Iron-type golf club head with flex structure

Abstract

To increase in bending of a face element while improving durability of a club head.SOLUTION: A club head 100 comprises a face element 120 for striking a golf ball. The face element is formed integrally with a flex structure 156. The flex structure comprises a curved (e.g., S-shaped or sinusoidal) profile that functions like a spring to support the face element during an impact on a golf ball. A face reinforcing structure comprises a looped rib 174 that provides support around a center of the face element. A variable face thickness includes thickened and thinned regions to further increase bending of or support the face element. The combination of the flex structure, the face reinforcing structure and the face thickness variation provides increased bending of the face element while improving durability of the club head.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 821,962, filed March 21, 2019, and U.S. Provisional Patent Application No. 62 / 745,176, filed October 12, 2018, the entire disclosures of which are incorporated herein by reference in their entirety.

[0002] FIELD OF THE INVENTION The present invention generally relates to iron-type club heads with structure that reinforces the face element. [Background technology]

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

[0004] The center of gravity and moment of inertia of a golf club's club head are functions of the distribution of the club head's mass. In particular, distributing the club head's mass closer to the sole of the club head, away from the face of the club head, and / or closer to the toe and heel ends of the club head can change the club head's center of gravity and / or moment of inertia. For example, distributing the club head's mass closer to the sole of the club head and / or away from the face of the club head can increase the flight angle of a golf ball struck by the club head. In turn, increasing the flight angle of the golf ball can increase the distance traveled by the golf ball. Furthermore, distributing the club head's mass closer to the toe and / or heel ends of the club head can affect the club head's moment of inertia, thereby increasing the forgiveness of the golf club.

[0005] Furthermore, the coefficient of restitution of a golf club's club head can be a function of at least the flexibility of the club head's face. Meanwhile, the flexibility of the club head's face can be a function of the face's geometry (e.g., height, width, and / or thickness) and / or the face's material properties (e.g., Young's modulus). That is, maximizing the face's height and / or width and / or minimizing the face's thickness and / or Young's modulus can increase the face's flexibility. As a result, the club head's coefficient of restitution can be increased. Furthermore, increasing the coefficient of restitution of a golf club's club head, which essentially measures the efficiency of energy transfer from the club head to the golf ball, can increase the distance the golf ball travels after impact, reduce the golf ball's spin rate, and / or increase the ball speed of the golf ball. Summary of the Invention [Problem to be solved by the invention]

[0006] However, while thinning the face of a club head allows mass to be redistributed from the face to other portions of the club head, making the face more flexible, thinning the face of a club head results in increased flex within the face, which can lead to buckling and breakage of the face. Thus, there is a need in the art for a club head that increases face flex while maintaining or improving face durability. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a front perspective view of an iron-type club head according to an embodiment. FIG. [Figure 2] FIG. 2 is a rear view of the iron-type club head of FIG. 1. [Figure 3] 3 is a side cross-sectional view of the iron-type club head of FIG. 1 taken at line 3-3 of FIG. 2. [Figure 4]3 is a side cross-sectional view of the iron-type club head of FIG. 1 taken at line 3-3 of FIG. 2. [Figure 5] FIG. 2 is a rear perspective view of the iron-type club head of FIG. 1. [Figure 6] FIG. 2 is a top view of the iron-type club head of FIG. 1. [Figure 7] FIG. 2 is a cross-sectional view of the flex structure of the iron-type club head of FIG. 1. [Figure 8] 1 is a cross-sectional view of a flex structure according to an embodiment. [Figure 9] 1 is a cross-sectional view of a flex structure according to an embodiment. [Figure 10] FIG. 10 is a rear view of an iron-type club head according to another embodiment. [Figure 11] 11 is a cross-sectional view of the iron-type club head of FIG. 10 taken at line 11-11 of FIG. 10. [Figure 12] FIG. 10 is a rear perspective view of an iron-type club head according to another embodiment. [Figure 13] FIG. 10 is a rear perspective view of an iron-type club head according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] For ease and clarity of illustration, the figures show schematic aspects of the configurations, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Furthermore, elements in the figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of the embodiments of the present disclosure. The same reference symbols in different figures refer to the same elements.

[0009] The present embodiment discussed below relates to an iron-type club head having a structure for supporting a face element. The club head includes a face element for striking a golf ball. The face element is integrally formed with a flex structure. The flex structure has a curved profile (e.g., an S-shape or a sinusoidal curve) that bends or flexes like a spring and supports the face element upon impact with a golf ball. To withstand stresses generated when the face element bends, the club head further includes a face reinforcing structure and various face element thicknesses. The face reinforcing structure is integrally formed with the face element and the flex structure to support the face element. The face reinforcing structure includes an annular rib that supports the face element near its geometric center. The face reinforcing structure allows the thickness of the face element to be intentionally varied in parts. In one example, the thickness of the face element is thinned at the geometric center within the face reinforcing structure, thickened around the geometric center, and thickened outside the face reinforcing structure near the heel end or toe end of the club head. The combination of the flex structure, face reinforcing structure, and thickness modification of the face element can increase the flex of the face element, thereby increasing ball speed. This, in turn, can transfer significant stresses away from the face element and into the face reinforcing structure upon impact with a golf ball. Transferring significant stresses into the face reinforcing structure improves the durability of the club head. Furthermore, iron-type club heads with the flex structure, face reinforcing structure, and thickness modification of the face element can have thinner overall face elements compared to face elements configured without the flex structure and / or face reinforcing structure. Club heads with the combination of the flex structure, face reinforcing structure, and thickness modification of the face element can increase internal energy by 3.7 lbf·in compared to club heads without the flex structure, face reinforcing structure, and thickness modification of the face element. A 3.7 lbf·in increase in internal energy equates to an increase in ball speed of approximately 0.5 mph and an increase in distance of approximately 4 to 7 yards.

[0010] The terms "first," "second," "third," "fourth," etc. in the description and claims, when present, are used to distinguish between similar elements and not necessarily to describe a particular order or chronology. It is to be understood that terms so used are interchangeable under appropriate circumstances, such that the embodiments described herein may, for example, operate in orders other than those illustrated or otherwise described herein. Furthermore, the terms "comprise" and "have," and any conjugations thereof, are intended to cover non-exclusive inclusions, whereby a process, method, system, article, device, or apparatus that includes a list of elements is not necessarily limited to those elements and may include other elements not expressly listed or inherent in such process, method, system, article, device, or apparatus.

[0011] The terms "left," "right," "front," "rear," "top," "bottom," "above," and "below" in this description and claims, when present, are used for descriptive purposes and not necessarily to describe permanent relative positions. It is understood that such terms are interchangeable under appropriate circumstances, such that the apparatus, method, and article of manufacture embodiments described herein, for example, can operate in orientations other than those illustrated or otherwise described herein.

[0012] 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 loft angle measuring device.

[0013]

[0006] Embodiments of golf club heads are described herein, and the golf club heads may comprise iron-type club heads. More specifically, the iron-type club heads may be muscle-back iron-type club heads, cavity-back iron-type club heads, blade-type iron-type club heads, hollow-body iron-type club heads, cavity-muscle-back iron-type club heads, high-MOI iron-type club heads, or any other type of iron-type club head. The iron-type club heads include a loft angle. The loft angle refers to the angle formed between the club face and the shaft. More specifically, the loft angle is measured from a vertical plane extending from the hosel / shaft central axis to the club face. The loft angle is measured from the vertical plane backward toward the club face of the iron-type club head.

[0014] For example, in some embodiments, the iron-type club head can have a loft angle of less than about 60 degrees. The iron-type club head can have a loft angle of less than about 59 degrees, less than about 58 degrees, less than about 57 degrees, less than about 56 degrees, less than about 55 degrees, less than about 54 degrees, less than about 53 degrees, less than about 52 degrees, less than about 51 degrees, less than about 50 degrees, less than about 49 degrees, less than about 48 degrees, less than about 47 degrees, less than about 46 degrees, less than about 45 degrees, less than about 44 degrees, less than about 43 degrees, less than about 42 degrees, less than about 41 degrees, less than about 40 degrees, or 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, less than about 30 degrees, less than about 29 degrees, less than about 28 degrees, less than about 27 degrees, less than about 26 degrees, less than about 25 degrees, less than about 24 degrees, less than about 23 degrees, less than about 22 degrees, less than about 21 degrees, less than about 20 degrees, less than about 19 degrees, or less than about 18 degrees.

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

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

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

[0018] Other features and aspects will become apparent upon consideration of the following detailed description and the accompanying drawings. Before describing embodiments of the present disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details or to the embodiments and arrangements of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of supporting other embodiments and of being practiced or carried out in various ways. It is to be understood that the description of specific embodiments is not intended to limit the disclosure to covering all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.

[0019] (Iron-type club head with flex structure) The present technology generally relates to an iron-type club head that increases the flex of a face element while improving the club head's durability. These advantages can be achieved by a club head having a one-piece body including a flex structure, a face reinforcing structure, and a face element thickness variation. The flex structure is integrally formed with the face reinforcing structure and the rear of the club head. The flex structure has a curved shape (e.g., an S-shape or a sinusoidal curve) extending between the face element and the rear. The flex structure is not connected to the club head except at the face reinforcing structure and the connection at the rear. This allows the flex structure to flex freely without interfering with the structure of the club head. Because the flex structure provides support to the face element, the face element can have a thinner overall thickness compared to a face element without the flex structure and / or face reinforcing structure.

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

[0021] The thickness of the face element is intentionally varied in some areas, including thickened and thinned regions. The thickened regions provide support to the face element, while the thinned regions increase the flex of the face element. In one example, the face element may have a minimum thickness at the geometric center and a maximum thickness along the face reinforcement structure. The face element may further include one or more thickness regions near the toe and heel ends of the club head, away from the face reinforcement structure. The one or more thickness regions provide additional support for impact with a golf ball near the heel and toe regions of the club head. The flex structure, face reinforcement structure, and thickness modification of the face element, integrally formed within a single club head body, can increase the flex of the face element and ball speed while improving the durability of the club head. A club head having a combination of the flex structure, face reinforcement structure, and thickness modification of the face element can increase internal energy by 3.7 lbf·in compared to a club head without the flex structure, face reinforcement structure, and thickness modification of the face element. An increase in internal energy of 3.7 lbf·in equates to an increase in ball speed of approximately 0.5 mph and an increase in distance of approximately 4 to 7 yards. A first embodiment of the disclosed technology and performance examples demonstrating the benefits of the present invention are described below.

[0022] Referring to the figures, in which the same reference characters are used to identify similar or identical components in the various views, Figures 1-6 generally illustrate a first embodiment of the inventive design. In particular, Figure 1 illustrates a front perspective view of an iron-type club head 100. Club head 100 includes a top rail 104, a sole 108 opposite top rail 104, a toe end 112, and a heel end 116 opposite to toe end 112.

[0023] 1 and 2, the club head 100 includes a face element 120. The face element 120 is integrally formed with the top rail 102, the sole 108, the toe end 112, and the heel end 116 of the club head 100. The face element 120 includes a striking face 124 for impacting a golf ball and a rear wall 128 opposite the striking face 124. The striking face 124 further defines a face center 132 located at the geometric center or midpoint of the striking face 124. The face element 120 further defines a perimeter 136 extending generally around the face element 120 near the top rail 104, the heel end 116, the sole 108, and the toe end 112.

[0024] 1-3, the face center 132 of the striking face 124 defines the origin of a coordinate system having an x-axis 700, a y-axis 800, and a z-axis 900. The club head 100 further defines a ground plane 1000 where the sole 108 meets the club head 100 when the club head 100 is in the address position. The x-axis 700 passes through the face center 132 and extends in a direction parallel to the ground plane 1000 from near the heel end 116 to near the toe end 112. The y-axis 800 passes through the face center 132 and extends from near the top end 104 to the bottom end 108, where the y-axis 800 is perpendicular to the x-axis 700 and the ground plane 1000. The z-axis 900 passes through the face center 132 and extends rearward of the face element 120 in a direction parallel to the ground plane 1000. The z-axis 900 is perpendicular to the x-axis 700 and the y-axis 800 .

[0025] 3 , the club head 100 defines a loft plane 2000 that is tangent to the striking face 124 and extends toward the top rail 104, the sole 108, the toe end 112, and the heel end 116. The loft plane 2000 is disposed at an acute angle relative to the y-axis 800, which may correspond to the loft angle of the club head 100. The club head 100 further defines a mid-plane 3000 that passes through the face center 132 and is perpendicular to the loft plane 2000. The mid-plane 3000 is disposed at an acute angle relative to the z-axis 900. The mid-plane 3000 extends from near the toe end 112 to near the heel end 116 and extends rearward of the face element 120 or loft plane 2000. The midplane 3000 intersects with the ground plane 1000 at a point spaced rearward from the face element 120 .

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

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

[0028] (Flexible structure) As previously described, the club head 100 includes a flex structure and a face reinforcement structure. The flex structure may include the flex structure 156, and the face reinforcement structure may include the face reinforcement structure 174. The flex structure 156 generally extends between the rear wall 128 and the rear portion 140. The flex structure 156 is integrally formed with the rear wall 128 and the rear portion 140. Specifically, the flex structure 156 is integrally formed with the face reinforcement structure 174 and the rear portion 140. The club head 100, having a one-piece body including the flex structure 156 and the face reinforcement structure 174, allows the face element 120 to flex more during impact with a golf ball while supporting the face element 120. The flex structure 156 and the face reinforcement structure 174 allow large impact stresses to be transferred into the face reinforcement structure 174 and away from the face element 120. By transferring high impact stresses away from the face element 120 and into the face reinforcing structure 174, the durability of the club head is improved.

[0029] 3-6, the flex structure 156 may further define a first end 158 and a second end 160. The first end 158 of the flex structure 156 is integrally formed with the face reinforcing structure 174. Specifically, the first end 158 of the flex structure 156 is integrally formed with the outer periphery 176 of the face reinforcing structure 174. The second end 160 of the flex structure 156 is integrally formed with the rear portion 140. Specifically, the second end 160 of the flex structure 156 is integrally formed with the top surface 144 of the rear portion 140. As shown in FIG. 6, the second end 160 of the flex structure 156 is attached to or coupled to the rear portion 140. This allows the player to view the flex structure 156 when the club head 100 is in the address position. Flex structure 156 extends across channel 152 between a first end 158 and a second end 160. Flex structure 156 extends across channel 152 such that it is not spaced apart from channel 152. Flex structure 156 does not contact channel 152. In other words, flex structure 156 is spaced apart from bottom wall 148 such that it does not contact bottom wall 148.

[0030] Flex structure 156 can be parabolic, curved, S-shaped, double curved, double curved, or sinusoidal in shape between first end 158 and second end 160. In some embodiments, flex structure 156 can comprise one or more interconnected parabolas. In some embodiments, flex structure 156 can comprise one or more interconnected curves. The curved nature of flex structure 156 can define an apex 162 and a nadir 164. apex 162 defines the highest or uppermost portion of flex structure 156 in relation to top rail 104. nadir 164 defines the lowest or bottommost portion of flex structure 156 in relation to sole 108. Flex structure 156 extends away from face reinforcement structure 174 in a direction toward sole 108 to form nadir 164. The flex structure 156 then extends from the lowest point 164 in a direction toward the top rail 104, above the top surface 144 of the rear portion 140, to form an apex 162. The flex structure 156 then extends from the apex 162 in a direction toward the sole 108 to connect with the rear portion 144.

[0031] In one configuration, the apex 162 can be located above the top surface 144 of the rear portion 140. In another configuration, the apex 162 can be located below the top surface 144 of the rear portion 140. The nadir 164 of the flex structure 156 is spaced from the channel 152 so as not to contact the bottom wall 148. However, it will be understood that the curved nature of the flex structure 156 can provide more than one apex 162 and more than one nadir 164. In other embodiments, the flex structure 156 can include one, two, three, four, or five nadirs. In still other embodiments, the flex structure 156 can include one, two, three, four, or five apexes.

[0032] Additionally, the apex 162 and the nadir 164 of the flex structure 156 may be designated relative to the structure of the club head 100 or relative to a plane defined by the club head 100. In one configuration, both the apex 162 and the nadir 164 may be located below the mid-plane 3000. In another configuration, the apex 162 may be located above the mid-plane 3000 and the nadir 164 may be located below the mid-plane 3000. In another configuration, both the apex 162 and the nadir 164 may be located above the mid-plane 3000. In another configuration, the nadir 164 may be located closer to the face element 120 than the apex 162. In another configuration, the apex 162 may be located closer to the face element 120 than the nadir 164.

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

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

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

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

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

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

[0039] (Face reinforcement structure) As previously mentioned, the club head 100 includes a face reinforcement structure. The face reinforcement structure may include a face reinforcement structure 174. The face reinforcement structure 174 is integrally formed with the face element 120 and extends away from the rear wall 128. The face reinforcement structure 174 supports the face element 120 upon impact with a golf ball. Specifically, the face reinforcement structure 174 provides localized thickness on the face element 120 near the face center 132, thereby making the face element 120 stiffer and more rigid at locations around the face center 132. Because the face element 120 is more flexible due to the flex structure 156 and the changes in face thickness, the face element 120 experiences greater stresses upon impact with a golf ball. The face reinforcing structure 174 transfers or shifts this maximum stress into the face reinforcing structure 174 and away from the face element 120, thereby improving the durability of the club head.

[0040] The face reinforcement structure 174 may comprise a rib. Specifically, the face reinforcement structure 174 may comprise an annular rib, a ring rib, a circular annular rib, or an elliptical annular rib extending around the face center 132. The face reinforcement structure 174 may comprise a closed annular structure that is continuous around the face center 132. The closed structure may resist deformation as a result of circumferential (i.e., hoop-like) stress acting on the face reinforcement structure 174. For example, circumferential stress acting on the face reinforcement structure 174 prevents opposite sides of the face reinforcement structure 174 from rotating away from each other, thereby stiffening the face element 120. This allows the face element 120 to thin at the face center 132 while directing stress away from the face element 120. By transferring stress into the face reinforcement structure 174 in this manner, the durability of the face element 120 and the club head 100 is improved.

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

[0042] The face reinforcing structure 174 includes a fillet on the rear wall 128 to provide a smooth connection between the face reinforcing structure 174 and the rear wall 128. By providing a fillet between the rear wall 128 and the outer periphery 176, impact stresses are directed into the face reinforcing structure 174 and away from the face element 120. The club head 100 may include a fillet 184 between the outer periphery 176 and the rear wall 128. The fillet 184 may include a radius of 0.012 centimeters or greater. In some embodiments, the fillet 184 may be in the range of 0.012 to 2.0 centimeters, 0.50 to 3.0 centimeters, or 1.0 to 4.0 centimeters. In other embodiments, the fillet 184 may be in the range of 0.012 to 1.5 centimeters, 0.5 to 2.0 centimeters, 1.0 to 2.5 centimeters, 1.5 to 3.0 centimeters, 2.0 to 3.5 centimeters, or 2.5 to 4.0 centimeters. For example, the fillet 184 can be 0.012, 0.02, 0.05, 0.08, 0.1, 0.2, 0.5, 0.8, 1.0, 1.2, 1.5, 1.8, 2.0, 2.2, 2.5, 2.8, 3.0, 3.2, 3.5, 3.8, or 4.0 centimeters.

[0043] The face reinforcing structure 174 may further define a rib span 186. The rib span 186 is located within the face reinforcing structure 174 at the inner periphery 180. The rib span 186 refers to the maximum distance from one side of the inner periphery 180 to the opposite side of the inner periphery 180. The rib span 186 may refer to the diameter of the inner periphery 180 of the face reinforcing structure 174. In embodiments in which the annular rib 174 comprises an elliptical annular rib, the rib span 186 refers to the major axis of the inner periphery 180. In embodiments in which the annular rib 174 comprises a circular annular rib, the rib span 186 refers to the diameter of the inner periphery 180.

[0044] Rib span 186 can be greater than or equal to 0.609 centimeters and less than or equal to 1.88 centimeters. In some embodiments, rib span 186 can range from 0.609 to 1.2 centimeters, or from 1.2 to 1.88 centimeters. In one example, rib span 186 can be 1.0 centimeter. Rib span 186 is important for directing impact stresses away from face element 120 and into face reinforcing structure 174. When rib span 186 is too large (i.e., greater than 1.88 centimeters), face reinforcing structure 174 is insufficient to reinforce face element 120 near face center 132. With a rib span 186 that is too large, the greatest impact stresses occur at face center 132, thereby fracturing or breaking face element 120 at face center 132. On the other hand, when the rib span 186 is too small (i.e., less than 0.609 centimeters), the face reinforcing structure 174 is insufficient to reinforce the face element 120 near the face center 132. With a rib span 186 that is too small, the greatest impact stresses occur in and around the face reinforcing structure 174, thereby fracturing or damaging the face element 120. When the rib span 186 is equal to or greater than 0.609 centimeters and equal to or less than 1.88 centimeters, the face reinforcing structure 174 reinforces the face element by directing the impact stresses away from the face element 120 (i.e., at the face center 132) and into the circular ribs of the face reinforcing structure 174.

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

[0046] (Face element) As previously mentioned, the face element 120 can vary in thickness. The face element 120 can be intentionally configured to vary its thickness in portions to support the face element 120 while increasing its flex. The face element 120 can be thinnest at the face center 132 within the face reinforcing structure 174 and thickest at the periphery 176 of the face reinforcing structure 174. The face element 120 can further include one or more thickness regions disposed away from the face reinforcing structure 174 to support the toe and heel regions of the face element 120. In other embodiments, the face element 120 can be free of one or more thickness regions near the toe end 112 and heel end 116 of the club head 100.

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

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

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

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

[0051] 2 and 5, the face element 120 may further include one or more thickness regions 198. The thickness regions 198 may be thickened regions on the face element 120 in locations that do not have the face reinforcing structure 174. The thickness regions 198 may be located away from or outside the face reinforcing structure 174. The thickness regions 198 may be located near the toe end 112 and the heel end 116 of the club head 100. The thickness regions 198 support the face element 120 near the toe end 112 and the heel end 116 against impact with a golf ball.

[0052] The thickness region 198 may have a shape. The thickness region 198 may have a semicircular shape, a C-shape, a kidney bean shape, or any other suitable shape. The thickness region 198 may be positioned relative to the central plane 3000. In some embodiments, the thickness region 198 may be located above the central plane 3000. In other embodiments, the thickness region 198 may be located below the central plane 3000. In other embodiments, the first thickness region 198 may be located above the central plane 3000 and the second thickness region 198 may be located below the central plane 3000. In other embodiments, a portion of the thickness region 198 may be located above the central plane 3000 and another portion of the thickness region 198 may be located below the central plane 3000. Positioning the thickness region 198 relative to the central plane 3000 can adjust the stiffness and rigidity of the heel and toe regions of the face element 120. The thickened region 198 provides additional support to the face element 120 near the heel and toe regions of the face element 120 upon impact with a golf ball.

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

[0054] Additional Embodiments While Figures 1-6 illustrate a first embodiment of how the present technology may be used, Figures 11-13 schematically illustrate three alternative configurations. In each embodiment (including the embodiment illustrated in Figures 1-6), the iron-type club head includes a flex structure, a face reinforcing structure, and a modified thickness of the face element to increase the flexibility of the face element while improving the durability of the club head. The iron-type club head illustrated in Figures 11-13 may be similar to club head 100 as illustrated in Figures 1-6, but differ in the number of flex structures.

[0055] 10 and 11 , an iron-type club head may include an iron-type club head 200. The club head 200 includes a first flex structure 256, a second flex structure 256, and a face reinforcement structure 274. In this embodiment, the first flex structure 256 may be integrally formed with the face reinforcement structure 256 and the rear portion 240, and the second flex structure 256 may be integrally formed with the face reinforcement structure 256 and the top rail 204. The first flex structure 256 and the second flex structure 256 may be disposed around the periphery of the face reinforcement structure 274 so as to be spaced 180° apart from each other.

[0056] 12 , an iron-type club head may include an iron-type club head 300. The club head 300 includes a first flex structure 356, a second flex structure 356, a third flex structure, and a face reinforcement structure 374. In this embodiment, the first flex structure 356 is integrally formed with the face reinforcement structure 374 and the rear portion 340 near the toe end 312 of the club head 300. The second flex structure 356 may be integrally formed with the face reinforcement structure 374 and the rear portion 340 near the heel end 318 of the club head 300. The third flex structure 356 may be integrally formed with the face reinforcement structure 374 and the top rail 304. The first flex structure 152, the second flex structure 152, and the third flex structure 152 may be arranged around the outer periphery of the face reinforcement structure 374 such that they may be spaced 60 degrees apart from one another.

[0057] 13 , an iron-type club head may include an iron-type club head 400. The club head includes a first flex structure 456, a second flex structure 456, a third flex structure 456, a fourth flex structure 456, and a face reinforcement structure 474. In this embodiment, the first flex structure 456 may be integrally formed with the face reinforcement structure 474 and the rear portion 440 near the toe end 412 of the club head 400. The second flex structure 456 may be integrally formed with the face reinforcement structure 474 and the rear portion 440 near the heel end 418 of the club head 400. The third flex structure 456 may be integrally formed with the face reinforcement structure 456 and the top rail 404 near the toe end 412 of the club head 400. The fourth flex structure 456 may be integrally formed with the face reinforcement structure 456 and the top rail 404 near the heel end 416 of the club head 400. The first flex structure 456, the second flex structure 456, the third flex structure 456, and the fourth flex structure 456 may be arranged around the outer periphery of the face reinforcement structure 474 such that they may be spaced 45° apart from one another.

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

[0059] (benefit) The flex structure 156 and the face reinforcement structure 174 support the face element 120, thereby allowing the overall face element 120 to be thinner, resulting in greater flex of the face element. The face reinforcement structure 174 provides a path for redirecting impact stresses from the face element 120 into the outer periphery 176 of the face reinforcement structure 174. Transferring impact stresses from the face element 120 into the face reinforcement structure 174 improves the durability of the face element 120 and the club head 100. The thickness of the face element 120 within the diameter of the face reinforcement structure 174 and near the face center 132 can be thinner than the thickness of the face element 120 at the outer periphery 176 of the face reinforcement structure 174, in areas without the face reinforcement structure 174, and at the face perimeter 136. The combination of flex structure 156 and face reinforcement structure 174 allows for a reduction in the overall thickness of face element 120 compared to a face element without the flex structure and / or face reinforcement structure. Club head 100 with the combination of flex structure 156, face reinforcement structure 174, and face element 120 with thickness variations allows for a 3.7 lbf·in increase in internal energy compared to a club head without the flex structure, face reinforcement structure, and variable face element thickness variations. The 3.7 lbf·in increase in internal energy equates to an increase in ball speed of approximately 0.5 mph and an increase in distance of approximately 4 to 7 yards.

[0060] The face element 120 of the club head 100 can be 5-20% thinner than a face element or striking surface without the flex structure and / or face reinforcing structure. In some embodiments, the face element 120 can be 5-10%, or 10-20% thinner than a face element or striking surface without the flex structure and / or face reinforcing structure. In other embodiments, the face element 120 can be 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, or 20% thinner than a face element or striking surface without the flex structure and / or face reinforcing structure.

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

[0062] Club head 100 with flex structure 156 has many improvements over known iron-type club heads. Flex structure 156 reinforces face element 120 without requiring an insert or material lining face element 120. In combination with face reinforcement structure 174, flex structure 156 and face reinforcement structure 174 can absorb impact stresses and direct them away from thinned face element 120 and into face reinforcement structure 174. Face reinforcement structure 174 provides support to face element 120, maintaining or improving the durability of the club head.

[0063] The flex structure 156, having a curved profile, acts like a spring to support the face element 120 upon impact with a golf ball. As the face element 120 flexes under the force of impact, the face element 120 and flex structure 156 flex toward the rear portion 140. The curved profile of the flex structure 156 causes the flex structure 156 to flex inward at the nadir 164 and the apex 162. In this first embodiment, the flex structure 156 flexes more at the nadir 164 than at the apex 162 because the nadir 164 is located closest to the source of the greatest force (i.e., the impact force acting on the face element 120). As the face element 120 flexes, stresses within the face element 120 are transferred toward the face reinforcing structure 174 and away from the face center 132 of the face element 120. Stresses are transferred away from face element 120 and into outer periphery 176 of face reinforcing structure 174. The transfer of stresses prevents face element 120 from breaking under impact forces. The transfer of stresses improves the durability of face element 120 and club head 100.

[0064] (Example 1 - Ball speed test for iron type club head) The exemplary iron-type club head 100 with the face reinforcing structure and flex structure was compared to a similar control iron-type club head with the face reinforcing structure but without the flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 has the face reinforcing structure, the flex structure, and a fourth or perimeter thickness of 0.079 inches. The control iron-type club head has the face reinforcing structure and a perimeter thickness of 0.088 inches.

[0065] Tests were conducted to compare golf ball speeds between the exemplary iron-type club head 100 and a comparative iron-type club head. The tests used an air cannon to fire a golf ball at each club head. The air cannon was positioned at a constant distance from each club head, and each club head was held in the address position (i.e., no loft adjustments were made during the tests). The tests compared golf ball speeds leaving the striking surface over a number of golf ball impacts. Test results showed that the exemplary iron-type club head 100 had an average golf ball speed of 124.9 mph, while the comparative iron-type club head had an average golf ball speed of 124.5 mph. This result indicates that the exemplary iron-type club head 100 had a ball speed that was 0.5 mph faster on average than the comparative iron-type club head. An increase in ball speed of 0.5 mph approximately equates to an increase in ball distance of 4 to 7 yards. The combination of the face reinforcement structure, flex structure, and reduced perimeter thickness results in faster golf ball speeds, thereby increasing the carry distance of the golf ball.

[0066] (Example 2 - Ball spin test for iron type club head) The exemplary iron-type club head 100 with the face reinforcing structure and flex structure was compared to a similar control iron-type club head with the face reinforcing structure but without the flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 has the face reinforcing structure, the flex structure, and a fourth or perimeter thickness of 0.079 inches. The control iron-type club head has the face reinforcing structure and a perimeter thickness of 0.088 inches.

[0067] A test was conducted to compare the golf ball spin rate (i.e., backspin rate) between the exemplary iron-type club head 100 and a control iron-type club head. The test measured the ball spin rate imparted from the striking face of each club head while keeping the club head dimensions, loft angle, shaft characteristics, and weather conditions constant. The test results showed that the golf ball spin rate of the exemplary iron-type club head 100 averaged 6,710 rpm, while the golf ball spin rate of the control iron-type club head averaged 6,517 rpm. This result indicates that the golf ball spin rate of the exemplary iron-type club head 100 was 200 rpm higher than that of the control iron-type club head. The combination of the face reinforcement structure, flex structure, and reduced perimeter thickness can increase ball spin rate and provide better golf ball control.

[0068] Example 3 - Stat-area test for iron-type clubheads The exemplary iron-type club head 100 with the face reinforcing structure and flex structure was compared to a similar control iron-type club head with the face reinforcing structure but without the flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 has the face reinforcing structure, the flex structure, and a fourth or perimeter thickness of 0.079 inches. The control iron-type club head has the face reinforcing structure and a perimeter thickness of 0.088 inches.

[0069] Tests were conducted to compare the stat area (i.e., the standard deviation of the golf ball carry distance aggregate multiplied by the standard deviation of the golf ball offline distance aggregate) between the exemplary iron-type club head 100 and a comparative iron-type club head. Golf ball carry distance is the distance a golf ball travels in the air. Golf ball offline distance is the distance a golf ball is offset from a line extending from the player to the desired target. Golf ball offline distance is measured perpendicular to the line extending from the player to the desired target. Stat area determines the accuracy of the grouping or dispersion of golf ball shot aggregates, where tighter dispersion indicates smaller stat area and larger dispersion indicates larger stat area. Tests showed that the stat area of ​​the exemplary iron-type club head 100 was reduced by an average of 32.8% compared to the comparative iron-type club head. The combination of the face reinforcement structure, flex structure, and reduced perimeter thickness can result in a desirable smaller stat area, which can increase the accuracy of golf ball shot dispersion.

[0070] (Example 4 - Internal energy test of iron type club head) The exemplary iron-type club head 100 with the face reinforcing structure and flex structure was compared to a similar control iron-type club head with the face reinforcing structure but without the flex structure and reduced perimeter thickness. The exemplary iron-type club head 100 has the face reinforcing structure, the flex structure, and a fourth or perimeter thickness of 0.079 inches. The control iron-type club head has the face reinforcing structure and a perimeter thickness of 0.088 inches.

[0071] Tests were conducted to compare the internal energy between the exemplary iron-type club head 100 and a comparative iron-type club head. The tests used finite element simulations to measure the internal energy of the club head at impact speed with a golf ball of 100 mph. The tests resulted in an average increase of 3.7 lbf·in in the peak internal energy of the exemplary iron-type club head 100 relative to the comparative club head. A 3.7 lbf·in increase in internal energy equates to an increase in ball speed of approximately 0.5 mph. A 0.5 mph increase in ball speed approximately equates to an increase in ball distance of 4 to 7 yards. The combination of the flex structure and face reinforcement structure supports the face element while increasing flex of the face element and ball speed.

[0072] The substitution of one or more claim elements constitutes a reconstruction, not a repair. Furthermore, benefits, other advantages, and solutions to problems have been described with respect to particular embodiments. However, the benefits, advantages, solutions to problems, and any element or elements that may cause or make more apparent any benefit, advantage, or solution are not to be construed as any or all critical, required, or essential features or elements of a claim.

[0073] Because the Rules of Golf may change from time to time (e.g., new Rules may be adopted, or old Rules may be eliminated or modified, by golf's standards organizations and / or governing bodies, such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St. Andrews (R&A), etc.), golf equipment related to the apparatus, methods, and articles of manufacture described herein may conform or non-conform to the Rules of Golf at any particular time. Accordingly, golf equipment related to the apparatus, methods, and articles of manufacture described herein may be advertised, marketed, and / or sold as conforming or non-conforming golf equipment. The apparatus, methods, and articles of manufacture described herein are not limited in this respect.

[0074] Furthermore, embodiments and limitations disclosed herein are not available to the public under the doctrine of dedication if the embodiment and / or limitation (1) is not explicitly claimed in the claims and (2) is a potential equivalent of an explicit element and / or limitation in the claims under the doctrine of equivalents.

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

[0076] (Item 2) The golf club head described in Item 1, wherein the club head further includes a bottom wall that connects the rear wall, the rear portion, the toe end, and the heel end together and is located on the opposite side of the sole, and the rear wall, the rear portion, the toe end, the heel end, and the bottom wall together form a channel, and the flex structure extends within the channel so as not to contact the channel.

[0077] (Item 3) The golf club head described in Item 1, wherein the flex structure has a curved shape, and the flex structure has a lowest point that defines the lowest portion of the flex structure and an apex that defines the highest portion of the flex structure.

[0078] (Item 4) The golf club head described in Item 3, wherein the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end, and the lowest point and the apex of the midplane are located below the midplane.

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

[0080] (Item 6) The golf club head according to item 5, wherein the inner circumferential surface defines a rib span that is equal to or greater than 0.609 centimeters and equal to or less than 1.88 centimeters.

[0081] (Item 7) The golf club head described in Item 5, wherein the thickness of the face element is variable and includes a first thickness measured in a direction perpendicular to the striking surface from the center of the face to the rear wall, a second thickness measured in a direction perpendicular to the striking surface from the striking surface to the outer periphery of the face reinforcing structure, a third thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall that does not have the reinforcing element, and a fourth thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall located at the periphery of the face, wherein the first thickness is the minimum thickness of the face element and the second thickness is the maximum thickness of the face element.

[0082] (Item 8) A golf club head comprising: a top rail; a sole located opposite the top rail; a toe end; a heel end located opposite the toe end; a bottom wall located opposite the sole; a rear portion connected to the sole and extending toward the top rail; a face element including a striking surface and a rear wall located opposite the striking surface; a reinforcing structure formed integrally with the face element; and a flex structure formed integrally with the face element and the rear portion, wherein the face element defines a face center, and the reinforcing structure includes a circular annular rib extending around the face center away from the rear wall, the flex structure having a first end formed integrally with the face reinforcing structure and a second end formed integrally with the rear portion, wherein the rear wall, the rear portion, the toe end, the heel end, and the bottom wall together form a channel, and the flex structure extends across the channel so as not to contact the channel.

[0083] (Item 9) The golf club head described in Item 8, wherein the flex structure has a curved shape, and the flex structure has a lowest point defining the lowest portion of the flex structure and an apex defining the highest portion of the flex structure.

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

[0085] (Item 11) The golf club head described in Item 9, wherein the club head further defines a mid-plane extending rearward of the face center toward the toe end and the heel end, the lowest point being located below the mid-plane, and the apex being located above the mid-plane.

[0086] (Item 12) The golf club head described in Item 8, wherein the face reinforcing structure comprises an inner peripheral surface located within the face reinforcing structure and extending perpendicular to the rear wall, and an outer peripheral surface located at a portion having the maximum thickness of the face element and adjacent to the inner peripheral surface.

[0087] (Item 13) The golf club head according to item 12, wherein the inner circumferential surface defines a rib span that is equal to or greater than 0.609 centimeters and equal to or less than 1.88 centimeters.

[0088] (Item 14) The golf club head described in Item 8, wherein the thickness of the face element is variable and includes a first thickness measured in a direction perpendicular to the striking surface from the center of the face to the rear wall, a second thickness measured in a direction perpendicular to the striking surface from the striking surface to the outer periphery of the face reinforcing structure, a third thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall that does not have the reinforcing element, and a fourth thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall located at the periphery of the face, wherein the first thickness is the minimum thickness of the face element and the second thickness is the maximum thickness of the face element.

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

[0090] (Item 16) The golf club head described in Item 15, wherein the flex structure has a lowest point that defines the lowest portion of the flex structure and an apex that defines the highest portion of the flex structure.

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

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

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

[0094] (Item 20) The golf club head described in Item 15, wherein the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end, the lowest point being located below the midplane, and the apex being located above the midplane.

[0095] Various features and advantages of the disclosure are described below.

Claims

1. The top rail and a sole located on the opposite side of the top rail; Toe End and a heel end located opposite the toe end; a rear portion connected to the rear end of the sole and extending toward the top rail; a face element including a striking surface and a rear wall opposite the striking surface; a face reinforcing structure integrally formed with the face element; a flex structure integrally formed with the face reinforcing structure and the rear portion; Equipped with the face element defines a face center; the face reinforcing structure includes a circular annular rib extending away from the rear wall and extending around the face center; the flex structure comprises a first end integrally formed with the face reinforcing structure, a second end integrally formed with the rear portion, and an S-shaped profile located between the first end and the second end; a front end of the S-shaped profile connected to the first end; a rear end of the S-shaped profile connected to the second end; the S-shaped profile extends from the first end to the second end; Golf club head.

2. the club head further includes a bottom wall that connects the rear wall, the rear portion, the toe end, and the heel end together and is located opposite the sole; the rear wall, the rear portion, the toe end, the heel end, and the bottom wall together form a channel; the flex structure extends within the channel so as not to contact the channel; The golf club head according to claim 1 .

3. The golf club head of claim 1 , wherein the flex structure comprises a nadir defining a lowermost portion of the flex structure and an apex defining an uppermost portion of the flex structure.

4. the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end; The golf club head of claim 3 , wherein the lowest point and the highest point of the flex structure are located below the mid-plane.

5. the club head further defines a midplane extending rearward from the face center toward the toe end and the heel end; the lowest point is located below the mid-plane; The vertex is located above the mid-plane. The golf club head according to claim 3 .

6. the club head further includes a fillet located between the face reinforcing structure and the rear wall; the fillet has a radius of 0.012 centimeters or greater. The golf club head according to claim 1 .

7. The top rail and a sole located on the opposite side of the top rail; Toe End and a heel end located opposite the toe end; a bottom wall located on the opposite side of the sole; a rear portion connected to the rear end of the sole and extending toward the top rail; a face element including a striking surface and a rear wall opposite the striking surface; a rear cavity formed between the rear portion, the bottom wall, the toe end, and the heel end, the rear cavity not being completely closed; a face reinforcing structure integrally formed with the face element; a flex structure integrally formed with the rear portion within the rear cavity; Equipped with the face element defines a face center; the face reinforcing structure includes a circular annular rib extending away from the rear wall and extending around the face center; the flex structure includes a first end integrally formed with an outer periphery of the face reinforcing structure and a second end integrally formed with the rear portion, the flex structure extending from the first end to the second end; the flex structure comprises an apex defining a highest or uppermost portion of the flex structure and a nadir defining a lowest or lowermost portion of the flex structure; the lowest point of the flex structure is spaced from the bottom wall such that the lowest point does not contact the bottom wall; the lowest point is located closer to the face element than the apex; Golf club head.

8. the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end; the lowest point and the apex of the flex structure are located below the mid-plane; 8. The golf club head according to claim 7.

9. the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end; the lowest point is located below the mid-plane; The vertex is located above the mid-plane. The golf club head according to claim 7.

10. The face reinforcing structure includes: a circular annular rib extending away from the rear wall and extending around the face center; an inner peripheral surface located within the face reinforcing structure and extending perpendicular to the rear wall; an outer peripheral surface located at a portion of the face element having a maximum thickness and adjacent to the inner peripheral surface; The golf club head of claim 7 , comprising:

11. The golf club head of claim 10 , wherein the inner periphery defines a rib span that is greater than or equal to 0.609 centimeters and less than or equal to 1.88 centimeters.

12. The thickness of the face element is: a first thickness measured in a direction perpendicular to the striking surface from the face center to the rear wall; a second thickness measured from the striking surface to the outer periphery of the face reinforcing structure in a direction perpendicular to the striking surface; a third thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall that does not have the face reinforcing structure; a fourth thickness measured in a direction perpendicular to the striking surface from the striking surface to the rear wall located at the perimeter of the face element; the first thickness is a minimum thickness of the face element; The golf club head of claim 7 , wherein the second thickness is a maximum thickness of the face element.

13. The top rail and a sole located on the opposite side of the top rail; Toe End and a heel end located opposite the toe end; a bottom wall located on the opposite side of the sole; a rear portion connected to the rear end of the sole and extending toward the top rail; a face element including a striking surface and a rear wall opposite the striking surface; a face reinforcing structure integrally formed with the face element; a flex structure integrally formed with the face reinforcing structure and the rear wall; the face element defines a face center; The face reinforcing structure includes a circular annular rib extending away from the rear wall and extending around the face center. the flex structure includes a first end integrally formed with the face reinforcing structure and a second end integrally formed with the rear portion; the flex structure comprises a sinusoidal shape having a double curved shape; a leading end of the sinusoidal shape connected to the first end; a trailing end of the sinusoidal shape connected to the second end; the sinusoidal shape extends from the first end to the second end; the flex structure comprises an apex defining a highest or uppermost portion of the flex structure and a nadir defining a lowest or lowermost portion of the flex structure; the lowest point of the flex structure is spaced from the bottom wall such that the lowest point does not contact the bottom wall; Golf club head.

14. the flex structure defines a first radius of curvature at the nadir and a second radius of curvature at the apex; the first radius of curvature is between 0.25 inches (0.635 centimeters) and 1 inch (2.54 centimeters); the second radius of curvature is between 0.25 inches (0.635 centimeters) and 1 inch (2.54 centimeters); The golf club head of claim 13.

15. The golf club head of claim 14 , wherein the first radius of curvature is different from the second radius of curvature.

16. The golf club head of claim 14 , wherein the first radius of curvature is equal to the second radius of curvature.

17. the club head further defines a midplane extending rearward of the face center toward the toe end and the heel end; the lowest point and the apex of the flex structure are located below the mid-plane; 14. The golf club head according to claim 13.

18. the club head further defines a midplane extending rearward from the face center toward the toe end and the heel end; the lowest point is located below the mid-plane; The vertex is located above the mid-plane. The golf club head of claim 13.

19. The flex structure further includes an upper surface facing the top rail and a lower surface facing the sole, a thickness of the flex structure is defined between the upper surface and the lower surface; the thickness of the flex structure is greater at the face element and tapers to decrease toward the nadir; The golf club head of claim 13.

20. The flex structure further includes an upper surface facing the top rail and a lower surface facing the sole, a thickness of the flex structure is defined between the upper surface and the lower surface; The thickness of the flex structure is greater at the rear and tapers to decrease toward the apex. The golf club head of claim 13.

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