and the apex of the flex structure are located below the central plane.

20. The club head further defines a central plane behind the center of the face, extending toward the toe end and the heel end. The lowest point is located below the central plane, The golf club head according to claim 15, wherein the vertex is located above the central plane.

Images