Golf club heads containing thermoplastic composite materials

Abstract

To provide an alternative design for a golf club head having a structural mass comprising metal to provide a means to maximize discretionary weight to maximize the club head's moment of inertia (MOI) and lower / rear center of gravity (CG).SOLUTION: A front body 12 includes: a striking face 30 defining a ball striking surface 32; a hosel 38; and a frame 34 at least partially surrounding the striking face and extending rearward from a periphery of the striking face away from the ball striking surface. The striking face and the frame are formed from a thermoplastic composite material including a thermoplastic polymer having a plurality of discontinuous fibers embedded therein. Each of the plurality of discontinuous fibers has a length of less than about 40 mm, and between the center 28 of the striking face and the hosel, greater than about 50% of the plurality of discontinuous fibers are aligned within about 30° of parallel to a horizontal axis extending from the center of the striking face to the hosel.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - reference to Related Applications This claims the benefit of priority of U.S. Provisional Application No. 62 / 619,631, filed on January 19, 2018; U.S. Provisional Application No. 62 / 644,319, filed on March 16, 2018; U.S. Provisional Application No. 62 / 702,996, filed on July 25, 2018; U.S. Provisional Application No. 62 / 703,305, filed on July 25, 2018; U.S. Provisional Application No. 62 / 718,857, filed on August 14, 2018; U.S. Provisional Application No. 62 / 770,000, filed on November 20, 2018; and U.S. Provisional Application No. 62 / 781,509, filed on December 18, 2018. The disclosure of each of the applications referenced above is hereby incorporated by reference in its entirety.

[0002] This disclosure relates to a golf club head having one or more components including a thermoplastic composite material.

Background Art

[0003] In an ideal club design, the amount of structural mass is minimized (without sacrificing resilience), and additional discretionary mass is strategically positioned to customize club performance. Generally, the total mass of the club head is the sum of structural mass and discretionary mass. Structural mass generally refers to the mass of material required to provide the club head with the structural resilience necessary to withstand repeated impacts. Structural mass is highly design-dependent and has little design control over a particular mass distribution. Conversely, discretionary mass is any additional mass that can be added to the club head design (beyond the minimum structural requirements) solely for the purpose of customizing the club's performance and / or forgiveness. Current golf club heads include metallic material in at least a portion of the structural mass of the club head (e.g., at least a portion of the striking surface and / or rear body). There is a need in the art for alternative designs of golf club heads with metallic structural mass to provide a means of maximizing discretionary weight to maximize the moment of inertia (MOI) and a lower / rearer center of gravity (CG) of the club head.

[0004] The background information provided herein is intended to be illustrative and not limiting, but aims to clarify certain club-related terms. Industry practices, rules and naming conventions established by golf organizations such as the United States Golf Association (USGA) or the R&A may supplement the description of these terms without departing from the scope of this application. [Brief explanation of the drawing]

[0005] [Figure 1] This is a schematic perspective view of a golf club head.

[0006] [Figure 2] This is a schematic partial cross-sectional view of the front portion of the golf club head in Figure 1, taken along line 2-2.

[0007] [Figure 3] This is a schematic perspective view of the front and top of a golf club head.

[0008] [Figure 4] This is a schematic partial cross-sectional view of a polymer wall in which multiple discontinuous fibers are embedded within the polymer.

[0009] [Figure 5] This is a schematic perspective view of the front body of a golf club head, including the sprue and molding gate that connect to the front body.

[0010] [Figure 6] This is a reversed version of the front body shown in Figure 5.

[0011] [Figure 7] This is a schematic perspective view of the rear portion of the body of a golf club head before it is molded.

[0012] [Figure 8] This is a schematic diagram of the mold flow for creating the front body of Figure 5, taken at the intermediate filling stage.

[0013] [Figure 9] Figure 8 is a schematic diagram of the mold flow taken when the part was nearing completion.

[0014] [Figure 10] This is a schematic perspective view of the rear portion of the body before the molding of a golf club head, with a reinforcing mesh embedded in the striking surface.

[0015] [Figure 11] This is a schematic cross-sectional view of the first embodiment of the golf club head of Figure 10, taken along line 11-11.

[0016] [Figure 12] This is a schematic cross-sectional view of the second embodiment of the golf club head of Figure 10, taken along line 11-11.

[0017] [Figure 13]FIG. 10 is a schematic cross-sectional view of a third embodiment of a golf club head taken along line 11-11. DETAILED DESCRIPTION

[0018] The present disclosure generally relates to embodiments of golf club heads having one or more thermoplastic composite materials incorporated into the club head face and / or body to form structural aspects of the club head. In so doing, the design results in a reduction of the structural mass of the head when compared to all-metal club heads of similar size, shape and appearance. Then, the additional discretionary mass provided by these designs becomes available to the club head designer and is strategically placed around the head to, for example, increase the moment of inertia of the club head and / or change the relative position of the center of gravity of the club head.

[0019] Since thermoplastic polymers are considerably less strong than most of the metals used in golf clubs, special care must be taken in the design, material selection and reinforcement of the polymer portions to avoid unexpected breakage while still maintaining the dynamic response, sound and feel expected by the golfer.

[0020] In the embodiments described below, it is further understood that the polymer to be filled can have anisotropic structural qualities that depend on the typical or average orientation of the embedded discontinuous fibers. More specifically, the polymer component to be filled generally has greater strength for loads aligned with the longitudinal axis of the embedded fibers and relatively less strength for loads applied transversely. Since the orientation of the fibers within the polymer to be filled depends greatly on the mold flow during initial part formation, the embodiments described below utilize mold and part designs that help to orient the embedded fibers along the most likely force / stress propagation paths.

[0021] "A," "an," "the," "at least one," and "one or more" are used synonymously to indicate the existence of at least one article, and unless otherwise specifically stated in the context, there may be multiple such articles. All numerical values ​​of parameters (e.g., quantities or conditions) in this specification, including in the appended claims, should be understood in all cases to be modified by the term "about," whether or not "about" actually precedes the numerical value. "About" indicates that the numerical value to be stated is tolerant of some degree of inaccuracy (approximating to some extent to the precise value, roughly or reasonably close to the value, i.e., approximately). Where the inaccuracy indicated by "about" is not understood in a different sense than this ordinary sense in the art, "about" as used herein at least indicates the variation that may arise from the ordinary methods of measurement and use of such parameters. In addition, disclosure of ranges includes all values ​​within the overall range and further subdivided values. Each value within the range and the endpoints of the range are inclusive of the terms “comprises,” “comprising,” “including,” and “having,” all of which are disclosed herein as separate embodiments. These terms indicate the existence of the items described, but do not exclude the existence of other items. As used herein, the term “or” includes any combination of one or more of the listed items. Where terms such as “first,” “second,” “third,” etc., are used to distinguish different items from one another, these notations are for convenience only and do not limit the items.

[0022] Where used herein, the term “loft” or “loft angle” of a golf club refers to the angle formed between the clubface and the shaft, as measured by any suitable loft and lie machine.

[0023] Where applicable, terms such as “first,” “second,” “third,” “fourth,” etc., in this specification and the claims are used to distinguish similar elements and are not necessarily intended to describe a specific consecutive or older order. Terms used in this manner should be understood to be interchangeable in appropriate contexts, so as to allow the embodiments described herein to be operable, for example, in an order other than those illustrated or otherwise described herein. Furthermore, the terms “include” and “have” and any inflections thereof are intended to cover non-exclusive inclusion, such that a process, method, system, article, device, or apparatus containing a list of elements is not necessarily limited to those elements, but may include other elements that are not expressly enumerated or specific to such process, method, system, article, device, or apparatus.

[0024] Where applicable, terms such as “left,” “right,” “front,” “rear,” “up,” “down,” “above,” and “below” in this specification and claims are used for the purpose of generally referring to a golf club held when addressed on level ground at a given loft and lie angle, but not necessarily to describe a permanent relative position. Terms used in this manner should be understood to be replaceable in appropriate circumstances, such as when embodiments of the manufacturing apparatus, manufacturing methods, and / or manufactured articles described herein are operable in orientations other than those illustrated or otherwise described herein.

[0025] Terms such as "couple," "couples," "coupled," and "connected" should be understood broadly to mean connecting two or more elements mechanically or otherwise. The connection (mechanically or otherwise) may last for any length of time, for example, permanently, semi-permanently, or even just for a moment.

[0026] Other features and aspects will become apparent from the following detailed description and consideration of the accompanying drawings. Before describing any embodiment of this disclosure in detail, it should be understood that in its application, this disclosure is not limited to the details, configurations, and arrangements of the parts described or shown in the following description or drawings. This disclosure can support other embodiments and can be implemented or performed in a variety of ways. It should be understood that the description of a particular embodiment is not intended to limit this disclosure to encompass all variations, equivalents, and substitutes within its spirit and scope. Furthermore, it should be understood that the expressions and terms used herein are for illustrative purposes only and should not be considered as limitations.

[0027] Typical club head structure Referring to drawings in which similar reference numerals are used to identify similar or identical components from various viewpoints, Figures 1 and 2 schematically illustrate an embodiment of a golf club head 10 comprising a front body portion 12 ("front body 12") and a rear body portion 14 ("rear body 14"). The front body 12 and the rear body 14 are joined together to define a substantially enclosed / hollow internal volume 16, as shown, for example, in Figure 2. As has conventionally been the case with wood-style heads, the golf club head 10 comprises a crown 20 and a sole 22 and may be broadly divided into a heel portion 24, a toe portion 26, and a central portion 28 located between the heel portion 24 and the toe portion 26.

[0028] The front body 12 generally comprises a striking surface 30 having a ball-striking surface 32 at the front, which is intended to strike a golf ball during a conventional swing. In some embodiments, the front body 12 may further comprise a frame 34 surrounding the perimeter 36 of the striking surface 30 and extending rearward from the perimeter 36, providing a front body 12 with a cup-shaped appearance, and may further comprise a hosel 38 for receiving a golf club shaft or shaft adapter.

[0029] In a playable, completed club head 10, the front body 12 and the rear body 14 are integrally connected by a joint 40, for example, through one or more bonding, joining, mechanical bonding, welding, or fusion operations. In a particular configuration shown in Figure 2, for example, the joint 40 may be an lap joint that maintains the outer surface 42 of the frame 34 substantially in line with the outer surface 44 of the rear body 14. The lap joint may include a joined interface 46 and a mechanical interface 48.

[0030] The bonded interface 46 can be formed when the bonding surface 50 (front bonding surface 50) of the front body 12 abuts against and is fixed to the fitting bonding surface 52 (rear bonding surface 52) of the rear body 14. In the illustrated embodiment, the front bonding surface 50 surrounds the rear bonding surface 52 and is radially outward, and both surfaces 50, 52 are coplanar with each other and extend substantially in the front / rear direction. The front bonding surface 50 can be connected to the rear bonding surface 52 by any of the means enumerated above, but in a particular embodiment, these two surfaces may each contain and / or be formed from a common thermoplastic polymer that facilitates bonding or welding of material to adjacent surfaces. Structurally, the interface between the front bonding surface 50 and the rear bonding surface 52 is substantially parallel to the insertion / removal direction of the front body 12 into / from the rear body 14, so the bonding / connection between the surfaces more effectively prevents the front body 12 from coming out via shear engagement at the interface. Specifically, shear joints tend to distribute stress more effectively across the entire joint surface than, for example, cantilevered joints which introduce non-uniform stress.

[0031] A mechanical interface can be formed when the rearmost surface 54 of the front body 12 (i.e., the rear end of the frame 34) contacts the fitting surface 56 of the rear body 14, which coincides with the outer wall 58 or the external structure of the rear body 14. This coincidence allows impact loads to be transmitted directly from the frame 34 to the rear body 14 and the transition surface 58 through direct contact between the materials, and does not depend on the strength of the bond or intermediate adhesive.

[0032] In some embodiments, the rear body 14 may further comprise one or more metal weight structures to help position the club head's center of gravity low and rearward. In embodiments provided in Figures 1 and 2, the rear body 14 comprises a weight structure 60 integrated with and enclosed within the rear body 14 at the sole and rear end of the club head 10. In these embodiments, the weight structure 60 can be molded together with the sole 22 and / or rear body 14. Furthermore, in these embodiments, the weight structure 60 may comprise a cavity (not shown) that is separately formed and capable of receiving weights (not shown) that are later attached to the weight structure. In other embodiments not shown, the rear body 14 may comprise a cavity or void that is separately formed and capable of removably receiving weights that are later attached to the cavity.

[0033] In some embodiments, the weight structure 60 and / or weight may have a mass of 50 to 80 grams. Furthermore, the weight structure 60 and / or weight may contain metallic materials, including but not limited to steel, tungsten, aluminum, titanium, bronze, brass, copper, gold, platinum, lead, silver, or zinc. In addition, in these embodiments, the weight structure 60 and / or weight may have a specific gravity of 2.5 to 18.

[0034] Furthermore, as shown in Figure 1, in some embodiments, the front body 12 may further include a hosel bushing 62 capable of operably receiving a portion of the golf shaft or shaft adapter. In one embodiment, the hosel bushing 62 may be formed from a metallic material such as aluminum. Furthermore, the hosel bushing may be positioned within the hosel 38 and the front body 12, for example, by being attached in place or by being overmolded through an insert molding process or the like. In some embodiments, the hosel bushing 62 or other metallic parts of the club head may have an anodic oxide outer layer or an electrolytic corrosion barrier to prevent electrolytic corrosion.

[0035] Polymer face structure Figure 3 schematically shows an embodiment of the front body 12 including a molded fiber-filled thermoplastic composite. Such a composite material includes both a thermoplastic resin and a plurality of dispersed discontinuous fibers (i.e., "short fibers"). Examples of discontinuous / short fibers include carbon short fibers or glass short fibers that are embedded in the resin before molding the front body 12. Possible material structures will be described later, but in one structure, the polymer material may be a "long-fiber thermoplastic" in which discontinuous fibers are embedded in the thermoplastic resin, each having a design fiber length of about 3 mm to about 12 mm. In another structure, the polymer material may be a "short-fiber thermoplastic" in which discontinuous fibers are similarly embedded in the thermoplastic resin, but each may have a design length of about 0.01 mm to about 3 mm. In either case, it should be noted that these lengths are premixed lengths and will be broken during the molding process, and some fibers may actually be shorter than the range described in the final part. In some structures, discontinuous short fibers may be characterized by an aspect ratio (e.g., fiber length / diameter) greater than about 10, more preferably greater than about 50, and less than about 1500. Regardless of the specific type of discontinuous short fibers used, in certain structures, the material may have a fiber length of about 0.01 mm to about 12 mm and a resin content of about 40% to about 90% by weight, or more preferably about 55% to about 70% by weight.

[0036] One suitable thermoplastic resin is thermoplastic polyamide (e.g., PA6 or PA66), which may be filled with carbon short fibers (i.e., carbon-filled polyamide). Other resins include certain polyimides, polyamide-imides, oriphenylene sulfide (PPS), polyetheretherketone (PEEK), polycarbonate, engineered polyurethane, and / or other similar materials.

[0037] The use of polymer composites within the club head 10 can result in overall (structural) weight reduction, but their use in high-stress areas of the club head 10 becomes complicated due to their relatively lower strength compared to typical metals and their highly anisotropic nature. This anisotropic nature is demonstrated by the fact that the tensile strength of the composite is considerably greater when measured along the average longitudinal fiber direction than when measured perpendicular to this average fiber direction. These differences become more pronounced as the embedded fibers are oriented more uniformly. Depending on the selected design and material, certain composites can only possess sufficient strength to withstand repeated impacts if the embedded fibers are properly oriented.

[0038] One attribute of injection-molded fiber-filled polymers is that the fiber orientation tends to follow the flow of the polymer / flowhead within the mold being created. Figure 4 schematically shows several short fibers 70 embedded in the polymer resin 72, such as within the wall of a hosel 38. As shown, each fiber 70 may have a length 76 of approximately 0.01 mm to approximately 12 mm (note that the illustrated fibers are not necessarily shown to scale in either size or density). During the molding process, such as injection molding, the embedded fibers 70 tend to coincide with the direction of the flowing polymer. In some fibers (i.e., short fiber-reinforced thermoplastics in particular) and resins, the fibers tend to align more closely with the mold wall or the edge of the part. These layers are called shear layers 78 or skin layers. Conversely, within the central core layer 80, the fibers 70 may sometimes be more random and / or perpendicular to the flowing polymer. In these embodiments, the thickness 82 of the core layer 80 can be changed by various molding parameters, including the molding speed (i.e., the slower the molding speed, the thinner the core layer 80 can be) and the mold design. In this design, it is desirable to minimize the thickness 82 of any randomly generated core layer 80 to better control the fiber orientation.

[0039] Since the striking surface 30, frame 34, and hosel 38 are generally the highest stress parts of the club head 10, special attention must be paid to the design when using a filler polymer composite material in the front body 12. A content of poorly oriented fibers can result in a striking surface 30 that lacks the structural integrity to withstand repeated impact forces. During impact, stress tends to spread radially outward from the impact point while propagating toward the rear of the club head 10. Furthermore, a bending moment is applied around the shaft, which causes material stress between the impact point and the hosel 38, along the hosel 38 and parallel to the hosel axis 90. Therefore, in an ideal design, it is preferable that the embedded fibers generally follow the same direction as these, i.e., parallel to the hosel axis 90 within the hosel 38, at least across the center of the face 30 (represented by the horizontal face axis 92), and with the fibers oriented approximately backward (i.e., parallel to the front-to-back axis 94) within the frame 34, and approximately outward from the face center.

[0040] Since discontinuous fibers are mixed in the fluid polymer before forming the part, it is impossible to guarantee perfect alignment. However, that being said, the design of the front body 12 and the injection molding method (e.g., filling speed, gating / ventilation, and temperature) can be controlled to align as much of the embedded fibers with these axes as possible. For example, within the hosel, it is preferable that more than about 50% of the fibers are aligned within 30° of the hosel axis 90. Between the center of the face and the hosel 38, it is preferable that more than about 50% of the fibers are aligned within 30° of the horizontal face axis 92, and within the frame 34, it is preferable that more than about 50% of the fibers are aligned within 30° of the front-to-back axis 94. In another embodiment, more than 60% of the fibers in the hosel 38 are aligned within 25° of the hosel axis 90, more than 60% of the fibers between the center of the face and the hosel 38 are aligned within 25° of the horizontal face axis 92, and more than 60% of the fibers in the frame 34 are aligned within 25° of the front-to-back axis 94. In yet another embodiment, more than 70% of the fibers in the hosel 38 are aligned within 20° of the hosel axis 90, more than 70% of the fibers between the center of the face and the hosel 38 are aligned within 20° of the horizontal face axis 92, and more than 70% of the fibers in the frame 34 are aligned within 20° of the front-to-back axis 94.

[0041] Figures 5 and 6 show the design of the front body that generally achieves the fiber alignment described above. The alignment of the flow and fibers is schematically shown in Figure 5 and can be seen more clearly in Figures 8 and 9 via the mold flow simulation output. As shown through these figures, the flowable polymer passes directly from the sprue 100 and the connected gate 102 into the toe portion 26 of the front body 12, for example, as shown in Figure 5. From there, the polymer can flow across the face 30 and then upward through the hosel 38. By flowing across the face 30 and upward through the hosel 38, any weld line is pushed upward towards the heel side of the hosel 38, which is generally the minimum stress region of the hosel 38. If the body 12 attempts to use the hosel 38 as a gate, the weld line is more likely to be in or near the face 30 or on the toe side of the hosel 38, resulting in relatively greater stress on the toe side than on the heel side. Since weld lines have lower ultimate strength than conventional polymers, it is important to ensure that weld lines do not form in areas where typically greater stress occurs.

[0042] To facilitate the polymer filling the hosel 38 from bottom to top, it may be desirable to begin filling the face from a position near the toe 26, i.e., the horizontal centerline 104 of the face 30 or preferably above it (i.e., between the centerline of the crown 20 and the face 106 and the line drawn parallel to the ground when the club is held at address). This can encourage the flow 108 and the alignment of the corresponding fibers to follow a substantially downward slope from above the horizontal centerline 104 of the toe 26, between the toe and the center 106, toward the center 106 of the face. Then, at the center 106, the flow 110 and the alignment of the corresponding fibers may generally be parallel to the horizontal centerline 104 at or just around the center 106 of the face. Finally, the flow 112 arcs upward, filling the hosel 38 mainly from the bottom toward the constricted part. The overall directional references shown in 108, 110, and 112 are generally intended to indicate that more than about 50% of the fibers in the polymer are aligned within about 30° of the indicated direction, or more preferably more than 60% of the fibers are aligned within about 25° of the indicated direction, or even more preferably more than 70% of the fibers are aligned within about 20° of the indicated direction.

[0043] As shown in Figure 5, in one embodiment, the gate 102 may be a fan gate located in the rear half of the frame 34 just below the crown 20. To facilitate a directional flow 108, 110 across the face 30, while also encouraging a slightly downward arc of 108, the flow leader 114 may protrude from the rear surface 116 of the striking surface 30, as shown, for example, in Figures 6-7. As illustrated, the flow leader 114 is an embossed channel extending from the gate or an edge of the face 30 near it, propagating away from the gate toward the central region of the face 30 to direct the flow of material. This can ensure a primary flow direction as it acts as a path with relatively little resistance for the material to flow. In some embodiments, the flow leader 114 may be raised about 0.5 mm to about 1.5 mm, or about 0.7 mm to about 1.0 mm, above the surrounding surface 116. Furthermore, when measured perpendicular to the height and perpendicular to the straight line from the starting point at the toe 26 of the flow leader to the face center 106, the flow leader may have a lateral width of approximately 5 mm to approximately 15 mm or approximately 7 mm to approximately 12 mm.

[0044] Furthermore, as illustrated in Figures 6-7, in one embodiment, the flow leader 114 may connect to a thickened central region 118 of the face 30. This thickened central portion 118 is primarily used to reinforce the central region of the face against impact so that the face moves more as a single unit while avoiding local deformation. From a molding standpoint, this thickened region 118 can function as a well or manifold of the kind that supplies polymer radially outward to fill the frame from front to back (or advance the polymer at least through the thinner region toward the rear edge 120 of the frame). The convergence of the flow from the thickened region 118 toward the surrounding thinner region also helps in the alignment of the embedded fibers.

[0045] As described above, Figures 8 and 9 show two molding simulation outputs illustrating the front body 12 at different stages of filling / molding. As illustrated, the main flow path starts from the upper tow portion 26 and is directed downward (108) through the flow leader 114 to the thickened central region 118, then crosses the face (110) and returns roughly upward (112) as the hosel 38 is filled from bottom to top. While the main flow descends and crosses the face 30, the polymer is directed backward (122) from this main flow path into the frame 34, which can also be seen as coinciding with the convergence of the flow from the flow leader and the thickened central region into the relatively thinner peripheral and frame regions.

[0046] In many embodiments, the face thickness can vary such that the minimum face thickness is in the range of 0.114 inches to 0.179 inches and the maximum face thickness is in the range of 0.160 inches to 0.301 inches. The minimum face thickness may be 0.110 inches, 0.114 inches, 0.115 inches, 0.120 inches, 0.125 inches, 0.130 inches, 0.135 inches, 0.140 inches, 0.145 inches, 0.150 inches, 0.155 inches, 0.160 inches, 0.165 inches, 0.170 inches, 0.175 inches, 0.179 inches, or 0.180 inches. The maximum face thickness is 0.160 inches, 0.165 inches, 0.170 inches, 0.175 inches, 0.180 inches, 0.185 inches, 0.190 inches, 0.195 inches, 0.200 inches, 0.205 inches, 0.210 inches, 0.215 inches, 0.220 inches, 0.225 inches, or 0.230 inches. It may also be 0.235 inches, 0.240 inches, 0.245 inches, 0.250 inches, 0.255 inches, 0.260 inches, 0.265 inches, 0.270 inches, 0.275 inches, 0.280 inches, 0.285 inches, 0.290 inches, 0.300 inches, 0.301 inches, 0.305 inches, or 0.310 inches.

[0047] Figure 10 schematically shows an embodiment of a thermoplastic composite front body 200 including an embedded reinforcing element 202 extending across at least a portion of the striking surface 30. In one configuration, the illustrated embodiment may be formed via an insert injection molding process, where the reinforcing element 202 is placed in the mold before the fluid polymer is injected.

[0048] The reinforcing element 202 may include a plurality of continuous fibers, wires, or other elongated elements extending over a substantial portion of the face (i.e., more than about 25 mm, or more than about 30 mm, or more than 35 mm, or more than about 40 mm). In some embodiments, these elements 202 may include a first plurality of elements 204 extending substantially parallel to each other in a first spaced-out arrangement. Furthermore, in some embodiments, the reinforcing element 202 may include a second plurality of elements 206 extending substantially parallel to each other in a second spaced-out arrangement, where the first plurality of elements 204 and the second plurality of elements 206 are not parallel. As shown in Figure 10, in some configurations, the first plurality of elements 204 and the second plurality of elements 206 may form an orthogonal mesh or grid. In some embodiments, the grid may be integral so that the first plurality of elements 204 and the second plurality of elements 206 are integral to each other. In other embodiments, they may be woven in an alternating pattern.

[0049] To ensure that the reinforcing elements 202 are properly embedded within the composite material and do not simply create weak internal boundary planes, it may be necessary to ensure a minimum spacing between adjacent elements. For example, as generally shown in the cross-sectional view provided in Figure 11, each element may have a diameter of approximately 208, and adjacent elements may be spaced apart by a separation distance 210. In one configuration, the minimum spacing is such that the separation distance 210 is greater than or equal to the average diameter 208 of the adjacent elements. In other embodiments, the separation distance 210 may be more than twice the average diameter 208 of the adjacent elements, or more than three times the average diameter 208 of the adjacent elements, or four times the average diameter 208 of the adjacent elements. In fact, the larger the spacing, the more completely the elements 202 are incorporated into the molded polymer. In one embodiment, the average diameter may be about 0.05 mm to about 1.5 mm, or about 0.1 mm to about 1.0 mm.

[0050] The continuous reinforcing elements 202 may be formed from any high-strength material, including carbon fibers, glass fibers, aramid fibers, etc. However, in some embodiments, the reinforcing elements 202 may be formed from a metal in which each reinforcing element is a wire or a bundle of wires. In some configurations, the metal may be a metal conventionally used to form a golf club face, such as stainless steel or steel alloys (e.g., C300, C350, Ni(nickel)-Co(cobalt)-Cr(chromium)-steel alloy, 565 steel, AISI type 304 or AISI type 630 stainless steel), titanium alloys (e.g., Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti15-3-3-3, Ti15-5-3, Ti185, Ti6-6-2, Ti-7s, Ti-92, or Ti-8-1-1 titanium alloy), or other similar materials.

[0051] For example, in one configuration shown in Figure 11, the reinforcing elements 202 may generally be aligned with and parallel to the ball-hitting surface 32. Such embodiments can help reinforce the polymer and its integrity against impact. However, in another configuration shown in Figure 12, for example, the reinforcing elements 202 may generally be aligned with and parallel to the rear surface 212 of the face 30. Such embodiments can provide greater rebound force against bending and face deflection, thereby reducing the face's characteristic time (measured according to USGA guidelines). In a further third configuration, as shown in Figure 13, for example, the first plurality of reinforcing elements 214 may be parallel to the ball-hitting surface 32, and the second plurality of reinforcing elements 216 may be parallel to the rear surface 212. Such embodiments can provide a combination of the benefits described with respect to Figures 11 and 12.

[0052] thermoplastic composite material As described above, the molded front body 12 may be formed from a thermoplastic composite material comprising a thermoplastic polymer matrix material and fillers. Examples of thermoplastic polymer matrix materials include polycarbonate (PC), polyester (PBT), polyphenylene sulfide (PPS), polyamide (PA) (e.g., polyamide 6 (PA6), polyamide 6-6 (PA66), polyamide-12 (PA12), polyamide-612 (PA612), polyamide-11 (PA11)), thermoplastic polyurethane (TPU), polyphthalamide (PPA), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyethylene (PE), polyphenylene ether / oxide (PPE), polyoxymethylene (POM), polypropylene (PP), styrene acrylonitrile (SAN), polymethylpentene (PMP), and polyethylene terephthalate. Examples include (PET), acrylonitrile styrene acrylate (ASA), polyetherimide (PEI), polyvinylidene fluoride (PVDF), polymethyl methacrylate (PMMA), polyetheretherketone (PEEK), polyetherketone (PEK), polyetherimide (PEI), polyethersulfone (PES), polyphenylene oxide (PPO), polystyrene (PS), polysulfone (PSU), polyvinyl chloride (PVC), liquid crystal polymer (LCP), thermoplastic elastomer (TPE), ultra-high molecular weight polyethylene (UHMWPE), or mixtures of the above thermoplastic materials, such as a mixture of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC), or a mixture of acrylonitrile butadiene styrene (ABS) and polyamide (PA).

[0053] For example, in some embodiments, the thermoplastic composite material may include thermoplastic polyurethane (TPU) as the thermoplastic polymer matrix material. The TPU has a chemical structure consisting of a linear segmented block copolymer having hard segments and soft segments. In some embodiments, the hard segments include aromatic or aliphatic structures, and the soft segments include polyether or polyester chains. In other embodiments, the thermoplastic polymer matrix material including TPU may have hard segments and soft segments having different chemical structures.

[0054] As a further example, in some embodiments, thermoplastic composite materials may include polyamine 6-6 (PA66) or polyamide 6 (PA6) as the thermoplastic polymer matrix material. Figure 10 shows the chemical structure of polyamide 6-6 (PA6-6). PA66 is a type of polyamide made of two monomers, hexamethylenediamine and adipic acid, each containing six carbon atoms. Figure 11 shows the chemical structure of polyamide 6 (PA6), which is a semicrystalline polyamide.

[0055] Examples of fillers for thermoplastic composites include fibers, beads, or other structures containing various materials (described later) that are mixed with a thermoplastic polymer. Fillers can impart structural reinforcement, weighting, weight reduction, or various other properties to thermoplastic composites. In many embodiments, the filler may contain carbon or glass. However, in other embodiments, the filler may contain other suitable materials. For example, a filler consisting of one or more thin layers may include aramid fibers (e.g., Nomex, Vectran, Kevlar, Twaron), bamboo fibers, natural fibers (e.g., cotton, hemp, flax), metal fibers (e.g., titanium, aluminum), glass beads, tungsten beads, or ceramic fibers (e.g., titanium dioxide, granite, silicon carbide).

[0056] The filler or fibers may be short (less than about 0.5 mm in length or diameter), long (ranging from about 0.5 mm to about 40 mm in length or diameter, or more preferably from about 5 mm to about 12 mm), or continuous (more than about 40 mm in length). In many embodiments, the front body 12 and the rear body 14 include short fibers and / or long fibers. In other embodiments, the front body 12 and the rear body 14 may include continuous fibers instead of, or in addition to, short fibers and long fibers.

[0057] In many embodiments, the thermoplastic composite material may contain 30–40 volume% of filler. In other embodiments, the thermoplastic composite material may contain up to 55 volume%, up to 60 volume%, up to 65 volume%, or up to 70 volume% of filler.

[0058] In many embodiments, the thermoplastic composite material has a specific gravity of about 1.0 to 2.0, which is considerably lower than the specific gravity of the metal materials used in golf (for example, titanium has a specific gravity of about 4.5 and aluminum has a specific gravity of about 3.5). Furthermore, in many embodiments, the thermoplastic composite material includes a strength-to-weight ratio greater than 1,000,000 PSI / (lb / in3), i.e., specific strength, and strength-to-modulus ratio greater than 0.009, i.e., specific flexibility. The specific gravity, specific strength, and specific flexibility of the thermoplastic composite material allow for a significant reduction in the weight of the club head 10 while maintaining durability.

[0059] Method for forming a golf club head made of thermoplastic composite material In the embodiments illustrated in Figures 1 to 3, the club head comprises (1) a front body 12 having a striking surface 30, a frame 34 surrounding the striking surface 30 and the return portion and extending rearward from them, and (2) a rear body 14 including a crown portion 20 and a sole portion 22. In these or other embodiments, the front body 12 and the rear body 14 can be formed separately and then joined together to form the club head 10. A method for forming the club head 10, which will be described in more detail below, includes (1) forming the front body 12, (2) forming the crown portion 20 and the sole portion 22, (3) joining the crown portion 20 and the sole portion 22 to form the rear body 14, and (4) joining the front body 12 and the rear body 14 via a joint 40 to form the club head 10, wherein the crown portion 20 and the sole portion 22 and / or the front body 12 and the rear body 14 are joined by fusion bonding. In this or other embodiments, fusion bonding may include, but is not limited to, thermal welding (e.g., hot jig welding, hot air welding, extrusion welding, infrared welding, laser welding), friction welding (e.g., spin welding, vibration welding, ultrasonic welding, stir welding), and electromagnetic welding (e.g., induction welding, high-frequency welding, microwave welding, resistance welding).

[0060] As described above, the front body 12 can be formed, for example, using an injection molding process. In such a process, a fluid thermoplastic polymer is injected into the cavity of a mold, which is a recess in the part to be molded. Before injecting the fluid polymer, several discontinuous fibers are mixed into the polymer so that they are generally uniformly dispersed. The fluid polymer is then injected into the mold, filling the cavity and solidifying.

[0061] For example, in one embodiment shown in Figures 10 to 13, the reinforcing element 202 may be formed first or otherwise provided in a substantially final form. This may be done by first providing a substantially uniform planar mesh or grid, and then compression molding or forging the mesh / grid into the desired final shape. Once the mesh is in the final shape, it may be inserted into a mold before the injection of the fluid polymer. During the injection process, the fluid polymer surrounds the formed mesh and fills the gaps.

[0062] In some embodiments, the rear body 14 is formed from one or more thermoplastic composite materials to facilitate fusion bonding with the front body 12 (i.e., via the joint 40 described above). In some configurations, the rear body 14 may be constructed from an injection-molded and compression-molded thermoplastic composite material, such as that described in U.S. Patent No. 9,925,432, which is incorporated in full by reference. By incorporating a thermoplastic polymer common to both the rear body 14 and the front body 12, fusion bonding can be made possible and the structure can be made more robust.

[0063] Advantages of club heads containing thermoplastic composite materials Thermoplastic composite materials allow for heating and modification (by the thermoplastic matrix material). Therefore, the entire hollow club head can be molded piece by piece and then fused together without the need for an intermediate adhesive. This is in contrast to many current club heads, which generally have a structural metal frame and composite panel inserts (containing a thermosetting matrix that cannot be modified when heated).

[0064] Furthermore, thermoplastic composite materials reduce the structural mass of the club head to a degree that is not possible with conventional metal and composite material forming techniques used in golf club heads. This structural weight reduction can be used to reduce the overall weight of the club head 10 (which can increase club head speed and / or distance) or to increase the amount of discretionary mass available for placement in the club head (i.e., relative to a given head weight). In a preferred embodiment, the additional discretionary mass is incorporated into the final club head design via one or more metal weights 60 connected to the sole 22 and / or the rear of the club head 10.

[0065] Thermoplastic composites provide the structural integrity necessary to withstand impact forces while reducing weight as described above. In many embodiments, fiber-reinforced thermoplastic composites can have strength-to-weight ratios and strength-to-modulus ratios (as described above) that are greater than those achievable with metallic materials.

[0066] Example 1: Face containing TPU thermoplastic composite material

[0067] According to one embodiment, a golf club head has a striking surface 30 comprising a thermoplastic composite material. The thermoplastic composite material comprises TPU as a thermoplastic polymer matrix material and is filled with 40% carbon fiber. The striking surface 30 has a thickness of 0.265 inches and yields an average coefficient of restitution (COR) of 0.821–0.826. For comparison, a similar striking surface containing a titanium alloy had a coefficient of restitution of approximately 0.828. Therefore, the coefficient of restitution of the exemplary striking surface 30, comprising TPU filled with 40% carbon fiber and having a thickness of 0.265 inches, maintained a similar coefficient of restitution (within 0.85%) compared to a similar striking surface containing a titanium alloy. Furthermore, the exemplary striking surface 30 maintained its durability during testing. The results described herein were obtained by testing the COR plate according to USGA methods.

[0068] Example 2: Face containing TPU thermoplastic composite material

[0069] According to another embodiment, the golf club head has a striking surface 30 comprising a thermoplastic composite material. The thermoplastic composite material comprises TPU as the thermoplastic polymer matrix material and is filled with 50% carbon fiber. The striking surface 30 has a thickness of 0.265 inches and yields an average coefficient of restitution (COR) of 0.815. For comparison, a similar striking surface comprising a titanium alloy had a coefficient of restitution of approximately 0.828. Thus, the coefficient of restitution of the exemplary striking surface 30, comprising TPU filled with 50% carbon fiber and having a thickness of 0.265 inches, remained similar (within 1.6%) to that of a similar striking surface comprising a titanium alloy. Furthermore, the exemplary striking surface 30 maintained its durability during testing. The results described herein were obtained by testing the COR plate according to USGA methods.

[0070] Example 3: Face containing PA6 thermoplastic composite material

[0071] According to one embodiment, a golf club head has a striking surface 30 comprising a thermoplastic composite material. The thermoplastic composite material comprises TPU as a thermoplastic polymer matrix material and is filled with 50% carbon fiber. The striking surface 30 has a thickness of 0.275 inches and yields an average coefficient of restitution (COR) of 0.814. For comparison, a similar striking surface comprising a titanium alloy had a coefficient of restitution of approximately 0.828. Thus, the coefficient of restitution of the exemplary striking surface 30, comprising TPU filled with 50% carbon fiber and having a thickness of 0.275 inches, maintained a similar coefficient of restitution (within 1.7%) compared to a similar striking surface comprising a titanium alloy. Furthermore, the exemplary striking surface 30 maintained its durability during testing. The results described herein were obtained by testing the COR plate according to USGA methods.

[0072] Example 4: Face containing PA6 thermoplastic composite material

[0073] According to one embodiment, a golf club head has a striking surface 30 comprising a thermoplastic composite material. The thermoplastic composite material comprises TPU as a thermoplastic polymer matrix material and is filled with 40% carbon fiber. The striking surface 30 has a thickness of 0.266 inches and yields an average coefficient of restitution (COR) of 0.808. For comparison, a similar striking surface comprising a titanium alloy had a coefficient of restitution of approximately 0.828. Thus, the coefficient of restitution of the exemplary striking surface 30, comprising TPU filled with 40% carbon fiber and having a thickness of 0.266 inches, maintained a similar coefficient of restitution (within 2.4%) compared to a similar striking surface comprising a titanium alloy. Furthermore, the exemplary striking surface 30 maintained its durability during testing. The results described herein were obtained by testing the COR plate according to USGA methods.

[0074] Example 5: Face containing PA6 thermoplastic composite material

[0075] According to one embodiment, a golf club head has a striking surface 30 comprising a thermoplastic composite material. The thermoplastic composite material comprises TPU as a thermoplastic polymer matrix material and is filled with 50% carbon fiber. The striking surface 30 has a thickness of 0.272 inches and yields an average coefficient of restitution (COR) of 0.802. For comparison, a similar striking surface comprising a titanium alloy had a coefficient of restitution of approximately 0.828. Thus, the coefficient of restitution of the exemplary striking surface 30, comprising TPU filled with 50% carbon fiber and having a thickness of 0.272 inches, maintained a similar coefficient of restitution (within 3.1%) compared to a similar striking surface comprising a titanium alloy. Furthermore, the exemplary striking surface 30 maintained its durability during testing. The results described herein were obtained by testing the COR plate according to USGA methods.

[0076] The replacement of one or more claimed elements constitutes a reconstruction, not a repair. Furthermore, benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, no benefit, advantage, solution to problem, or any element(s) that may produce or make more apparent any benefit, advantage, or solution should be construed as an essential, necessary, or indispensable feature or element of any or all of the claims.

[0077] Because the rules of golf can change from time to time (for example, new rules may be adopted, or old rules may be deleted or modified by the standard organization and / or governing body of golf, such as the United States Golf Association (USGA), the Royal and Advanced Golf Club of St. British Golf (R&A), etc.), the golf equipment relating to the devices, methods and articles described herein may or may not conform to the rules of golf at any particular time. Accordingly, the golf equipment relating to the devices, methods and articles described herein may be advertised, marketed, and / or sold as conforming or non-conforming golf equipment. The devices, methods, and articles described herein are not limited in this respect.

[0078] While the above embodiments may be described in relation to driver-type golf clubs, the apparatus, methods, and articles described herein can also be applied to other types of golf clubs, such as fairway wood-type golf clubs, hybrid-type golf clubs, iron-type golf clubs, wedge-type golf clubs, or putter-type golf clubs. Alternatively, the apparatus, methods, and articles described herein can also be applied to other types of sports equipment, such as hockey sticks, tennis rackets, fishing rods, ski poles, etc.

[0079] Furthermore, embodiments and limitations disclosed herein are not available to the public under the principle of public ownership if (1) embodiments and / or limitations are not expressly claimed in the claims and (2) are potential equivalents of obvious elements and / or limitations of the claims under the doctrine of equivalents.

[0080] The various features and benefits of this disclosure are described in the following sections.

[0081] Item 1: A golf club head comprising a front body having a striking surface defining a ball-striking surface, a hosel, and a frame at least partially surrounding the striking surface and extending rearward from the periphery of the striking surface away from the ball-striking surface, and a rear body connected to the front body and defining a hollow cavity between them, wherein the striking surface and the frame are formed from a thermoplastic composite material comprising a thermoplastic polymer with a plurality of discontinuous fibers embedded therein, each of the discontinuous fibers having a length of less than about 40 mm, and between the center of the striking surface and the hosel, more than about 50% of the plurality of discontinuous fibers are aligned within about 30° parallel to the horizontal axis extending from the center of the striking surface to the hosel.

[0082] Item 2: The golf club head as described in Item 1, wherein the front body has a rear edge that contacts the rear body when the rear body is connected to the front body, and within the frame, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the axis that extends perpendicular to the horizontal axis from the ball-hitting surface to the rear edge.

[0083] Item 3: The golf club head described in Item 2, in which the axis extending from the ball-striking surface to the rear edge is perpendicular to the rear edge.

[0084] Item 4: A golf club head as described in any one of Items 1-3, wherein the front body comprises a toe portion opposite to the hosel of the striking surface, a frame defining part of the crown and sole, a horizontal axis extending between the crown and sole through the center of the striking surface, and a rear surface opposite to the ball-striking surface of the striking surface, the striking surface having a flow leader that protrudes from the rear surface away from the ball-striking surface and extends from the toe portion toward the center of the striking surface between the crown and the horizontal axis.

[0085] Item 5: A golf club head as described in Item 4, further comprising a thickened central area centered on the center of the striking surface, which protrudes from the rear face surface away from the ball-striking surface.

[0086] Item 6: A golf club head as described in any one of Items 1-5, wherein the thermoplastic composite material is polyamide and the multiple discontinuous fibers are each carbon fiber.

[0087] Item 7: A golf club head according to any one of items 1-6, further comprising multiple continuous reinforcing elements embedded within a thermoplastic polymer on the striking surface.

[0088] Item 8: A golf club head as described in Item 7, with multiple continuous reinforcing elements including an orthogonal mesh.

[0089] Item 9: A golf club head described in any one of items 7-8, with multiple reinforcing elements including metal wire.

[0090] Item 10: A golf club head according to any one of items 7-9, wherein the multiple reinforcing elements each have a diameter, at least a first subset of the multiple reinforcing elements are arranged in parallel, and adjacent reinforcing elements of the first subset of the multiple reinforcing elements are spaced a minimum distance apart from each other, the minimum distance being at least twice the average diameter of the first subset of reinforcing elements.

[0091] Item 11: A polymer front body for a golf club head, comprising: a striking surface defining the ball-striking surface, having a geometric center, and defining a horizontal axis extending through the geometric center; a frame at least partially surrounding the striking surface, extending rearward from the periphery of the striking surface away from the ball-striking surface, and defining a crown portion and a sole portion; a hosel with a horizontal axis extending between the geometric center and the hosel, and between at least a portion of the crown and the sole; and a fan gate extending from the frame between the horizontal axis and the crown.

[0092] Item 12: The polymer front body according to Item 11, wherein the hitting surface further defines a rear surface opposite to the hitting surface, and the front body further comprises flow leaders projecting from the rear surface away from the hitting surface and extending from the portion of the hitting surface closest to the fan gate toward the center of the hitting surface.

[0093] Item 13: The polymer front body as described in Item 12, further comprising a thickened central region centered on the geometric center of the hitting surface, which protrudes from the rear face surface away from the hitting surface.

[0094] Item 14: The striking surface and frame comprises a thermoplastic composite material containing a thermoplastic polymer in which multiple discontinuous fibers are embedded, each having a length of less than approximately 40 mm, as described in any one of Items 11-13.

[0095] Item 15: The polymer pre-body as described in Item 14, wherein more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the horizontal axis between the center of the striking surface and the hosel.

[0096] Item 16: The polymer front body as described in Item 14 or 15, wherein the frame defines a rear edge opposite to the hitting surface, and within the frame, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to an axis that extends perpendicular to the horizontal axis from the hitting surface to the rear edge.

[0097] Item 17: The polymer front body as described in Item 16, wherein the axis extending from the ball-hitting surface to the rear edge is perpendicular to the rear edge.

[0098] Item 18: A polymer pre-body according to any one of items 11-17, further comprising multiple reinforcing elements embedded within the striking surface.

[0099] Item 19: Multiple reinforcing elements include an orthogonal mesh, as described in Item 18, for the polymer pre-body.

[0100] Item 20: A polymer pre-body according to Item 18 or 19, wherein each of the multiple reinforcing elements has a diameter, at least a first subset of the multiple reinforcing elements is arranged in parallel, and adjacent reinforcing elements of the first subset of the multiple reinforcing elements are spaced apart from each other by a minimum distance, the minimum distance being at least twice the average diameter of the first subset of reinforcing elements.

[0101] Item 21: Multiple reinforcing elements, including metal wires, are polymer pre-body as described in any one of items 18-20.

Claims

1. It is a golf club head, A front body comprising a hitting surface defining the surface of the ball being hit, a hosel, and a frame that at least partially surrounds the hitting surface and extends rearward from the periphery of the hitting surface so as to be away from the surface of the ball being hit, A rear body connected to the aforementioned front body, defining a hollow cavity between it and the front body. Equipped with, The striking surface and frame are formed from a thermoplastic composite material containing a thermoplastic polymer in which a plurality of discontinuous fibers are embedded. Each of the aforementioned discontinuous fibers has a length between approximately 0.01 and 3 mm. The thermoplastic composite material consists of 30 to 70 volume percent fibers. Between the center of the striking surface and the hosel, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the horizontal axis extending from the center of the striking surface to the hosel. Within the frame, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the axis extending perpendicular to the horizontal axis from the ball-hitting surface to the rear edge. A golf club head in which the axis extending from the ball-hitting surface to the rear edge is perpendicular to the rear edge.

2. The aforementioned front body is The toe portion on the opposite side of the striking surface from the hosel, The frame defining a portion of the crown and sole, A horizontal axis extends between the crown and the sole, passing through the center of the striking surface. The rear surface of the hitting surface opposite to the hitting surface and Equipped with, The golf club head according to claim 1, wherein the striking surface protrudes from the rear surface so as to be away from the ball-hitting surface, and a flow leader extends from the toe portion toward the center of the striking surface between the crown and the horizontal axis.

3. The golf club head according to claim 2, further comprising a thickened central region that protrudes from the rear surface so as to be away from the ball-hitting surface and is centered on the center of the hitting surface.

4. The aforementioned thermoplastic composite material is polycarbonate (PC), polyester (PBT), polyphenylene sulfide (PPS), polyamide (PA), thermoplastic polyurethane (TPU), polyphthalamide (PPA), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyethylene (PE), polyphenylene ether / oxide (PPE), polyoxymethylene (POM), polypropylene (PP), styrene acrylonitrile (SAN), polymethylpentene (PMP), polyethylene terephthalate (PET), acrylonitrile styrene acrylate (ASA) The golf club head according to claim 1, comprising a thermoplastic polymer matrix material selected from the group consisting of polyetherimide (PEI), polyvinylidene fluoride (PVDF), polymethyl methacrylate (PMMA), polyetheretherketone (PEEK), polyetherketone (PEK), polyetherimide (PEI), polyethersulfone (PES), polyphenylene oxide (PPO), polystyrene (PS), polysulfone (PSU), polyvinyl chloride (PVC), liquid crystal polymer (LCP), thermoplastic elastomer (TPE), ultra-high molecular weight polyethylene (UHMWPE), or mixtures thereof.

5. The golf club head according to claim 1, wherein the material of the plurality of discontinuous fibers is selected from the group consisting of carbon, glass, aramid, bamboo, cotton, hemp, flax, titanium, aluminum, titanium dioxide, granite, and silicon carbide.

6. The golf club head according to claim 1, further comprising a plurality of continuous reinforcing elements embedded in the thermoplastic polymer of the striking surface.

7. The golf club head according to claim 6, wherein the plurality of continuous reinforcing elements include metal wires.

8. The thermoplastic composite material has a viscosity of 1,000,000 lbs / in ３ The golf club head according to claim 1, having an exceptionally high strength-to-weight ratio, i.e., specific strength.

9. The golf club head according to claim 1, wherein the thermoplastic composite material has a strength-to-elastic modulus ratio greater than 0.009, i.e., specific flexibility.

10. The golf club head according to claim 1, further comprising a thermoplastic resin selected from the group consisting of polyetheretherketone (PEEK) and engineering polyurethane.

11. It is a golf club head, A front body comprising a hitting surface defining the surface of the ball being hit, a hosel, and a frame that at least partially surrounds the hitting surface and extends rearward from the periphery of the hitting surface so as to be away from the surface of the ball being hit, A rear body connected to the aforementioned front body, defining a hollow cavity between it and the front body. Equipped with, The striking surface and frame are formed from a thermoplastic composite material containing a thermoplastic polymer in which a plurality of discontinuous fibers are embedded. Each of the aforementioned discontinuous fibers has a length between approximately 0.01 and 3 mm. Multiple continuous reinforcing elements are embedded within the thermoplastic polymer of the striking surface. The first set of the plurality of continuous reinforcing elements extends generally parallel to one another, Between the center of the striking surface and the hosel, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the horizontal axis extending from the center of the striking surface to the hosel. Within the frame, more than 50% of the multiple discontinuous fibers are aligned within approximately 30° parallel to the axis extending perpendicular to the horizontal axis from the ball-hitting surface to the rear edge. A golf club head in which the axis extending from the ball-hitting surface to the rear edge is perpendicular to the rear edge.

12. The golf club head according to claim 11, wherein the rear edge abuts against the rear body when the rear body is connected to the front body.

13. The aforementioned front body is The toe portion on the opposite side of the striking surface from the hosel, The frame defining a portion of the crown and sole, A horizontal axis extends between the crown and the sole, passing through the center of the striking surface. The rear surface of the hitting surface opposite to the hitting surface and Equipped with, The golf club head according to claim 12, wherein the striking surface protrudes from the rear surface so as to be away from the ball-hitting surface, and a flow leader extends from the toe portion toward the center of the striking surface between the crown and the horizontal axis.

14. The golf club head according to claim 13, further comprising a thickened central region that protrudes from the rear surface so as to be away from the ball-hitting surface and is centered on the center of the hitting surface.

15. The aforementioned thermoplastic composite material is polycarbonate (PC), polyester (PBT), polyphenylene sulfide (PPS), polyamide (PA), thermoplastic polyurethane (TPU), polyphthalamide (PPA), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyethylene (PE), polyphenylene ether / oxide (PPE), polyoxymethylene (POM), polypropylene (PP), styrene acrylonitrile (SAN), polymethylpentene (PMP), polyethylene terephthalate (PET), acrylonitrile styrene acrylate (ASA) The golf club head according to claim 11, comprising a thermoplastic polymer matrix material selected from the group consisting of polyetherimide (PEI), polyvinylidene fluoride (PVDF), polymethyl methacrylate (PMMA), polyetheretherketone (PEEK), polyetherketone (PEK), polyetherimide (PEI), polyethersulfone (PES), polyphenylene oxide (PPO), polystyrene (PS), polysulfone (PSU), polyvinyl chloride (PVC), liquid crystal polymer (LCP), thermoplastic elastomer (TPE), ultra-high molecular weight polyethylene (UHMWPE), or mixtures thereof.

16. The golf club head according to claim 11, wherein the material of the plurality of discontinuous fibers is selected from the group consisting of carbon, glass, aramid, bamboo, cotton, hemp, flax, titanium, aluminum, titanium dioxide, granite, and silicon carbide.

17. The golf club head according to claim 11, further comprising a thermoplastic resin selected from the group consisting of polyetheretherketone (PEEK) and engineering polyurethane.

18. The golf club head according to claim 11, wherein the plurality of continuous reinforcing elements include metal wires.

Images