Hybrid material golf club head

Abstract

To make it possible that a structure of a mixed material rear body provides a significant reduction in structural mass and allows for an improved distribution of discretionary mass thus allowing for improved MOI and CG of a golf club head.SOLUTION: A hollow golf club head 100 includes a metallic front body 104 coupled with a composite rear body 108. The front body includes a strike face 120 and a surrounding frame that extends rearward from a perimeter of the strike face. The rear body includes a crown member 112 coupled with a sole member 116. The sole member has a structural layer formed from a filled thermoplastic material, while a resilient layer is bonded to the external surface of the structural layer and is formed from a fiber-reinforced thermoplastic composite material. The resilient layer has an opening through which a metallic weight pad at least partially extends. The weight pad is bonded to the structural layer and includes an aperture for attaching a metallic weight.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] Cross - Reference to Related Applications This contract claims the benefit of U.S. Provisional Application No. 62 / 779,335, filed on December 13, 2018 (the content of which is hereby incorporated by reference in its entirety). Further, this is a continuation - in - part of U.S. Patent Application No. 16 / 380,873, filed on April 10, 2019 (the content of which is hereby incorporated by reference in its entirety).

[0002] This disclosure generally relates to golf club heads having hybrid material structures.

Background Art

[0003] Generally, there are many important physical parameters (i.e., volume, mass, etc.) that affect the overall performance of a golf club head. One of the most important physical parameters is the total mass of the golf club head. The total mass of the golf club head is the sum of the total structural mass and the total optional mass. The structural mass generally refers to the mass of the material required to give the club head the structural elasticity necessary to withstand repeated impacts. The structural mass is highly design - dependent and provides the designer with a relatively small amount of control over a particular mass distribution. Conversely, the optional mass is any additional mass (beyond the minimum structural requirements of the golf club head) that can be added to the club head design for the sole purpose of customizing the performance and / or forgiveness of the club. In the art, there is a need for alternative designs for all metal golf club heads to provide means for maximizing the optional weight in order to maximize the club head moment of inertia (MOI) and the lower / back center of gravity (CG).

Brief Description of the Drawings

[0004] This disclosure generally relates to sports equipment, and more particularly to golf club heads and related methods.

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[0005] Other aspects of the present disclosure will become apparent by considering the detailed description and the accompanying drawings.

Mode for Carrying Out the Invention

[0006] A golf club head comprising a hybrid material rear body combined with a metal front body is described herein. The golf club head includes a striking face and a surrounding frame. The hybrid material rear body is composed of a fiber-reinforced thermoplastic composite elastic layer, a molded thermoplastic structural layer, a metal weight pad, and a metal weight fixed within the metal weight pad. The structure of the hybrid material rear body provides a significant reduction in structural mass and enables improved distribution of optional mass, and thus enables improvement of the MOI and CG of the golf club head.

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

[0008] The terms "left", "right", "front", "back", "top", "bottom", "upper", "lower", etc. in the description and claims are used for illustrative purposes, if any, and are not necessarily used to describe a permanent relative position. Such terms are interchangeable under appropriate circumstances so that the embodiments of the devices, methods, and / or manufactured articles described herein can operate in other orientations than those illustrated or otherwise described herein.

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

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

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

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

[0013] In embodiments where the club head includes a fairway wood, the volume of the club head is less than about 400 cc, less than about 375 cc, less than about 350 cc, less than about 325 cc, less than about 300 cc, less than about 275 cc, less than about 250 cc, less than about 225 cc, or less than about 200 cc. In these examples, the volume of the club head can be about 150 cc - 200 cc, about 150 cc - 250 cc, about 150 cc - 300 cc, about 150 cc - 350 cc, about 150 cc - 400 cc, about 300 cc - 400 cc, about 325 cc - 400 cc, about 350 cc - 400 cc, about 250 cc - 400 cc, about 250 cc - 350 cc, or about 275 cc - 375 cc.

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

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

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

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

[0018] The structural weight savings achieved by using the elastomeric layer 148 and the structural layer 152 can be used either to reduce the total weight of the club head 100 (which may provide a faster club head speed and / or a longer strike distance) or to increase any amount of mass available for placement on the golf club head 100. In one embodiment, the additional optional mass obtained from using the composite elastomeric layer 148 and the composite structural layer 152 can be reintroduced into the club head 100 in the form of the metal weight pad 156. The combination of the lightweight composite rear body 108 and the metal weight pad 156 allows the club head 100 to allocate most of the mass of the club head to positions that maximize the MOI and CG, leading to a more forgiving and longer shot.

[0019] I. Front Body Referring to FIGS. 4-7, the front body 104 of the club head 100 includes a striking face 120 for striking a golf ball. The front body 104 includes a peripheral frame 136 that extends rearward from a periphery 140 around the striking face 120 to give the front body 104 a cup-shaped appearance. The peripheral frame 136 has an inner surface 170 and an outer surface 172. Further, the peripheral frame 136 can include a flange 174 to provide an attachment surface for connecting the front body 104 and the rear body 108. When the front body 104 is combined with the rear body 108, the outer surface 172 of the front body 104 forms part of the crown 112 and part of the sole 116 of the club head 100. The front body 104 further includes a hosel 144 for receiving a golf club shaft or shaft adapter in the heel region 124 of the golf club head 100.

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

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

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

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

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

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

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

[0027] The main axis 184 forms an angle of approximately 20 degrees with the ground plane 180. For example, the angle formed between the main axis 184 and the ground plane 180 in the central region 192 can vary from 0 degrees to 60 degrees. In some embodiments, the angle formed between the main axis 184 and the ground plane 180 in the central region 192 can vary from 2 to 20, 2 to 30, 5 to 40, 10 to 50, or 15 to 60 degrees. In other embodiments, the main axis 184 can form an angle of 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, or 60 degrees with the ground plane 180. By arranging the central region 192 at an angle, it is further possible for the oval-shaped elongated portion to extend towards the toe portion above the strike face 120, where high CT values exist, and as a result, the ball speed is improved.

[0028] The elliptical or oval or egg-shaped shape, along with the angle of the central region 192 of the variable thickness profile 196, enables the thicker regions of the strike face 120 to be placed in regions having essentially high CT, and the thinner regions of the strike face 120 to be placed in regions having essentially low CT, thus reducing the area of the face having essentially high CT and increasing the area of the face having essentially low CT, resulting in a normalized CT across the strike face 120. In many embodiments, the variable thickness profile 196 results in a characteristic time range of less than 115 microseconds (μs), less than 110 μs, less than 105 μs, less than 100 μs, less than 95 μs, less than 90 μs, or less than 85 μs. Further, in many embodiments, the variable thickness profile 40 results in an average characteristic time that exceeds 230 μs, exceeds 235 μs, or exceeds 240 μs. For example, in many embodiments, the average CT of the face plate 20 can be 230 μs to 240 μs, 235 μs to 240 μs, or 240 μs to 245 μs.

[0029] Furthermore, since the angled VFT is designed to position the thick portion of the striking face 120 in the required area, the striking face 120 can experience a weight reduction compared to a striking face without the variable thickness profile 196 described herein. To manipulate the center of gravity position of the clubhead, increase the moment of inertia of the clubhead, and further improve the performance of the clubhead, any extra weight in other areas of the clubhead can be reintroduced. In the illustrated embodiment, as described herein, the clubhead 100 having the variable thickness profile 196 saves 2.1 grams of weight compared to a similar clubhead lacking the variable thickness profile 196.

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

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

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

[0033] The flange 174 provides a surface for achieving an overlap joint where the rear body 108 can be attached. The flange 174 extends rearward from the entire peripheral frame 136 and forms a stepped structure downward from the outer surface 172 of the peripheral frame 136. In many embodiments, the flange 174 of the front body 104 allows the rear body to overlap the flange 174 and join to the front body 104 by epoxy, adhesion, welding, bonding, laser-assisted metal-plastic welding, brazing, or any other suitable attachment method. The overlap joint style flange 174 further allows the front body 104 and the rear body 108 to fit securely without using any mechanical fasteners.

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

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

[0036] In this design, the rear body 108 can include a mixture of a molded thermoplastic material (e.g., an injection molded thermoplastic material) and a fiber reinforced thermoplastic composite material. As used herein, a molded thermoplastic material relies on the polymer itself to provide structure and rigidity to the final component. The molded thermoplastic material is readily adaptable to molding techniques such as injection molding, whereby the material is freely flowable when heated to a temperature above the melting point of the polymer. A molded thermoplastic material mixed with a filler material is referred to as a filled thermoplastic (FT) material. The filled thermoplastic material is freely flowable when in a heated / melted state. To facilitate the flow characteristics, the filler generally includes discrete particles having a maximum dimension of less than about 25 mm, or more generally less than about 12 mm. For example, the filler material can include discrete particles having a maximum dimension of 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. Filler materials useful in this design can include, for example, glass beads or discontinuous reinforcing fibers formed from carbon, glass, or aramid polymers.

[0037] In contrast to the formed and filled thermoplastic material, a fiber reinforced composite (FRC) material generally includes one or more layers of a unidirectional or multi-directional fiber fabric extending across a greater portion of the polymer. Unlike the reinforcing fibers that can be used in an FT material, the maximum dimension of the fibers used in an FRC can be substantially larger / longer than those used in an FT material and can have sufficient size and properties to be provided as a continuous fabric separate from the polymer. When formed from a thermoplastic polymer, the continuous fibers included are generally not flowable even when the polymer is freely flowable when melted.

[0038] FRC materials are generally formed by arranging fibers in a desired configuration and then impregnating the fiber material with a sufficient amount of polymeric material to provide rigidity. In this way, FT materials can have a resin content exceeding about 45% by volume, or more preferably exceeding about 55% by volume, while FRC materials preferably have a resin content of less than about 45% by volume, or more preferably less than about 35% by volume. FRC materials conventionally use a two-component thermosetting epoxy as the polymer matrix, but it is also possible to use a thermoplastic polymer as the matrix. In many cases, FRC materials are pre-prepared prior to final manufacture, and such intermediate materials are often referred to as prepregs. When a thermosetting polymer is used, the prepreg is partially cured in an intermediate form, and final curing occurs when the prepreg is formed into its final shape. When a thermoplastic polymer is used, the prepreg can include a cooled thermoplastic matrix, which can subsequently be heated and formed into its final shape. This technique enables the creation of complex and lightweight shapes, such as the rear body 108, without sacrificing strength.

[0039] a. Crown member The rear body 108 includes a crown member 204. Referring to FIGS. 4 and 9, the crown member 204 has an outer surface 206 such that when the rear body 108 and the front body 104 are joined, the outer surface 206 of the crown member 204 and the outer surface 172 of the surrounding frame 136 form the entire crown 112 of the golf club head 100. The outer surface 206 of the crown member 204 has a generally curved shape that is concave with respect to the ground surface 180. Due to the generally curved shape of the crown member 204, the crown member is completely disposed on the flange 174 of the front body 104, enabling the rear body 208 to be seamlessly joined to the front body 104.

[0040] In many embodiments, the crown member 204 is made of a carbon fiber fabric and is not any layer of a composite ply or unidirectional composite ply. In one embodiment, the crown member 204 may be substantially formed from a formed fiber reinforced composite material that includes a woven glass or carbon fiber reinforcement layer embedded in a polymer matrix. In such an embodiment, the polymer matrix is preferably a thermoplastic material such as, for example, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. In other embodiments, the crown member 204 may instead be formed from a filled thermoplastic material that includes 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. In yet other embodiments, the crown member 204 can have a hybrid material structure that includes both a filled thermoplastic material and a formed fiber reinforced composite material.

[0041] b. Sole member The rear body 108 includes a sole member 208. Referring to FIGS. 4 and 9, the sole member 208 includes a structural layer 156 and an elastic layer 152 and provides a lightweight yet strong sole 116 of the golf club head 100. Referring to the ground contact surface 180, the elastic layer 152 is disposed in contact with the ground contact surface, and the structural layer 156 is disposed above the elastic layer 152 within the golf club head 100.

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

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

[0044] The elastic layer 152 may be coupled to the structural layer 156 such that it directly abuts or overlaps at least a portion of the front portion 236, the peripheral portion 240, and the plurality of structural members 248. By doing so, the elastic layer 152 can completely cover each of the plurality of openings 244 when viewed from the outside of the club head 100. Similarly, one or more of the structural members 248 can act as a selective reinforcement for the inner portion of the elastic layer 244, similar to a reinforcing rib or a gusset.

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

[0046] c. Weight Pad Referring to FIGS. 4 and 9 - 11, in many embodiments, the structural layer 156 can include a weight pad 212. The weight pad 212 has a cavity 216 adapted to receive a metal weight 220. In some embodiments, the weight pad 212 is generally disposed toward the most rearward point on the club head 100 and can thus be integrated with and / or directly coupled to the rear portion 132 of the structural layer 156. In some embodiments, holes or openings 252 can be provided in the elastic layer 152 through which a portion of the weight pad 212 can extend. In some embodiments, the opening 250 is spaced at least 25 mm, or at least 30 mm, or at least 35 mm (i.e., measured along the outer surface of the club head) from the front body 104. As shown in FIG. 9, when assembled, the outer surface of the weight pad 212 can be coplanar with the outer surface of the directly adjacent sole member 208 and / or the elastic layer 152. In this way, a portion of the weight pad 212 can form part of the sole 116 outside the golf club head 100. Further, in some embodiments, the inner surface of the weight pad 212 may be exposed inside the club head. The weight pad 212 functions to provide a high - density rear mass to improve the overall MOI of the golf club head. The weight pad 212 and the weight 220 form a composite rear body 108, thereby achieving substantial weight savings and providing a region for placing any mass of high concentration.

[0047] The weight pad 212 can include any desired shape in order to dispose as much mass as possible around the rear portion 132 of the golf club head 100. The shape of the weight pad 212 can be any one of the following shapes, namely, circular, triangular, square, rectangular, trapezoidal, pentagonal, curved, spade-shaped, or any other polygon or shape having at least one curved surface. In one embodiment, the weight pad 212 can be substantially trapezoidal in shape. In another embodiment, the weight pad 212 can be substantially rectangular in shape. Further, in another embodiment, the weight pad 212 can be substantially circular in shape. Further, in another embodiment, the weight pad 212 can be substantially triangular in shape.

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

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

[0050] In one configuration, the weight pad 212 can be attached to the sole member 208 without using mechanical fasteners. In one embodiment, the weight pad 212 is cast and then the structural layer 156 can be formed around at least the edge 252 of the weight pad 212, for example, by insert injection molding or co - molding techniques. As described above, the filled thermoplastic structure of the structural layer 156 is particularly suitable for receiving the weight pad 212 by its ability to form complex geometric shapes and extend around the edge in a structurally stable manner. Depending on the geometry of the weight pad, such joining techniques may be more difficult with tape or FRC due to its more uniform profile.

[0051] The cavity 216 of the weight pad 212 extends inwardly from the weight pad 212. In the illustrated embodiment, the cavity 216 includes a circular shape. In other embodiments, the cavity 216 can include any shape. For example, the shape of the cavity 216 can include a circle, an ellipse, a triangle, a rectangle, an octagon, or any other polygon or shape having at least one curved surface. The cavity 216 provides a recess for securing the metal weight 220 therein. The metal weight 220 further adds any weight to the golf club head 100, and thus further improves the MOI and CG of the golf club head 100. Additionally, the cavity 216 and the metal weight 220 allow for a change in the total weight of the golf club head 100 by removably attaching different metal weights of different densities.

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

[0053] Furthermore, the cavity 212 includes an opening 228 in the bottom 224. The opening 228 extends inwardly from the bottom 224 of the cavity 212 toward the crown 112 of the golf club head 100. In some embodiments, the opening 228 can include threads that mate with the threading of the fastener 230 for securing the metal weight 220 within the cavity 216. In other embodiments, the opening 228 can omit the threads for use with self-tapping or self-drilling fasteners.

[0054] The metal weight 220 is configured to be disposed together with the cavity 216 of the weight pad 212. In the illustrated embodiment, the weight 220 is circular in shape to correspond to the shape of the cavity 212. In other embodiments, the weight 220 can include any geometric shape (e.g., circular, elliptical, triangular, rectangular, trapezoidal, octagonal, or any other polygonal shape or shape having at least one curved surface) corresponding to the shape of the cavity 212.

[0055] The metal weight 220 further includes an opening 232 that extends completely through the weight 220. The opening 232 is substantially the same size as the opening 228 of the cavity 212, and the opening 232 of the weight 220 is aligned with the opening 228 of the cavity 212 when the weight is disposed within the cavity 212. In most embodiments, the opening 232 lacks threading that would allow the fastener 230 to pass through the weight 220 and be fixed to the opening 228 of the weight pad 212 by threading. Further, in some embodiments, a washer 214 can be disposed within the cavity 212 before the metal weight 220 is disposed within the cavity 212.

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

[0057] When the composite shell portion is in the appropriate shape, at step 320, the filled polymer support structure can be injection molded and brought into direct contact with the shell. Such a process is generally referred to as insert molding. In this process, the shell is placed directly into a heated mold having a gated cavity exposed in a part of the shell. The molten polymer is forced into the cavity and then either directly mixed with the molten polymer of the heated composite shell or locally bonded to the softened shell. When the mold is cooled, the polymer of the composite shell and the support structure cures together in a fused relationship. The bond is strengthened if the polymer of the shell portion and the polymer of the support structure are compatible, and further strengthened if the two components contain a common thermoplastic resin component. Insert molding is a preferred technique for forming the structure, but other molding techniques such as compression molding can also be used.

[0058] Continuing to refer to FIG. 14, when the sole member 208 is formed by steps 310 and 320, the FRC crown member 204 can be joined to the sole member 208 to substantially complete the structure of the rear body 108 (step 330). In a preferred embodiment, the crown member 204 can be formed from a thermoplastic FRC material molded using a thermoforming technique similar to that described with respect to step 310. By forming the crown member 204 from a thermoplastic composite material, the crown member 204 can be joined to the sole member 208 using a local welding technique. Such welding techniques can include, for example, laser welding, ultrasonic welding, or potentially resistance welding if the polymer is conductive. Alternatively, if the crown member 204 is formed using a thermosetting polymer, the crown member 204 may be joined to the sole member 208 using, for example, an adhesive or a mechanical attachment technique (studs, screws, posts, mechanical interference engagement, etc.).

[0059] The rear body 108, which includes the fixed crown member 204 and the sole member 208, may then be adhesively bonded to the metal front body 104 at step 340. While adhesives bond readily to most metals, the process of bonding to 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 108.

[0060] III. Advantages By utilizing the structure of the hybrid material rear body, it is possible to significantly reduce the structural weight while providing a robust means for reintroducing any mass without sacrificing design flexibility. Such a design may be formed entirely from a filled thermoplastic resin such as polyphenylene sulfide (PPS) as described above, but the use of fiber-reinforced composites provides a stronger and lighter structure over the continuous outer surface. Conversely, an all-FRC design cannot easily incorporate a weight-bearing structure and thus cannot easily utilize any increased mass.

[0061] Metal weight pads are more beneficial than hybrid material golf club heads in that they provide durability and a fixed location for securing the metal weight while allowing for the dispersion and compatibility of the metal weight. Compared to a golf club head without metal weight pads, the metal weight pads can reliably withstand the torque applied to the weight pads when the weights are attached. Further, the metal weight pads allow the manufacturer to change the metal weights and adjust manufacturing tolerances (i.e., change the desired swing weight of the entire club head from 206 grams to 209 grams) or adjust customer specifications (i.e., a golfer wants their club head to be heavier, from 206 grams to 209 grams).

[0062] The replacement of one or more claimed elements constitutes a reconstruction and does not constitute a repair. Further, effects, other advantages, and problem-solving methods have been described with respect to specific embodiments. However, an element or group of elements that provides, or further enhances, an effect, advantage, or problem-solving method shall never be construed as an essential, necessary, or fundamental feature, or element, of any or all of these claims.

[0063] The rules of golf can change from time to time (e.g., new rules can be adopted, or old rules can be eliminated or modified by golf standard organizations and / or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St Andrews (R&A)), and thus, golf equipment related to the devices, methods, and articles of manufacture described herein may or may not comply with the rules of golf at any given point in time. Accordingly, golf implements related to the devices, methods, and products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf implements. The devices, methods, and products described herein are not limited in this regard.

[0064] The above examples may be described in relation to a wood-type golf club, the devices, methods, and articles of manufacture described herein. Alternatively, the devices, methods, and products described herein may be applicable to other types of sports implements such as hockey sticks, tennis rackets, fishing poles, ski poles, and the like.

[0065] Furthermore, the embodiments and limitations disclosed herein shall not contribute to the public under the doctrine of equivalents where the embodiments and / or limitations (1) are not expressly recited in the claims and (2) would be equivalents of the recited elements and / or limitations in the claims under the doctrine of equivalents, or have the potential to be equivalents.

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

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

[0068] (Item 2) The metal front body further includes a flange recessed inward from the outer surface of the peripheral frame, The structural layer of the sole member is adhesively joined to the flange. The outer surface of the elastic layer of the sole member is in the same plane as the outer surface of the peripheral frame. The golf club head according to item 1.

[0069] (Item 3) The metal front body further includes an extension wall that couples the peripheral frame to the flange. The structural layer of the sole member includes a structural member that extends from the weight pad toward the metal front body. The structural member operates to transmit a dynamic load between the weight pad and the extension wall during impact between the striking face and the golf ball. The golf club head according to item 2.

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

[0071] (Item 5) The metal front body further includes a striking face insertion portion and a receiving frame. The receiving frame has a higher density than the striking face insertion portion. The golf club head according to any one of items 1 to 4.

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

[0073] (Item 7) Mechanical fasteners fix the metal weight within the opening of the metal weight pad. The opening of the metal weight pad in the structural layer includes threading. The metal weight is a golf club head according to any one of items 1 to 6, not including threading.

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

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

[0076] (Item 10) The metal front body further includes a flange recessed inward from the outer surface of the peripheral frame. The structural layer of the sole member is adhesively joined to the flange. The outer surface of the elastic layer of the sole member is in the same plane as the outer surface of the peripheral frame. The golf club head according to item 9.

[0077] (Item 11) The metal front body further includes an extension wall that couples the peripheral frame to the flange that joins it. The structural layer of the sole member includes a structural member that extends from the weight pad toward the metal front body. The structural member operates to transmit a dynamic load between the weight pad and the extension wall during impact between the striking face and the golf ball. The golf club head according to item 9 or 10.

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

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

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

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

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

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

[0084] (Item 18) The metal front body further includes a strike face insertion portion and a receiving frame, The golf club head according to any one of items 9 to 17, wherein the receiving frame has a higher density than the strike face insertion portion.

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

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

Claims

1. A golf club head, Heels and a toe located opposite the heel; a metal front body including a strike face and a perimeter frame extending rearwardly from a perimeter of the strike face, the strike face having a center point, a loft plane along the strike face and tangent to the center point, and an intermediate plane extending through the center point from the heel to the toe and perpendicular to the loft plane; a rear body coupled to the metal front body, the rear body and the metal front body forming a substantially hollow structure having a cavity therebetween; Equipped with The rear body includes a crown member and a sole member. The sole member is connected to the crown member, The sole member is a structural layer formed from a filled thermoplastic material, the structural layer including a thermoplastic element and a plurality of reinforcing fibers; a metal weight pad bonded to the structural layer, the metal weight pad including an opening for attaching a metal weight; Including, The golf club head further comprises: a head center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the mid-plane, measured in a direction perpendicular to the mid-plane, the head CG depth being greater than 1.7 inches; The crown member includes a crown filling thermoplastic layer and a crown elastic layer; the crown-filling thermoplastic layer is formed of a first material comprising a first plurality of fibers disposed within a first thermoplastic polymer; the crown elastic layer is formed of a second material comprising a second plurality of fibers disposed within a second thermoplastic polymer; the amount of said first thermoplastic polymer in said crown filling thermoplastic layer by volume is greater than the amount of said second thermoplastic polymer in said crown elastomeric layer by volume; Golf club head.

2. The golf club head of claim 1 , wherein the crown member includes a crown structural layer formed from a filled thermoplastic material.

3. 3. The golf club head of claim 2, wherein the filled thermoplastic material of the crown structural layer is the same as the filled thermoplastic material of the structural layer of the sole member.

4. The golf club head of claim 1 , wherein the crown member comprises a plurality of continuous fibers woven together as a fabric and embedded in a thermoplastic resin.

5. The golf club head of claim 1 , wherein the first thermoplastic polymer and the second thermoplastic polymer share a common thermoplastic resin.

6. the first plurality of fibers comprises a plurality of discontinuous fibers; the first plurality of fibers each having a maximum dimension less than 0.43 inches; The golf club head of claim 1 , wherein the second plurality of fibers comprises a plurality of continuous fibers woven together as a fabric.

7. The golf club head of claim 1 , wherein the crown member includes a generally curvilinear shape that is concave relative to the ground surface.

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

9. the metal front body further includes an extension wall connecting the perimeter frame to the flange; the structural layer of the sole member includes a structural member extending from the metal weight pad toward the metal front body; The golf club head of claim 8 , wherein the structural member operates to transfer dynamic loads between the metal weight pad and the extension wall during impact between the striking face and a golf ball.

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

11. Further comprising a rear portion, The golf club head of claim 1 , wherein the metal weight pad is directly bonded to the structural layer around the periphery of the rearward portion.

12. A golf club head, Heels and a toe located opposite the heel; a metal front body including a strike face and a perimeter frame extending rearwardly from a perimeter of the strike face, the strike face having a center point, a loft plane along the strike face and tangent to the center point, and an intermediate plane extending through the center point from heel to toe and perpendicular to the loft plane; a rear body coupled to the metal front body, the rear body and the metal front body forming a substantially hollow structure having a cavity therebetween; Equipped with The rear body includes a crown member and a sole member. The sole member is connected to the crown member, The sole member is a structural layer formed from a molded thermoplastic material, the structural layer including a plurality of openings extending along a thickness of the structural layer; an elastic layer coupled to an outer surface of the structural layer, the elastic layer extending across each of the plurality of openings; and a metal weight pad bonded to the structural layer, the metal weight pad including an opening for attaching a metal weight; Including, The golf club head further comprises: a head center of gravity located at a head CG depth from the loft plane, measured in a direction perpendicular to the loft plane, and at a head CG height from the mid-plane, measured in a direction perpendicular to the mid-plane, the head CG depth being greater than 1.7 inches; The crown member comprises a non-metallic material. Golf club head.

13. The golf club head of claim 12 , wherein the molded thermoplastic material of the structural layer is a filled thermoplastic material.

14. The golf club head of claim 13 , wherein the resilient layer of the sole member is formed from a fiber reinforced thermoplastic composite material.

15. The golf club head of claim 14 , wherein the crown member comprises a crown-filled thermoplastic layer.

16. The golf club head of claim 15 , wherein the crown filler thermoplastic layer comprises the same material as the structural layer of the sole member.

17. The golf club head of claim 12 , wherein the crown member includes a crown filled thermoplastic layer and a crown resilient layer.

18. the crown-filling thermoplastic layer is formed of a first material comprising a first plurality of fibers disposed within a first thermoplastic polymer; 18. The golf club head of claim 17, wherein the crown resilient layer is formed of a second material comprised of a second plurality of fibers disposed within a second thermoplastic polymer.

19. The golf club head of claim 18 , wherein the first thermoplastic polymer and the second thermoplastic polymer share a common thermoplastic resin.

20. the first plurality of fibers comprises a plurality of discontinuous fibers; the first plurality of fibers each having a maximum dimension less than 0.43 inches; The golf club head of claim 18 , wherein the second plurality of fibers comprises a plurality of continuous fibers woven together as a fabric.

21. the structural layer of the sole member and the elastic layer of the sole member each include a common thermoplastic resin element; The golf club head of claim 12 , wherein the structural layer is bonded directly to the resilient layer without an intermediate adhesive.

22. The golf club head of claim 12 , wherein the crown member comprises a generally curvilinear shape that is concave relative to the ground surface.

23. the metal front body further includes a flange recessed inwardly from an outer surface of the perimeter frame; the structural layer of the sole member is adhesively bonded to the flange; The golf club head of claim 12 , wherein an outer surface of the sole member is flush with the outer surface of the perimeter frame.

24. 13. The golf club head of claim 1 or 12, wherein the metal front body has a mass not exceeding 140g and the golf club head has a mass not exceeding 210g.

25. a mechanical fastener secures the metal weight within the opening in the metal weight pad; the opening in the metal weight pad of the structural layer includes a threaded portion; The golf club head of claim 1 or 12, wherein the metal weight does not include threading.

26. 13. The golf club head of claim 1 or 12, wherein the metal weight has a mass in the range of 5 grams to 30 grams.

27. 13. The golf club head of claim 1 or 12, wherein a portion of the metal weight pad is encapsulated in the structural layer of the sole member to increase the strength of the bond between the metal weight pad and the structural layer.

28. an encapsulation layer between the metal weight pad and the structural layer of the sole member; 13. The golf club head of claim 1 or 12, wherein the encapsulation layer is a structural tape that extends over the edge of the metal weight pad and is formed with a strong adhesive that bonds between the metal weight pad and the structural layer of the sole member.

29. the metal weight pad extends through an opening in the structural layer of the sole member; 13. The golf club head of claim 1 or 12, wherein the opening is spaced from the metal front body by a minimum distance of at least 25 mm.

30. 30. The golf club head of claim 29, wherein an inner surface of the metal weight pad is exposed to an interior of the golf club head.

31. 13. The golf club head of claim 1 or 12, wherein the metal weight pad comprises a material selected from the group consisting of stainless steel, titanium, aluminum, and steel alloys.

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