Mixed Material Golf Club Heads

Abstract

To provide means for maximizing discretionary weight to maximize moment of inertia (MOI) of a club head and to lower / retreat a center of gravity (COG).SOLUTION: A golf club head 10 includes a metal front body 14 joined to a rear body 16 to define a substantially hollow structure. The metal front body includes: a strikeface 30; and a peripheral frame 32 extending rearwardly from a periphery of the strikeface. The rear body includes: a crown member 50; and a sole member 52 coupled to the crown member. The sole member includes a fiber-reinforced decoded structural layer 56 formed from a filled thermoplastic material. The structural layer includes a plurality of openings 66 extending through a thickness of the structural layer; an elastic layer 54 extends across each of the plurality of openings. The structural layer and the elastic layer each include a common thermoplastic resin component and are directly bonded without using an intermediate adhesive.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority from U.S. Provisional Patent Application No. 62 / 342,741, filed May 27, 2016, which is incorporated by reference in its entirety.

[0002] The present invention relates generally to golf club heads utilizing mixed material construction. [Background technology]

[0003] In an ideal club design for a given total swing weight, the amount of structural mass would be minimized (without sacrificing resiliency) to provide the designer with additional discretionary mass to specifically place in an effort to customize club performance. In general, the total mass of all golf club heads is the sum of the total amount of structural mass and the total amount of discretionary mass. Structural mass generally refers to the mass of material required to provide the club head with the structural resiliency required to withstand repeated impacts. Structural mass is highly design dependent and provides the designer with a relatively low amount of control over the specific mass distribution. Conversely, discretionary mass is any additional mass (beyond the minimum structural necessity) that can be added to the club head design for the sole purpose of customizing the club's performance and / or restitution tolerance. There is a need in the art for an alternative design to all metal golf club heads that provides a means to maximize discretionary weight to maximize the club head's moment of inertia (MOI) and lower / retract the center of gravity (COG).

[0004] The background provided herein seeks to clarify some club terminology, but is by way of example and not meant to be limiting. Industry practices, rules established by golf organizations such as the United States Golf Association (USGA) or the R&A, and naming conventions may augment this explanation of terminology without departing from the scope of this application. [Brief description of the drawings]

[0005] [Figure 1] 1 is a schematic perspective view of a mixed material golf club head. [Diagram 2] FIG. 2 is a schematic bottom view of a mixed material golf club head. [Diagram 3] 2 is a schematic exploded perspective view of an embodiment of a mixed material golf club head similar to that shown in FIG. 1. [Figure 4] 1 is a schematic perspective view of a sole member of a mixed material golf club head. [Diagram 5] 5 is a schematic, enlarged cross-sectional view of a portion of the sole member of FIG. 4 taken along section 5-5. [Figure 6] 6 is a schematic partial cross-sectional view of the joining structure of the golf club head of FIG. 2 taken along line 6-6. [Figure 7] 7 is a schematic partial cross-sectional view of the joining structure of the golf club head of FIG. 2 taken along line 7-7. [Figure 8] 1 is a schematic flow diagram illustrating a method of manufacturing a mixed material golf club head. [Figure 9] FIG. 2 is a schematic top perspective view of a mixed material crown piece. [Figure 10] FIG. 2 is a schematic bottom perspective view of a mixed material crown piece. [Figure 11] 11 is a schematic side cross-sectional view of an embodiment of a mixed material golf club head, such as taken along line 11-11 of FIG. 2. [Figure 12] 1 is a schematic top perspective view of an embodiment of a mixed material sole member. [Figure 13] 1 is a schematic top perspective view of an embodiment of a mixed material sole member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] The present embodiments discussed below are directed to a club head that utilizes a mixed material rear body construction in combination with a metallic striking face and front frame structure. The mixed material rear body is composed of a resilient layer of fiber reinforced thermoplastic composite and a molded thermoplastic structural layer. Utilizing a mixed material rear body construction significantly reduces structural weight while not sacrificing any design flexibility.

[0007] An additional benefit of the mixed material rear body embodiments described below is the ability to provide a robust means for manufacturers to reintroduce discretionary mass. Such designs can be formed entirely from filled thermoplastics such as polyphenylene sulfide (PPS), and the use of fiber reinforced composites provides a stronger, lighter construction across the continuous exterior surface. The molded resilient layer further comprises a filled thermoplastic. Having thermoplastics in both the fiber reinforced thermoplastic composite resilient layer and the molded thermoplastic structural layer provides the ability to mold these materials together. This provides unique geometric club head designs that save weight with the thermoplastic structural layer, but also provides the manufacturing ability to merge layers with stiffness strength with the composite resilient layer. Overall, integrating these mixed material rear constructions with the metal striking face and front frame structure facilitates the transfer of dynamic impact loads from the weight / weighted portion to the metal front of the club head.

[0008] Additionally, the use of thermoplastic resins can provide several acoustic advantages not possible with other polymers: Using a thermoplastic polymer in this configuration allows the assembled golf club head to acoustically respond closer to that of an all-metal design.

[0009] "A," "an," "the," "at least one," and "one or more" are used interchangeably to indicate the presence of at least one item, and a plurality of such items may be present unless the context clearly indicates otherwise. All values ​​of parameters (e.g., amounts or conditions) in this specification, including the appended claims, are to be understood in all instances to be modified by the term "about," regardless of whether "about" is actually present before the value. "About" indicates that the stated value allows for some slight imprecision (some proximity to the precision of the value, approximately, or reasonably close to, the value). When the imprecision provided by "about" is not otherwise understood in the art in this ordinary sense, as used herein, "about" indicates at least the variation that may result from ordinary methods of measuring and using such parameters. In addition, the disclosure of a range includes the disclosure of all values ​​and sub-divided ranges contained throughout the range. Each value within a range, and the endpoints of the range, are all disclosed herein as separate embodiments. The terms "comprises," "comprising," "including," and "having" are inclusive and thus specify the presence of stated items but do not exclude the presence of other items. As used herein, the term "or" includes any and all combinations of one or more of the listed items. When terms first, second, third, etc. are used to distinguish various items from one another, these designations are merely for convenience and do not limit the items.

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

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

[0012] In this description and in the claims, terms such as "left," "right," "front," "back," "top," "bottom," "upper," "lower," and similar terms are used for descriptive purposes, if any, with general reference to a golf club addressed on a horizontal ground plane and held at a given loft and lie angle, but are not necessarily intended to describe permanent relative positions. Terms so used are interchangeable under appropriate circumstances. Thus, it should be understood that the apparatus, method, and / or article embodiments described herein can operate in orientations other than those shown or otherwise described herein, for example.

[0013] Terms such as "couple," "coupled," "connection," and "coupled" should be understood broadly and refer to connecting two or more elements, mechanically or otherwise. The connection (mechanical or otherwise) can be for any length of time, for example, permanently or semi-permanently, or only momentarily.

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

[0015] Like reference numerals are used in the various views to identify similar or identical components. Referring to the drawings, Figure 1 generally illustrates a perspective view of a golf club head 10. In particular, the present technology relates to wood-style head designs, such as drivers, fairway woods, or hybrid irons.

[0016] Golf club head 10 includes a front body portion 14 (front body 14) and a rear body portion 16 (rear body 16) secured together to define a substantially closed / hollow interior volume. As is conventional for wood-style heads, golf club head 10 includes a crown 18 and a sole 20, which may be generally divided into a heel portion 22, a toe portion 24, and a central portion 26 located between heel portion 22 and toe portion 24.

[0017] The front body 14 generally includes a strike face 30 intended to impact a golf ball, a frame 32 that surrounds a perimeter 34 of the strike face 30 and extends rearwardly therefrom to provide the front body 14 with a cup-shaped appearance, and a hosel 36 for receiving a golf club shaft or shaft adapter. The front body 14 is formed from a metal or metal alloy, preferably a lightweight metal alloy, such as, for example, a stainless steel or alloy steel (e.g., C300, C350, Ni (nickel)-Co (cobalt)-Cr (chromium)-alloy steel, 565 steel, AISI type 304 or AISI type 630 stainless steel), a titanium alloy (e.g., Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti15-3-3-3, Ti15-5-3, Ti185, Ti6-6-2, Ti-7s, Ti-92, or Ti-8-1-1 titanium alloy), an amorphous metal alloy, or other similar material, to withstand the impact stresses that occur when the club head 10 strikes a golf ball.

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

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

[0020] In the present design, the rear body 16 may comprise a mixture of molded thermoplastics (e.g., injection molded thermoplastics) and fiber reinforced thermoplastic composites. As used herein, molded thermoplastics are those that rely on the polymer itself to provide structure and rigidity to the final component. Molded thermoplastics are those that are easily adapted to molding techniques such as injection molding, whereby the material flows freely when heated above the melting point of the polymer. Molded thermoplastics with mixed filler materials are referred to as filled thermoplastic (FT) materials. Filled thermoplastics are freely flowable when in a heated / molten state. To facilitate the flowable properties, the filler materials generally include discrete particulates having a maximum dimension of less than about 25 mm, or more commonly less than about 12 mm. For example, the filler materials may comprise discrete particulates having a maximum dimension of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. Filler materials useful in the present design may comprise, for example, glass beads or discontinuous reinforcing fibers formed from carbon, glass, or aramid polymers.

[0021] In contrast to filled thermoplastic materials for molding, fiber reinforced composite (FRC) materials generally comprise one or more layers of unidirectional or multidirectional woven fibers that extend over a larger portion of the polymer. Unlike the reinforcing fibers that can be used in FT materials, the maximum dimensions of the fibers used in FRC materials can be substantially larger / longer than those used in FT materials and can have sufficient size and properties such that they can be provided as a continuous woven fabric separate from the polymer. When formed with thermoplastic polymers, the continuous fibers contained generally do not flow, even if the polymer is freely flowable when melted.

[0022] FRC materials are generally formed by arranging fibers in a desired configuration and then impregnating the fiber material with a sufficient amount of polymeric material to provide stiffness. Thus, FT materials may have a resin content of more than about 45% by volume, or more preferably more than about 55% by volume, while FRC materials desirably have a resin content of less than about 45% by volume, or more preferably less than about 35% by volume. FRC materials traditionally use two-part thermoset epoxies as the polymer matrix, but it is also possible to use thermoplastic polymers as the matrix. Often, FRC materials are pre-processed before final fabrication, with such intermediate materials often being referred to as prepregs. When thermoset polymers are used, the prepregs are partially cured in an intermediate form, with the final curing occurring after the prepregs are formed into their final shape. When thermoplastic polymers are used, the prepregs can comprise a cooled thermoplastic matrix that can then be heated and molded into their final shape.

[0023] With continued reference to FIG. 3, in embodiments, the crown member 50 may be formed substantially from a formed fiber reinforced composite material comprising a woven glass or carbon fiber reinforcement layer embedded in a polymer matrix. In such embodiments, the polymer matrix is ​​preferably a thermoplastic material, such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide, such as PA6 or PA66. In other embodiments, the crown member 50 may instead be formed from a filled thermoplastic material, including, for example, glass beads or discontinuous glass, carbon, or aramid polymer fiber fillers embedded throughout a thermoplastic material, such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide. Additionally, in other embodiments, the crown member 50 may have a mixed material construction including both a filled thermoplastic material and a formed fiber reinforced composite material, such as those described below with respect to FIGS. 9 and 10.

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

[0025] With regard to the polymeric construction of both the crown member 50 and the sole member 52, both filled thermoplastics and fiber reinforced thermoplastic composites should preferably incorporate one or more engineering polymers that have sufficiently high material strength and / or strength / weight ratio properties to withstand typical use while providing weight saving benefits to the design. Specifically, it is important for the design and materials to efficiently withstand the stresses imparted during impact between the strike face 30 and the golf ball, but not contribute substantially to the total weight of the golf club head 10. In general, preferred polymers can be characterized by a tensile strength at yield of greater than about 60 MPa (net). Also, if filled, they may have a tensile strength at yield of greater than about 110 MPa, or more preferably, greater than about 180 MPa, and even more preferably, greater than about 220 MPa. In some embodiments, suitable filled thermoplastic polymers may have a tensile strength at yield of about 60 MPa to about 350 MPa. In some embodiments, these polymers can have a density ranging from about 1.15 to about 2.02 in either the filled or unfilled state, and can preferably have a melting temperature greater than about 210° C., or more preferably greater than about 250° C.

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

[0027] With continued reference to FIG. 3, the present design utilizes the strength-to-weight ratio benefits of FRC using a mixed material sole construction, and also utilizes the design flexibility and dimensional stability / consistency offered by FT. More specifically, FRC is usually stronger and less dense than FT of the same polymer, but its strength is usually dependent on smooth and continuous geometries. Conversely, FT is slightly denser than FRC, but can form much more complex geometries, and is generally stronger than FRC in intricate or discontinuous designs. These differences are believed to be largely due to FRC relying more on continuous fibers to provide strength, while FT relies more on the structure of the polymer itself.

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

[0029] 4 more clearly illustrates an embodiment of the sole member 52 with the FRC resilient layer 54 bonded to the FT structural layer 56. As shown, the structural layer 56 may generally include a forward portion 60 and a rear peripheral portion 62 that defines an outer perimeter 64 of the sole member 52. In the assembled club head 10, the forward portion 60 is bonded to the metal front body 14 and the rear peripheral portion 62 is bonded to the crown member 50. The structural layer 56 defines a plurality of openings 66 each located inwardly of the perimeter 64 and extending through the thickness of the layer 56. Finally, the structural layer 56 may include one or more structural members 68 extending from the forward portion 60 between at least two of the plurality of openings 66.

[0030] 4, and more clearly in FIGS. 5-7, the resilient layer 54 may be bonded to an outer surface 70 of the structural layer 56 such that it directly abuts and / or overlaps the forward portion 60, the rear peripheral portion 62, and at least a portion of the one or more structural members 68. In doing so, the resilient layer 54 may completely cover each of the plurality of openings 66 when viewed from the outside of the club head 10. Similarly, the one or more structural members 68 may act as selective reinforcement to an inner portion of the resilient layer 54, similar to a reinforcing rib or gusset.

[0031] 2-4, in some embodiments, the structural layer 56 may include a weighted portion 72 adapted to receive one or more of a plurality of metallic weights 40 (e.g., tungsten-based swing weights, etc.) by directly adhering or incorporating the weights into a molded cavity or by providing a recess 74 operable to receive a removable metallic mass. The weighted portion 72 is generally located toward the rearmost point on the club head 10. Thus, the weighted portion 72 may be integral with and / or directly bonded to the rear peripheral portion 62 of the structural layer 56 and spaced from the forward portion 60. As noted above, the filled thermoplastic construction of the structural layer 56 is particularly well suited to receive one or more weights 40 due to its ability to form complex geometric shapes in a structurally stable manner. More specifically, the filled thermoplastic construction of structural layer 56 allows for the inclusion of one or more dimensional recesses in the design that are not typically possible with all-FRC constructions (i.e., because the strength benefits of FRC are usually only available over a continuous surface geometry). For example, as shown in FIG. 3 and more clearly in the cross-sectional view of FIG. 11, weighted portion 72 can be molded to define grooves or recesses that receive one or more weights that have a non-uniform thickness, extend around a corner, and / or join other surfaces at an acute angle, all of which would be difficult or impossible to precisely form using fiber-reinforced composites.

[0032] Attaching one or more weights 40 to the structural layer 56 at the rear portion of the club head 10 may desirably shift the center of gravity of the club head 10 rearward and downward, creating a cantilevered mass spaced apart from the more structural metal front body 14 while also increasing the rotational moment of the club head. Thus, in some embodiments, one or more structural members 68 may span between the weighted portion 72 and the forward portion 60 to provide an enhanced load path between the one or more weights 40 and the metal front body 14. In this manner, the one or more reinforcing members 68 may act to help transfer dynamic loads between the weighted portion 72 and the front body 14 during impact between the strike face 30 and the golf ball. At the same time, these same ribbed reinforcing members 68 may act to strengthen the resilient layer 54 and increase the modal frequencies of the club head at impact. Thus, the natural frequency is above about 3500 Hz at impact and exists without substantial damping from the polymer. When this surface enhancement is combined with the desirable metallic-like acoustic impact properties of a polymer such as PPS or PEEK, a user will find the club head 10 to be acoustically similar to an all-metal club head, and the design can provide significantly improved mass properties (CG location and / or moment of inertia).

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

[0034] 8 illustrates an embodiment of a method 80 for manufacturing a golf club head 10 having an integrally bonded resilient layer 54 and structural layer 56 of a sole member 52. The method 80 includes, at step 82, thermoforming a fiber reinforced thermoplastic composite into a shell portion of the club head 10. The thermoforming process may include, for example, preheating a thermoplastic prepreg to a molding temperature at least above the glass transition temperature of the thermoplastic polymer, molding the prepreg into the shape of the shell portion, and then trimming the molded portion to size.

[0035] After the composite shell portion is in the proper shape, at step 84, a filled polymeric support structure may be injection molded into direct contact with the shell. Such a process is commonly referred to as insert molding. In this process, the shell is placed directly into a heated mold having a gated cavity exposed to a portion of the shell. Molten polymer is forced into the cavity and then either directly mixed with the molten polymer of the heated composite shell or locally bonded with the softened shell. When the mold cools, the polymer of the composite shell and the support structure harden together in a fused relationship. Bonding is improved if the polymer of the shell portion and the polymer of the support structure are compatible, and is further improved if the two components comprise a common thermoplastic resin composition. Insert molding is the preferred technique for forming the structure, although other molding techniques such as compression molding may be used.

[0036] Continuing with reference to FIG. 8, once the sole member 52 has been formed through steps 82 and 84, the FRC crown member 50 is bonded to the sole member 52 to substantially complete the construction of the rear body 16 (step 86). In a preferred embodiment, the crown member 50 may be formed from a thermoplastic FRC material that is formed into a shape using thermoforming techniques similar to those described with respect to step 82. Forming the crown member 50 from a thermoplastic composite material allows the crown member 50 to be bonded to the sole member 52 using localized welding techniques. Such welding techniques may include, for example, laser welding, ultrasonic welding, or potentially electrical resistance welding if the polymer is conductive. If the crown member 50 is formed using a thermosetting polymer, the crown member 50 may be bonded to the sole member 52 using, for example, adhesives or mechanical fastening techniques (such as studs, screws, posts, mechanical interference fit engagements, etc.).

[0037] 6 illustrates generally an embodiment of an interface 90 that serves to join the crown member 50 and the sole member 52. As illustrated, the structural layer 56 receives the resilient layer 54 and the crown member 50 separately and forms a continuous outer surface 92 (i.e., the outer surface 92 of the rear body 16 comprises the outer surface 94 of the crown member 50, the outer surface 70 of the structural layer 56, and the outer surface 96 of the resilient layer 54).

[0038] 8, in step 88, the rear body 16 with the secured crown and sole members 50, 52 may then be adhesively bonded to the metallic front body structure 14. While the adhesive adheres easily to most metals, the process of bonding polymers may require the use of one or more adhesion promoters or surface treatments to enhance the bond between the adhesive and the polymer of the rear body 16.

[0039] FIG. 7 shows a schematic example of a joint interface 100 between the sole member 52 and the frame 32 of the front body 14. As shown, the joint interface 100 resembles a lap joint in which the structural layer 56 and / or the elastic layer 54 overlap a joint flange 102 recessed inwardly from the outer surface 104 of the frame 32. In the illustrated embodiment, the structural layer 56 may be adhesively bonded directly to the joint flange 102 via an intermediately disposed adhesive 106. Alternatively, the elastic layer 54 may extend across the entire forward portion 60 of the structural layer 56 such that the outer surface 96 of the elastic layer 54 is flush with the outer surface 104 of the frame 32. By recessing the joint flange 102 as shown, the structural layer 56 and / or the elastic layer 54 may directly abut an extension wall 108 that joins the frame 32 and the flange 102, further facilitating the transfer of dynamic impact loads from the weight 40 / weighted portion 72 to the frame 32.

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

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

[0042] While the method 80 described in FIG. 8 is primarily focused on forming a club head similar to that shown in FIG. 3 (i.e., step 82 forms the resilient layer 54 of the sole member 52 and step 84 forms the structural layer 56 of the sole member 52), the processes described with respect to steps 82 and 84 may alternatively be used to form the crown member 50. For example, as shown in FIGS. 9 and 10, the crown member 50 may include one or both of an outer structural layer 110 and an inner structural layer 112 bonded to a thermoplastic FRC resilient crown layer 114. The inner structural layer 112 may generally function similarly to the structural layer 56 of the sole member 52, while the outer structural layer 110 may provide additional weight-saving benefits by concentrating reinforcing structures in areas that provide the most structural benefits, and also allowing for thinner component thickness in the spaces between the lattices. This concept of structural ribs generally results in the creation of weight-reducing zones between the ribs. These weight reduction zones can be in the sole or crown and are further described in US Pat. No. 7,361,100 and US Pat. No. 7,686,708, which are incorporated by reference in their entireties.

[0043] Specific to the construction of the mixed material crown member 50, formation similar to that described above with respect to the sole member 52 may begin by thermoforming a fiber reinforced thermoplastic composite into the shell portion of the club head 10. The thermoforming process may include, for example, preheating a thermoplastic prepreg to a molding temperature at least above the glass transition temperature of the thermoplastic polymer, molding the prepreg into the shape of the shell portion, and then trimming the molded portion to size.

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

[0045] Additional aerodynamic features 116, such as turbulators, shown in Figure 1, may be used to reduce the air resistance of the club head and increase the club's speed. These aerodynamic features 116 are further described in U.S. Patent No. 9,555,294 (the "294" patent), which is incorporated by reference in its entirety.

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

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

[0048] Utilizing a mixed-material rear body construction can provide a significant reduction in structural weight, providing a robust means to reintroduce discretionary mass without sacrificing any design flexibility. While such designs could be formed entirely from filled thermoplastics such as polyphenylene sulfide (PPS), as previously discussed, the use of fiber-reinforced composites provides a stronger, lighter construction across the continuous exterior surface. Conversely, an all-FRC design would not be able to easily incorporate a weight-accepting structure and thus would not be able to easily utilize increased discretionary mass.

[0049] Table 1 provides mass estimates based on the comparison between the all-filled PPS configuration discussed above and the mixed material design for the rear body 16 design shown in Figure 3. As shown, the mixed material design contributes significant weight savings over the all-filled PPS configuration, which can be reintroduced into the weighted section 72 to lower and move the center of mass further aft to increase recovery forgiveness and dynamic loft.

[0050] [Table 1]

[0051] If all of the restored mass is relocated to the rearward weighted portion of the sole member 52, the mixed material design can result in a net shift of the center of gravity approximately 0.008 mm lower and 0.058 mm rearward (for a club head having a total mass of 205 g) when compared to an all filled PPS configuration.

[0052] Table 2 shows the effect of this mixed material configuration on the club head's moment of inertia for a club head having a total mass of 205 g. Specifically, Table 2 shows the effect of the moment of inertia along the vertical axis (I YY ) about a horizontal axis (I XX ) Compare the club head moment of inertia around the club head.

[0053] [Table 2]

[0054] As shown in Table 2, this mixed material design achieved a 100% filler PPS sole clubhead impact resistance of 1.0 mm. XX Approximately 6.3% increase in I XX Similarly, this mixed material design can provide an increase of approximately 31.8% in I versus an all filled PPS sole clubhead. YY Approximately 3.3% increase in I YY The composite material design can provide approximately a 6.6% increase in sole strength / resilience when compared to the all-filled PPS sole member design, or the reference metal design. Thus, the composite material design provides a significantly more stable club head during off-center impacts than either the all-filled PPS sole member design, or the reference metal design. Additionally, the composite material design provides a 2.5-3.0 times increase in sole strength / resilience when compared to the all-filled PPS design, and exhibits approximately 90%-98% of the strength / resilience of the all-metal reference design.

[0055] Again, as noted above, these stability benefits are produced without sacrificing the sound quality of the impact. In particular, using PPS or PEEK thermoplastics can provide certain acoustic advantages not possible with other polymers. In particular, PPS or PEEK have particularly metallic acoustic properties when impacted. Thus, using these polymers in the present configuration allows the assembled golf club head 10 to have an acoustic response that more closely resembles that of an all-metal design. Although polyamide and some thermoplastic polyurethane materials may have sufficient strength to be suitable for current designs, their use may provide a substantially different acoustic response.

[0056] 11-13 illustrate alternative sole member designs that may also be used with the present golf club head configurations. For example, FIG. 11 illustrates an embodiment in which at least one of the plurality of reinforcing members 68 extends into the rear peripheral portion 62 away from the weighted portion 72. In this embodiment, the reinforcing member 68 may resemble a "Y" that extends between the forward portion 60, the weighted portion 72, and the rear peripheral portion 62 away from the weighted portion 72. This design may further utilize a reinforced "skirt" (i.e., a reinforced band of material where the crown 18 meets the sole 20) to operatively reinforce the sole and provide an additional load path from the weighted portion 72.

[0057] FIG. 12 illustrates an embodiment of a sole member 52 in which a plurality of reinforcing members 68 extend directly from the forward portion 60 of the structural layer 56 to the rear peripheral portion 62, away from the weighted portion 72. However, one reinforcing member 68 remains extending directly between the weighted portion 72 and the forward portion. FIG. 12 further illustrates, in a schematic manner, an embodiment in which the structural layer 56 can have a non-uniform / non-sheet-like geometry. Such a configuration for at least the reinforcing members 68 can be used in any of the previously illustrated embodiments as well. In an embodiment having a non-uniform structural layer, such as the one illustrated in FIG. 12 in a schematic manner, some configurations can provide the elastic layer 54 with a substantially uniform thickness, which is attributed to the nature of a fiber-reinforced composite. This thickness can range, for example, from about 0.5 mm to about 1.0 mm, from about 0.6 mm to about 0.9 mm, or from about 0.7 mm to about 0.8 mm. Finally, FIG. 13 illustrates an embodiment in which weighted portion 72 is supported only by rear peripheral portion 62 and has no structural member 68 connected thereto.

[0058] Substitution of one or more claim elements constitutes a rearrangement, not a prosthesis. Moreover, advantages, other advantages, and solutions to a problem have been described in connection with particular embodiments. However, the advantages, other advantages, and solutions to a problem, and any one or more elements that make any advantage, advantage, or solution occur or become apparent, do not constitute a critical, essential, or essential feature or element of any or all elements of a claim, unless such advantage, advantage, solution, or element is expressly recited in such claim.

[0059] Because the rules of golf change from time to time (e.g., new rules may be adopted, or old rules may be repealed or modified, by golf standards organizations and / or governing bodies such as the United States Golf Association (USGA), the Royal and American Golf Association (R&A), etc.), golf equipment related to the devices, methods and products described herein may or may not conform to the rules of golf at any particular time. Accordingly, golf equipment related to the devices, methods and products described herein may be advertised, offered for sale and / or sold as conforming or non-conforming golf equipment. The devices, methods and products described herein are not limited in this respect.

[0060] Although the above embodiments are described in the context of iron-type golf clubs, the devices, methods and products described herein may be applied to other types of golf clubs, such as driver-type golf clubs, fairwood-type golf clubs, hybrid-type golf clubs, iron-type golf clubs, wedge-type golf clubs, or putter-type golf clubs, while the devices, methods and products described herein may be applicable to other types of sporting goods, such as hockey sticks, tennis racquets, fishing rods, ski poles, etc.

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

[0062] Various features and advantages of the disclosure are set forth in the following paragraphs.

[0063] (Clause 1) A golf club head comprising: a metallic front body including a strike face and a peripheral frame extending rearwardly from a perimeter of the strike face; and a rear body coupled to the metallic front body to define a substantially hollow structure, the rear body comprising a crown member and a sole member coupled to the crown member, the sole member comprising: a structural layer formed from a filled thermoplastic material and bonded to the crown member, the structural layer having a plurality of openings extending through a thickness of the structural layer; and an elastic layer bonded to an outer surface of the structural layer so as to extend across each of the plurality of openings, the elastic layer being formed from a fiber reinforced thermoplastic composite material, the structural layer and the elastic layer each comprising a common thermoplastic resin composition, and the structural layer is bonded directly to the elastic layer without the use of an intermediate adhesive.

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

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

[0066] (Clause 4) A golf club head described in any one of clauses 1 to 3, wherein the metal front body further includes a joining flange recessed inward from an outer surface of the frame, the structural layer is adhesively joined to the joining flange, and the outer surface of the elastic layer is flush with the outer surface of the frame.

[0067] (Clause 5) The golf club head described in Clause 4, wherein the metal front body further includes an extension wall connecting the frame to the joining flange, the structural layer and the elastic layer each abut against the extension wall, and the reinforcing member acts to transfer dynamic loads between the weighted portion and the extension wall during impact between the strike face and a golf ball.

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

[0069] (Clause 7) A golf club head as described in any one of Clauses 1 to 6, wherein the frame comprises a crown portion and a sole portion, the golf club head comprises a heel region, a toe region, and a central region disposed between the heel region and the toe region, the sole portion of the frame defines a rear edge extending a first average distance from the strike face in the heel region, a second average distance from the strike face in the toe region, and a third average distance from the strike face in the central region, the third average distance being greater than both of the first average distance and the second average distance.

[0070] (Clause 8) A golf club head comprising: a metal front body including a strike face and a perimeter frame extending rearwardly from a perimeter of the strike face; and a rear body coupled to the metal front body to define a substantially hollow structure, the rear body including a crown member coupled to a sole member, the sole member including a structural layer including a forward portion in contact with and joined to the metal front body, a weighted portion spaced from the forward portion, a plurality of openings extending through a thickness of the structural layer, the forward portion and the weighted portion being disposed on opposite sides of at least one of the plurality of openings; and a plurality of reinforcing members, each of the plurality of reinforcing members extending from the forward portion to the weighted portion and extending between at least two of the plurality of openings. a resilient layer bonded to an outer surface of the structural layer so as to abut the metal front body and extend across each of the plurality of openings; and a metal weight at least partially embedded in or bonded to the weighted portion of the structural layer by an adhesive, wherein the structural layer is formed from a filled thermoplastic material and the resilient layer is formed from a fiber reinforced thermoplastic composite material.

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

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

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

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

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

[0076] (Clause 14) The golf club head described in Clause 13, wherein the metal front body further includes an extended wall connecting the frame to the joining flange, each of the structural layer and the elastic layer abutting the extended wall, and the plurality of reinforcing members acting to transfer dynamic loads to the weighted portion and the extended wall during impact between the strike face and a golf ball.

[0077] (Clause 15) A golf club head as described in any one of Clauses 8 to 14, wherein the frame comprises a crown portion and a sole portion, the golf club head comprises a heel region, a toe region, and a central region disposed between the heel region and the toe region, the sole portion of the frame defines a rear edge extending a first average distance from the strike face in the heel region, a second average distance from the strike face in the toe region, and a third average distance from the strike face in the central region, the third average distance being greater than both of the first average distance and the second average distance.

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

[0079] (Clause 17) A golf club head described in any one of clauses 8 to 16, wherein each of the filled thermoplastic material and the fiber reinforced thermoplastic composite material includes a common resin component, the common resin component being present in the filled thermoplastic material in a first amount and being present in the fiber reinforced thermoplastic composite material in a second amount less than the first amount.

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

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

[0082] (Clause 20) A method for manufacturing a multi-material golf club head, comprising: thermoforming a first sole layer from a fiber reinforced composite having a thermoplastic resin matrix and a woven fiber reinforced layer; injection molding a second sole layer in direct contact with the thermoformed first sole layer, the second sole layer comprising a filled thermoplastic resin, the thermoplastic resin matrix and the filled thermoplastic resin each comprising a common thermoplastic polymer; bonding a crown member to the second sole layer; and bonding the first sole layer and the crown member to a metal forward body to define a substantially hollow structure, the metal forward body comprising a strike face and a hosel.

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

[0084] (Clause 22) The method of any one of clauses 20 to 21, further comprising forming a crown member by thermoforming a first crown layer from a fiber reinforced composite comprising a thermoplastic resin matrix and a woven fiber reinforced layer, and injection molding a second crown layer in direct contact with the thermoformed first crown layer, the second crown layer comprising a filled thermoplastic resin, and the thermoplastic resin matrix and the filled thermoplastic resin each comprising a common thermoplastic polymer.

[0085] (Clause 23) A golf club head comprising: a metallic front body having a strike face and a peripheral frame extending rearwardly from a perimeter of the strike face; and a rear body coupled to the metallic front body to define a substantially hollow structure, the rear body comprising a crown member and a sole member coupled to the crown member, the crown member comprising: a structural layer formed from a filled thermoplastic material and bonded to the sole member, the structural layer having a plurality of openings extending through a thickness of the structural layer; and an elastic layer bonded to the structural layer so as to extend across each of the plurality of openings, the elastic layer being formed from a fiber reinforced thermoplastic composite material, the structural layer and the elastic layer each comprising a common thermoplastic resin composition, and the structural layer is bonded directly to the elastic layer without the use of an intermediate adhesive.

Claims

1. A golf club head, A metal front body including a strike face and a peripheral frame extending rearward from a periphery of the strike face; a rear body coupled to the metallic front body to define a substantially hollow structure; The rear body includes a crown member and a sole member coupled to the crown member. The sole member is A structural layer formed from a filled thermoplastic material, a front portion having a rear edge in contact with and joined to the metal front body, the rear edge defining a protruding section having a radius of curvature of 25-125 mm; a rear peripheral portion defining a perimeter of the sole member; a weighted portion spaced from the forward portion; a structural member extending from the forward portion to the weighted portion, the structural member being integrally molded with both the forward portion and the weighted portion; The structural layer comprises: an elastic layer joined to an outer surface of the structural layer so as to abut against the metal front body, the elastic layer being made of a fiber-reinforced thermoplastic composite material; the elastic layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; the structural layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; The total thickness of the elastic layer and the structural layer is 1.0 mm to 2.0 mm. Golf club head.

2. The golf club head of claim 1, wherein each of the filled thermoplastic material and the fiber reinforced thermoplastic composite material contains a common resin component.

3. The filled thermoplastic material and the fiber reinforced thermoplastic composite each contain a common thermoplastic resin component, 2. The golf club head of claim 1, wherein the common thermoplastic resin component comprises polyphenylene sulfide or polyether ether ketone.

4. The golf club head of claim 1, wherein the crown member comprises a crown structural layer formed from a filled thermoplastic material, and a crown elastic layer formed from a fiber reinforced thermoplastic composite material.

5. The weighted portion is integral with the rear peripheral portion, The golf club head of claim 1 , wherein the weighted portion defines one or more weight-receiving channels having a non-uniform thickness.

6. A golf club head, A metal front body including a strike face and a peripheral frame extending rearward from a periphery of the strike face; a rear body coupled to the metallic front body to define a substantially hollow structure; The rear body includes a crown member and a sole member coupled to the crown member. The sole member is A structural layer formed from a filled thermoplastic material, a front portion having a rear edge in contact with and joined to the metal front body, the rear edge defining a protruding section having a radius of curvature of 25-125 mm; a rear peripheral portion defining a perimeter of the sole member; a weighted portion spaced from the forward portion; a first reinforcing member extending from the forward portion to the weighted portion, the first reinforcing member being integrally molded with both the forward portion and the weighted portion; a plurality of second reinforcing members, each of the plurality of second reinforcing members extending from the forward portion to the rear peripheral portion and spaced from the weighted portion; The structural layer comprises: an elastic layer joined to an outer surface of the structural layer so as to abut against the metal front body, the elastic layer being made of a fiber-reinforced thermoplastic composite material; the elastic layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; the structural layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; The total thickness of the elastic layer and the structural layer is 1.0 mm to 2.0 mm. Golf club head.

7. The metal front body further includes a joining flange recessed inwardly from the outer surface of the peripheral frame, the structural layer is adhesively bonded to the interface flange; an outer surface of the elastic layer is flush with an outer surface of the peripheral frame; The metal front body further includes an extension wall that connects the perimeter frame to the joint flange; each of the structural layer and the elastic layer abuts the extension wall; 7. The golf club head of claim 6, wherein the first reinforcing member and the plurality of second reinforcing members act to transfer dynamic loads to the weight portion and the extension wall during impact between the strike face and a golf ball.

8. The filled thermoplastic material and the fiber reinforced thermoplastic composite each contain a common resin component, 7. The golf club head of claim 6, wherein the common resin component is present in the filled thermoplastic material in an amount greater than about 55% by volume and in the fiber reinforced thermoplastic composite material in an amount less than about 35% by volume.

9. The filled thermoplastic material and the fiber reinforced thermoplastic composite each contain a common thermoplastic resin component, 7. The golf club head of claim 6, wherein the common thermoplastic resin component comprises polyphenylene sulfide or polyether ether ketone.

10. The golf club head of claim 6, wherein the crown member comprises a crown structural layer formed from a filled thermoplastic material and a crown elastic layer formed from a fiber reinforced thermoplastic composite material.

11. The golf club head of claim 6, wherein the weighted portion defines one or more weight-receiving channels having a non-uniform thickness.

12. A golf club head, A metal front body including a strike face and a peripheral frame extending rearward from a periphery of the strike face; a rear body coupled to the metallic front body to define a substantially hollow structure; The rear body includes a crown member and a sole member coupled to the crown member. The sole member is A structural layer formed from a filled thermoplastic material, a front portion having a rear edge in contact with and joined to the metal front body, the rear edge defining a protruding section having a radius of curvature of 25-125 mm; a rear peripheral portion defining a perimeter of the sole member; a weighted portion spaced from the forward portion; a plurality of openings extending through a thickness of the structural layer; The structural layer comprises: an elastic layer joined to an outer surface of the structural layer so as to abut the metal front body and extend across each of the plurality of openings, the elastic layer being formed from a fiber-reinforced thermoplastic composite material; the elastic layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; the structural layer has a uniform thickness in the range of 0.5 mm to 1.0 mm; The total thickness of the elastic layer and the structural layer is 1.0 mm to 2.0 mm. Golf club head.

13. The filled thermoplastic material and the fiber reinforced thermoplastic composite each have a common thermoplastic resin component; the structural layer is bonded directly to the elastic layer without the use of an intermediate adhesive; 13. The golf club head of claim 12, wherein the common thermoplastic resin component comprises polyphenylene sulfide or polyether ether ketone.

14. The weighted portion is integral with the rear peripheral portion, The golf club head of claim 12 , wherein the weighted portion defines one or more weight-receiving channels having a non-uniform thickness.

15. The metal front body further includes a joining flange recessed inwardly from the outer surface of the peripheral frame, the structural layer is adhesively bonded to the interface flange; an outer surface of the elastic layer is flush with an outer surface of the peripheral frame; The metal front body further includes an extension wall that connects the perimeter frame to the joint flange; The golf club head of claim 12 , wherein each of the structural layer and the resilient layer abuts the extension wall.

16. The golf club head further comprises: a crown member formed from a band of reinforcing material, the crown member including a skirt mating with the sole member; The golf club head of claim 15 , wherein the skirt operatively reinforces the sole member and provides a load path from the weighted portion and the extension wall during impact between the strike face and a golf ball.

17. The filled thermoplastic material and the fiber reinforced thermoplastic composite material each comprise a common resin component; 13. The golf club head of claim 12, wherein the common resin component is present in the filled thermoplastic material in an amount greater than about 55% by volume and in the fiber reinforced thermoplastic composite material in an amount less than about 35% by volume.

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