Golf club face including voids

Abstract

A golf club face including voids is disclosed herein. In accordance with the presently disclosed technology, the golf club face may include a front surface to impact a golf ball, a rear surface, and a plurality of two or more voids between the front surface and the rear surface distributed in a pattern.

Description

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to golf club faces, and more specifically to a golf club face including voids.SUMMARY

[0002] Embodiments of the presently disclosed technology may include golf club faces. In accordance with some aspects of the presently disclosed technology, a golf club face may include a front surface to impact a golf ball, a rear surface, and a plurality of two or more voids between the front surface and the rear surface distributed in a pattern.

[0003] In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mm3 to about 8.5 mm3.

[0004] In embodiments, each of the plurality of two or more voids may be spherical.

[0005] In embodiments, the plurality of two or more voids may be distributed radially around a center of the golf club face.

[0006] In embodiments, each of the plurality of two or more voids may be cylindrical.

[0007] In embodiments, each of the plurality of two or more voids may extend across the golf club face horizontally.

[0008] In embodiments, each of the plurality of two or more voids may extend across the golf club face vertically.

[0009] In embodiments, each of the plurality of two or more voids may be separated by at least 1 diameter length from a center of adjacent ones of the plurality of two or more voids.

[0010] In embodiments, at least some of the plurality of two or more voids may have different volumes.

[0011] In embodiments, each of the plurality of two or more voids may extend radially outward from a center of the golf club face.

[0012] In embodiments, the golf club face may further include a fill material to fill each of the plurality of two or more voids.

[0013] In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane.

[0014] In embodiments, the golf club face has a diameter-to-thickness ratio between about 0.5 to about 1.0, wherein the diameter-to-thickness ratio is defined asDiameter-To-Thickness⁢ Ratio=a⁢ diameter⁢ of⁢ one⁢ of⁢ the⁢ multiple⁢ voidsa⁢ thickness⁢ of⁢ the⁢ golf⁢ club⁢ face.

[0015] In accordance with some aspects of the presently disclosed technology, a golf club head may include a face. The face may include a front surface to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include a plurality of two or more voids distributed in a pattern.

[0016] In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mm3 to about 25.0 mm3.

[0017] In embodiments, each of the plurality of two or more voids may be spherical.

[0018] In embodiments, at least some of the plurality of two or more voids may have different volumes.

[0019] In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane between about 0.025 mm to about 2.00 mm.

[0020] In accordance with some aspects of the presently disclosed technology, a method of forming voids in a golf club face is disclosed. The method may include a number of steps. One step may include forming an initial face insert. The initial face insert may include an initial front surface. The initial front surface may include a first set of ribs. The initial face insert may include an initial rear surface opposite the initial front surface. The initial rear surface may include a second set of ribs opposite the first set of ribs. The initial face insert may include an initial body extending between the initial front surface and the initial rear surface. Another step may include cooling the initial face insert to form an intermediate face insert. This may form a plurality of two or more voids in an intermediate body between the first set of ribs and the second set of ribs.

[0021] In embodiments, another step may include removing the first set of ribs and the second set of ribs to form a final face insert. The final face insert may include a front surface intended to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include the plurality of two or more voids.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0023] FIG. 2 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0024] FIG. 3 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0025] FIG. 4 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0026] FIG. 5 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0027] FIG. 6 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0028] FIG. 7 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0029] FIG. 8 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0030] FIG. 9 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0031] FIG. 10 is a perspective view of a golf club head in accordance with one or more embodiments of the presently disclosed technology.

[0032] FIG. 11 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0033] FIG. 12 is a cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4.

[0034] FIG. 13 is a set of cross-sectional views of golf club faces in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4.

[0035] FIG. 14 is a rear view of a golf club face in accordance with one or more embodiments of the presently disclosed technology.

[0036] FIG. 15 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14.

[0037] FIG. 16 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14.

[0038] FIG. 17 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line C-C′ of FIG. 14.

[0039] FIG. 18 is a rear view of a golf club face in accordance with one or more embodiments of the presently disclosed technology.

[0040] FIG. 19 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0041] FIG. 20 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line D-D′ of FIG. 18.

[0042] FIG. 21 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line E-E′ of FIG. 18.

[0043] FIG. 22 illustrates an example flow diagram for making a face insert in accordance with one or more embodiments of the present disclosure.

[0044] These and other features of the presently disclosed technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts, may be clearer upon consideration of the following detailed description and the claims with reference to these drawings, all of which form a part of this specification, with like reference numerals designating corresponding parts in the various figures. It is to be expressly understood that these drawings are for illustration purposes and description and are not intended to be limiting. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” may include plural referents unless the context clearly dictates otherwise.DETAILED DESCRIPTION

[0045] Existing ways to form golf club faces are generally cast or forged to form a solid face. However, the shape, volume, and / or other characteristics of many golf club faces are very limited to maintain golf club head characteristics. These existing golf club faces However, these existing methods fail to improve structural integrity and / or durability while improving CG, MOI, and / or other characteristics.

[0046] The presently disclosed technology described herein contemplates a golf club head, such as an iron, a fairway wood, a driver, or another type of golf club head, that includes a face with voids. The voids may provide mass redistribution benefits, durability benefits, structural integrity benefits, and / or other golf club performance benefits. The voids may allow for further adjustment of CG and / or MOI of the golf club head. The voids may provide for increased ball speed. The voids may also improve sound and feel. The voids may be filled with fill material, as will be discussed herein. The voids may allow for thicker or otherwise larger faces because of the mass savings created by the voids allows for additional material to have a mass of the face reach the intended weight.

[0047] Establishing a reference coordinate system for the presently disclosed technology, an x-axis may refer to the axis that is horizontal to the face from a heel-to-toe direction, a y-axis may refer to the vertical axis through the club in a crown to sole direction, a z-axis may refer to the horizontal axis that is horizontal front to back in a forward and rear direction. Alternatively speaking, the x-axis may be defined as a horizontal axis tangent to a geometric center of the face with the positive direction towards a heel of the golf club head, a y-axis is a vertical axis orthogonal to the x-axis with a positive direction towards a top of the golf club head, and a z-axis being orthogonal to both the x-axis and the y-axis with a positive direction towards a front of the golf club head. The x-y-z coordinate system described above shall be the same for all subsequent discussions. For example, the x-y-z coordinate system may be used to describe the CG of the golf club head. The golf club head may have a CG-x, a CG-y, and a CG-z component corresponding to the x-, y-, and z-coordinates discussed herein.

[0048] FIG. 1 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Golf club head 100 may include a face 102. The face 102 may include front surface (at least shown as front surface 1004 in FIG. 10), voids 106, body 108, and rear surface (at least shown as rear surface 1310 in FIG. 13). Front surface (at least shown as front surface 1004 in FIG. 10) may refer to a frontal surface of face 102. Front surface (at least shown as front surface 1004 in FIG. 10) may be the striking surface intended to impact a golf ball and may be substantially planar. In some embodiments, front surface (at least shown as front surface 1004 in FIG. 10) may have a bulge and roll. The bulge may refer to a curvature between a heel-to-toe direction of face 102, or a horizontal curvature. The roll may refer to a curvature between a bottom-to-top direction of face 102, or a vertical curvature.

[0049] Rear surface (at least shown as rear surface 1310 in FIG. 13) may be the back surface of face 102. Rear surface (at least shown as rear surface 1310 in FIG. 13) may be the opposite surface of front surface (at least shown as front surface 1004 in FIG. 10). Rear surface (at least shown as rear surface 1310 in FIG. 13) may face an interior of golf club head 100.

[0050] Between front surface (at least shown as front surface 1004 in FIG. 10) and rear surface (at least shown as rear surface 1310 in FIG. 13) may be body 108. Body 108 may be the material between these two opposing surfaces. Front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and body 108 may include, or be, the same material. For example, the material may include metal, plastic, composite, and / or other materials. The metal may include tungsten, steel, titanium, aluminum, scandium, zinc, nickel, copper, iron, alloys, and / or other metals without departing from the spirit and scope of the presently disclosed technology. The plastic may include thermosets, thermoplastics, and / or other plastics. Composites may include a variety of materials known to those skilled in the art, including for example, graphite, carbon fiber, resins, ceramics, boron fiber, polymers, foams, and so on. In some embodiments, each of front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and body 108 may include, or be, different materials.

[0051] Body 108 may include voids 106. Voids 106 may be between front surface (at least shown as front surface 1004 in FIG. 10) and rear surface (at least shown as rear surface 1310 in FIG. 13). Voids 106 may be empty regions or chambers in body 108. Voids 106 may be channels. Voids 106 may be substantially cylindrical. In some embodiments, voids 106 may be substantially spherical, though it should be appreciated that voids 106 may be differently shaped, sized, and / or dimensioned without departing from the spirit and scope of the presently disclosed technology. Voids 106 may extend out radially from a point on face 102. For example, voids 106 may extend out radially from a geometric center, a sweet spot, and / or another point on face 102. Voids 106 may be fully contained by face 102. For example, no portion of void may extend beyond front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and / or sides of face 102. In some embodiments, these voids 106 may be referred to as internal voids. The presently disclosed technology may include a diameter-to-thickness ratio. A diameter-to-thickness ratio may be defined asDiameter-To-Thickness⁢ Ratio=a⁢ diameter⁢ of⁢ one⁢ of⁢ voids⁢ 106a⁢ thickness⁢ of⁢ golf⁢ club⁢ face⁢ 102In some embodiments, the diameter used or the diameter-to-thickness ratio may be based on a smallest void, a largest void, or another void. In embodiments, void may be selected in a cross-section along a thickest portion of face 102, a thinnest portion of face 102, and / or another portion of face 102. In some embodiments, the thickness of face 102 for the diameter-to-thickness ratio may be based on a thickest portion of face 102, a thinnest portion of face 102, and / or another portion of face 102. In some embodiments, the diameter-to-thickness ratio between about 0.5 and about 1.0. In some embodiments, a total void volume may be less than about 50% of the face volume. For example, it may be less than about 15% of the total face volume, which may include the void volume and the rest of the face volume. In an example, voids 106 may be between about 700 mm3 and about 1500 mm3, and the total face volume may be between about 5500 mm3 and about 8500 mm3. This ratio may provide a lighter face which may be more responsive for users. Each individual void may have a volume between about 0.025 mm3 and about 25.0 mm3. In some embodiments, each individual void may have a volume between about 0.05 mm3 and about 8.5 mm3. For example, cylindrical voids, as discussed herein, may be about 0.5 mm to about 5.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. Spherical voids may have diameters of about 0.25 mm to about 2.5 mm.FIG. 2 is a cross-sectional view of golf club face 202 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 202 may include voids 206 and body 208. Voids 206 may be a different pattern than other voids discussed herein. Voids 206 may be substantially spherical. Voids 206 may be distributed in a symmetrical pattern around a geometric center or another point on face 202. While nine voids 206 are illustrated, it should be appreciated that there may be more or fewer without departing from the spirit and scope of the presently disclosed technology. A total void volume may be less than about 10% of the face volume.

[0053] FIG. 3 is a cross-sectional view of golf club face 302 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 302 may include voids 306 and body 308. Voids 306 may be a different pattern than other voids discussed herein. Voids 306 may be substantially spherical. Voids 306 may be distributed in an elliptical-like pattern around a point on face 302. In some embodiments, some or each of the voids 306 may be differently shaped, sized, and / or dimensioned. For example, voids 306 closer to the center of the pattern may be larger while voids 306 on the edge of the distribution pattern may be smaller. Voids 306 may be spaced apart such that they are each at least one diameter length away from adjacent voids 306. In some embodiments, voids 306 may be spaced apart from each other at least one diameter length of the smallest void 306. In embodiments, voids 306 may be spaced apart from each other at least one diameter length of the largest void 306. In embodiments, voids 306 may be spaced apart from each other less than one diameter length away from adjacent voids 306. It should be appreciated that voids 306 may be differently spaced without departing from the spirit and scope of the presently disclosed technology.

[0054] FIG. 4 is a partial cross-sectional view of golf club head 400 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 402 may include voids 406 and body 408. Voids 406 may be a different pattern than other voids discussed herein. Voids 406 may be substantially cylindrical. Voids 406 may extend across a toeward surface of face 402. For example, toeward portions of voids 406 may be exposed to outside of golf club head 400. Voids 406 may loop around at heelward portions of voids 406. For voids 406 that loop back around, an individual void 406 may have a volume between about 125.0 mm3 and about 1000.0 mm3. For example, cylindrical voids 406, as discussed herein, may be about 10.0 mm to about 200.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. In some embodiments, the cylindrical voids 406 may be between about 50.0 mm and about 100 mm across face 402 and then loop back across face 402 between about 50.0 mm and about 100 mm.

[0055] FIG. 5 is a partial cross-sectional view of golf club head 500 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 502 may include voids 506 and body 508. Voids 506 may be a different pattern than other voids discussed herein. Voids 506 may be substantially cylindrical. Voids 506 may extend across an entire heel-to-toe direction of face 502. For example, toeward portions of voids 506 may be exposed to outside of golf club head 500. Heelward portions of voids 506 may be exposed to other internal portions of golf club head 500 (e.g., toeward portion of a hosel). Face 502 may be solid from a central portion downward.

[0056] FIG. 6 is a partial cross-sectional view of golf club head 600 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 602 may include voids 606 and body 608. Voids 606 may be a different pattern than other voids discussed herein. Voids 606 may be substantially cylindrical. Voids 606 may extend across a toeward surface of face 602. For example, toeward portions of voids 606 may be exposed to outside of golf club head 600. A portion of voids 606 may extend across a top of face 602. For example, the top-most void 606 on the heel side may be exposed to outside of golf club head 600. Voids 606 on the toe-end of face 602 may loop around at heelward portions of voids 606. Voids 606 on the heel-end of face 602 may loop around at toeward portions of voids 606. A central region of face 602 may be voidless or otherwise free from voids 606. In other words, a central region of face 602 may be solid.

[0057] FIG. 7 is a partial cross-sectional view of golf club head 700 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 702 may include voids 706 and body 708. Face 702 may be the same as, or substantially similar to, face 602, except face 702 has more of a central region of face 702 that is solid. For example, a solid portion of face 702 may extend further heelward and toeward than the solid portion of face 602.

[0058] FIG. 8 is a partial cross-sectional view of golf club head 800 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 802 may include voids 806 and body 808. Voids 806 may be a different pattern than other voids discussed herein. Voids 806 may be substantially cylindrical. A first set of voids 806 along the top of face 802 may extend across a toeward surface of face 802 and a heelward surface of face 802. A second set of voids 806 along a bottom heelward section of face 802 may loop around at heelward portions of the second set of voids 806. A third set of voids 806 along a bottom toeward section of face 802 may loop around at toeward portions of the second set of voids 806. A small lower region of face 802 may be solid.

[0059] FIG. 9 is a partial cross-sectional view of golf club head 900 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 902 may include voids 906 and body 908. Face 902 may be the same as, or substantially similar to, face 802, except face 902 has less of a central region of face 902 that is solid. For example, a solid portion of face 902 may extend less downward than the solid portion of face 802. The set of voids 906 extending heel-to-toe direction across face 902 may be on an upper and lower section of face 902.

[0060] FIG. 10 is a perspective view of golf club head 1000 in accordance with one or more embodiments of the presently disclosed technology. Golf club head 1000 may include face 1002, which may include front surface 1004 and voids 1006. Voids 1006 may be exposed on a toeward side as discussed herein. In some embodiments, these exposed portions of voids 1006 may be plugged, sealed, injected, and / or covered with a material. The material may be metal, plastic, or a composite as discussed herein.

[0061] FIG. 11 is a partial cross-sectional view of golf club head 1100 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 1102 may include voids 1106 and body 1108. Voids 1106 may be a different pattern than other voids discussed herein. Voids 1106 may be substantially cylindrical. Voids 1106 may extend across the entire top-to-bottom direction of face 1102. For example, topward portions of voids 1106 may be exposed to outside of golf club head 1100. Bottomward portions of voids 1106 may be exposed to outside of golf club head 1100. It should be appreciated that based on the varied examples described herein, that the patterns, locations, shapes, number, offset, distribution, and / or other characteristics of the presently disclosed voids may vary without departing from the spirit and scope of the presently disclosed technology.

[0062] FIG. 12 is a cross-sectional view of golf club head 1200 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4. Golf club head 1200 may include face 1202, front surface 1204, voids 1206, body 1208, and rear surface 1210. Voids 1206 may be between front surface 1204 and rear surface 1210. In some embodiments, voids 1206 may be filled with a fill material (not shown). The fill material (not shown) may include metal, plastic, glass, polymer, or a composite as discussed herein. The fill material may be an artifact of the manufacturing process to form voids 1206. In some embodiments, the fill material may cause performance benefits by having different densities than the rest of face 1202 and / or golf club head 1200. Face 1202 may be similar to face 402.

[0063] FIG. 13 is a set of cross-sectional views of golf club faces 1302, 1342, and 1382 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4. Face 1302 may include front surface 1304, voids 1306, body 1308, rear surface 1310, and axis 1312. In some embodiments, voids 1306 may be centered along axis 1312. Axis 1312 may represent a midplane of face 1302, that is a geometric middle or center plane of face 1302.

[0064] Face 1342 may include front surface 1344, fill material 1347, body 1348, and / or rear surface 1350. Face 1342 may be the same as, or substantially similar to, face 1302. Fill material 1347 may include metal, plastic, glass, polymer, or a composite as discussed herein. Each of fill material 1347 may be a different material than other fill material 1347. In some embodiments, a set of fill material 1347 may be different from a second set of fill material 1347.

[0065] Face 1382 may include front surface 1384, voids 1386, body 1388, rear surface 1390, and axis 1392. Face 1382 may be the same as, or substantially similar to, face 1302 except voids 1386 are offset from axis 1392. In some embodiments, voids 1386 may be offset faceward. In embodiments, voids 1386 may be offset backward. The offset may be up to about 1.0 mm. In some embodiments, the offset may be up to about 0.1 mm. In embodiments, the offset may be about 0.05 mm. In some embodiments, In embodiments, the offset may be between about 0.025 mm to about 2.00 mm.

[0066] FIG. 14 is a rear view of golf club face 1402 in accordance with one or more embodiments of the presently disclosed technology. Face 1402 may be an initial face insert. Face 1402 may be just, or immediately, formed, casted, forged, formed, molded, additive manufactured. Face 1402 may include front surface 1404, body 1408, and / or rear surface 1410. Front surface 1404 may include first set of ribs 1414. First set of ribs 1414 may be distributed in a radial pattern extending away from a point on face 1402. As described herein, the initial face insert may include composite faces, metal faces, forged faces, cast faces, L cup face, C cup faces, and / or other types of faces without departing from the spirit and scope of the presently disclosed technology.

[0067] FIG. 15 is a cross-sectional view of golf club face 1502 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14. Face 1502 may be an initial face insert. Face 1502 may be the same as, or substantially similar to, face 1402. Face 1502 may include front surface 1504, body 1508, and rear surface 1510. Rear surface 1510 may include second set of ribs 1514. Body 1508 may extend between front surface 1504 and rear surface 1510.

[0068] FIG. 16 is a cross-sectional view of golf club face 1602 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14. Face 1602 may be an intermediate face insert. The intermediate face insert may be cooled. For example, the intermediate face insert may be formed by cooling, chilling, and / or resting the initial face insert. Face 1602 may include front surface 1604, voids 1606, body 1608, rear surface 1610, and ribs 1614. Face 1602 may be formed from face 1402 and / or face 1502. Cooling face 1402 or face 1502 may form voids 1606 in body 1608. Voids 1606 may be between the first set of ribs 1614 and the second set of ribs 1614. A height of ribs 1614, a dimension measuring perpendicularly away from face 1602, may determine a size, shape, and / or position of voids 1606 in body 1608. For example, taller ribs 1614 on front surface 1604 than ribs 1614 on rear surface 1610 may offset the position of voids 1606 more toward front surface 1604. For example, ribs 1614 may dissipate heat from body 1608 forming voids 1606. After the initial face insert is cast, ribs 1614 may act as cooling fins and cause voids 1606 in face 1602. In some embodiments, ribs 1614 may be made of a first material and rest of face 1602 may be made of a second material to change the dissipation rate of the heat from body 1608. For example, more thermally conductive materials may increase the dissipation rate while less thermally conductive materials may decrease the dissipation rate. Along this cross-section, voids 1606 may appear rectangular.

[0069] FIG. 17 is a cross-sectional view of golf club face 1702 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line C-C′ of FIG. 14. Face 1702 may be an intermediate face insert. Face 1702, including front surface 1704, voids 1706, body 1708, rear surface 1710, and ribs 1714 may be the same as, or substantially similar to, face 1602, including front surface 1604, voids 1606, body 1608, rear surface 1610, and ribs 1614. Along this cross-section, voids 1706 may appear circular.

[0070] FIG. 18 is a rear view of golf club face 1802 in accordance with one or more embodiments of the presently disclosed technology taken along line B-B′ of FIG. 14. Face 1802 may be a final face insert. The final face insert may be formed by removing the first set of ribs and the second set of ribs. In some embodiments, polishing and / or other finishing techniques may be applied to face 1802 to form the final face insert. Face 1802 may include front surface 1804, body 1808, and rear surface 1810. The final face insert may be visually indistinguishable from traditional faces.

[0071] FIG. 19 is a cross-sectional view of golf club face 1902 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 1902 may be a final face insert. Face 1902 may include voids 1906 and / or body 1908. Voids 1906 may correspond to the rib shapes, sizes, dimensions, and / or locations. For example, face 1902 may be formed from face 1402.

[0072] FIG. 20 is a cross-sectional view of golf club face 2002 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line D-D′ of FIG. 18. Face 2002 may be a final face insert. Face 2002 may include front surface 2004, voids 2006, body 2008, and / or rear surface 2010. Body 2008 may include voids 2006. Voids 2006 may be between front surface 2004 and rear surface 2010. Along this cross-section, voids 2006 may appear rectangular.

[0073] FIG. 21 is a cross-sectional view of golf club face 2102 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line E-E′ of FIG. 18. Face 2102 may be a final face insert. Face 2102, including front surface 2104, voids 2106, body 2108, and rear surface 2110 may be the same as, or substantially similar to, face 2002, including front surface 2004, voids 2006, body 2008, and rear surface 2010. Along this cross-section, voids 2106 may appear circular.

[0074] FIG. 22 illustrates an example flow diagram 2200 for making a face insert in accordance with one or more embodiments of the present disclosure. The operations of flow diagram 2200 presented below are intended to be illustrative. In some embodiments, flow diagram 2200 may be accomplished with additional operations not described and / or without one of the operations discussed. Additionally, the order in which the operations of method 2200 are illustrated in FIG. 22 and described below is not intended to be limiting.

[0075] In some embodiments, at least some operations of method 2200 may be implemented in a processing device (e.g., a physical computer processor, a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and / or other mechanisms for electronically processing information). The processing device may include a device executing some or all of the operations of method 2200 in response to instructions stored electronically on an electronic storage medium. The processing device may include a device configured through hardware, firmware, and / or software to be specifically designed for execution of operations of method 2200.

[0076] 2202 may include forming an initial face insert. Forming may include casting, forging, forming, molding, additive manufacturing, welding, brazing, polishing, bonding, and / or adhering materials into a shape to intended golf club face specification values. The initial face insert may include an initial front surface, an initial rear surface opposite the initial front surface, and an initial body extending between the initial rear front surface and the initial rear surface. In some embodiments, forming the initial face insert may include fill material such as glue, metals, plastics, and / or other materials to help form the voids discussed herein. As described herein, the initial face insert may include composite faces, metal faces, forged faces, cast faces, L cup face, C cup faces, and / or other types of faces without departing from the spirit and scope of the presently disclosed technology. 2202 may be fully or partially performed by hand or without computer and / or automated aid. In some embodiments, 2202 may be performed by a physical computer processor configured by machine-readable instructions. For example, a computer-aided manufacturing (CAM) tool may convert a design into a set of instructions for a computer numerical control (CNC) device to form the initial face insert. Any of these devices and / or tools may be configured to communicate with a system to form the initial face insert. Forming the initial face insert may include casting, forging, forming, molding, additive manufacturing, welding, brazing, polishing, bonding, adhering, and / or other manufacturing techniques used to form face inserts and / or golf club heads. The physical computer processor may be developed to form the initial face insert.

[0077] 2204 may include forming an intermediate face insert. Forming the intermediate face insert may include cooling, chilling, or otherwise forming the intermediate face insert. 2204 may be fully or partially performed by hand or without computer and / or automated aid. In some embodiments, 2204 may be performed by a physical computer processor configured by machine-readable instructions as discussed herein, including, for example, a CNC device. This may include a physical computer processor developed to remove manufacturing components, move manufacturing components, cool the initial face insert, and / or otherwise form the intermediate face insert.

[0078] 2206 may include forming a final face insert. Forming the final face insert may include removing a portion of the intermediate face insert. For example, this may be accomplished by grinding, machining, and / or otherwise removing a portion of the intermediate face insert. In some embodiments, this may include removing the ribs discussed herein. 2206 may be fully or partially performed by hand or without computer and / or automated aid. In embodiments, 2206 may be performed by a physical computer processor configured by machine-readable instructions as discussed herein, including, for example, a CNC device. This may include a physical computer processor developed to remove or otherwise form the final face insert.

[0079] Other than in at least some of the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, moment of inertias, center of gravity locations, loft, angles, various ratios, and others in the aforementioned portions of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear in the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the above specification and appended claims are approximations that may vary depending upon the desired properties sought to be obtained by the presently disclosed technology. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0080] In some examples, substantially parallel may be defined to include zero degrees, or between zero degrees and one degree, or between zero degrees and two degrees, or between zero degrees and five degrees, or between zero degrees and ten degrees of deviation from being exactly parallel to the disclosed front surface. Substantially may be defined to be a value within 10% of the identified value.

[0081] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the presently disclosed technology are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.

[0082] While various embodiments of the disclosed technology have been described above, it should be appreciated these are examples only, and not limiting. Likewise, the various figures may depict an example configuration or structure to aid in understanding the features and functionality that can be included in the disclosed technology. The presently disclosed technology is not intended to be restricted to the illustrated example configurations and structures, and the desired features can be implemented with a variety of alternative configurations and structures. It may be apparent to one of skill in the art how alternative embodiments can be implemented to impart the desired features of the presently disclosed technology. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the presently disclosed technology.

[0083] While the presently disclosed technology may be described herein in terms of various exemplary embodiments, it should be understood that the various features described in any individual embodiment is not limited to its particular embodiment, and can be applied, whether alone or in combinations with features of other embodiments, to another embodiment, whether or not such an embodiment is described herein or described as part of a single embodiment. Thus, the breadth and scope of the presently disclosed technology should not be limited to any of the above-described exemplary embodiments.

[0084] Words, phrases, and their variations that are used herein, unless otherwise expressly stated, should be construed as open ended, not as limiting. For example, the term “include” should be read to mean “include, without limitation”; the term “example” should be read to mean the following provides exemplary instances, not an exhaustive or limiting list thereof; “a” or “an” should be read as meaning “at least one,”“one or more” etc.; and “traditional,”“normal,” and similar terms should not be construed as limiting to a given time period, but should be read to encompass traditional, normal, like technologies that may be known now or at any future point; and a heel-to-toe direction should be read as meaning either the toe-to-heel direction or the heel-to-toe direction, a bottom-to-top direction should be read as meaning either the bottom-to-top direction or the top-to-bottom direction, and a back-to-front direction should be read as meaning either a back-to-front direction or a front-to-back direction. In addition, references herein to technologies that would be apparent or known to one of ordinary skill in the art includes such technologies that are apparent or known to one of ordinary skill in the art now or at any time in the future.

[0085] The presence of words and phrases such as “one or more,”“at least,”“not limited to,” or other similar phrases shall not be read to necessarily mean that the narrower case is intended in instances where such broadening phrases may be absent. The presence of words such as “first,”“second,” or other similar words shall not be read to mean that there can only be one or two elements.

Examples

Embodiment Construction

[0045]Existing ways to form golf club faces are generally cast or forged to form a solid face. However, the shape, volume, and / or other characteristics of many golf club faces are very limited to maintain golf club head characteristics. These existing golf club faces However, these existing methods fail to improve structural integrity and / or durability while improving CG, MOI, and / or other characteristics.

[0046]The presently disclosed technology described herein contemplates a golf club head, such as an iron, a fairway wood, a driver, or another type of golf club head, that includes a face with voids. The voids may provide mass redistribution benefits, durability benefits, structural integrity benefits, and / or other golf club performance benefits. The voids may allow for further adjustment of CG and / or MOI of the golf club head. The voids may provide for increased ball speed. The voids may also improve sound and feel. The voids may be filled with fill material, as will be discussed ...

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to golf club faces, and more specifically to a golf club face including voids.SUMMARY

[0002] Embodiments of the presently disclosed technology may include golf club faces. In accordance with some aspects of the presently disclosed technology, a golf club face may include a front surface to impact a golf ball, a rear surface, and a plurality of two or more voids between the front surface and the rear surface distributed in a pattern.

[0003] In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mm3 to about 8.5 mm3.

[0004] In embodiments, each of the plurality of two or more voids may be spherical.

[0005] In embodiments, the plurality of two or more voids may be distributed radially around a center of the golf club face.

[0006] In embodiments, each of the plurality of two or more voids may be cylindrical.

[0007] In embodiments, each of the plurality of two or more voids may extend across the golf club face horizontally.

[0008] In embodiments, each of the plurality of two or more voids may extend across the golf club face vertically.

[0009] In embodiments, each of the plurality of two or more voids may be separated by at least 1 diameter length from a center of adjacent ones of the plurality of two or more voids.

[0010] In embodiments, at least some of the plurality of two or more voids may have different volumes.

[0011] In embodiments, each of the plurality of two or more voids may extend radially outward from a center of the golf club face.

[0012] In embodiments, the golf club face may further include a fill material to fill each of the plurality of two or more voids.

[0013] In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane.

[0014] In embodiments, the golf club face has a diameter-to-thickness ratio between about 0.5 to about 1.0, wherein the diameter-to-thickness ratio is defined asDiameter-To-Thickness⁢ Ratio=a⁢ diameter⁢ of⁢ one⁢ of⁢ the⁢ multiple⁢ voidsa⁢ thickness⁢ of⁢ the⁢ golf⁢ club⁢ face.

[0015] In accordance with some aspects of the presently disclosed technology, a golf club head may include a face. The face may include a front surface to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include a plurality of two or more voids distributed in a pattern.

[0016] In embodiments, each of the plurality of two or more voids may have a volume of between about 0.05 mm3 to about 25.0 mm3.

[0017] In embodiments, each of the plurality of two or more voids may be spherical.

[0018] In embodiments, at least some of the plurality of two or more voids may have different volumes.

[0019] In embodiments, the plurality of two or more voids may be offset toward the front surface from a midplane between about 0.025 mm to about 2.00 mm.

[0020] In accordance with some aspects of the presently disclosed technology, a method of forming voids in a golf club face is disclosed. The method may include a number of steps. One step may include forming an initial face insert. The initial face insert may include an initial front surface. The initial front surface may include a first set of ribs. The initial face insert may include an initial rear surface opposite the initial front surface. The initial rear surface may include a second set of ribs opposite the first set of ribs. The initial face insert may include an initial body extending between the initial front surface and the initial rear surface. Another step may include cooling the initial face insert to form an intermediate face insert. This may form a plurality of two or more voids in an intermediate body between the first set of ribs and the second set of ribs.

[0021] In embodiments, another step may include removing the first set of ribs and the second set of ribs to form a final face insert. The final face insert may include a front surface intended to impact a golf ball, a rear surface opposite the front surface, and a body extending between the front surface and the rear surface. The body may include the plurality of two or more voids.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0023] FIG. 2 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0024] FIG. 3 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0025] FIG. 4 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0026] FIG. 5 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0027] FIG. 6 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0028] FIG. 7 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0029] FIG. 8 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0030] FIG. 9 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0031] FIG. 10 is a perspective view of a golf club head in accordance with one or more embodiments of the presently disclosed technology.

[0032] FIG. 11 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0033] FIG. 12 is a cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4.

[0034] FIG. 13 is a set of cross-sectional views of golf club faces in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4.

[0035] FIG. 14 is a rear view of a golf club face in accordance with one or more embodiments of the presently disclosed technology.

[0036] FIG. 15 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14.

[0037] FIG. 16 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14.

[0038] FIG. 17 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line C-C′ of FIG. 14.

[0039] FIG. 18 is a rear view of a golf club face in accordance with one or more embodiments of the presently disclosed technology.

[0040] FIG. 19 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to the front surface.

[0041] FIG. 20 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line D-D′ of FIG. 18.

[0042] FIG. 21 is a cross-sectional view of a golf club face in accordance with one or more embodiments of the presently disclosed technology taken substantially along line E-E′ of FIG. 18.

[0043] FIG. 22 illustrates an example flow diagram for making a face insert in accordance with one or more embodiments of the present disclosure.

[0044] These and other features of the presently disclosed technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts, may be clearer upon consideration of the following detailed description and the claims with reference to these drawings, all of which form a part of this specification, with like reference numerals designating corresponding parts in the various figures. It is to be expressly understood that these drawings are for illustration purposes and description and are not intended to be limiting. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” may include plural referents unless the context clearly dictates otherwise.DETAILED DESCRIPTION

[0045] Existing ways to form golf club faces are generally cast or forged to form a solid face. However, the shape, volume, and / or other characteristics of many golf club faces are very limited to maintain golf club head characteristics. These existing golf club faces However, these existing methods fail to improve structural integrity and / or durability while improving CG, MOI, and / or other characteristics.

[0046] The presently disclosed technology described herein contemplates a golf club head, such as an iron, a fairway wood, a driver, or another type of golf club head, that includes a face with voids. The voids may provide mass redistribution benefits, durability benefits, structural integrity benefits, and / or other golf club performance benefits. The voids may allow for further adjustment of CG and / or MOI of the golf club head. The voids may provide for increased ball speed. The voids may also improve sound and feel. The voids may be filled with fill material, as will be discussed herein. The voids may allow for thicker or otherwise larger faces because of the mass savings created by the voids allows for additional material to have a mass of the face reach the intended weight.

[0047] Establishing a reference coordinate system for the presently disclosed technology, an x-axis may refer to the axis that is horizontal to the face from a heel-to-toe direction, a y-axis may refer to the vertical axis through the club in a crown to sole direction, a z-axis may refer to the horizontal axis that is horizontal front to back in a forward and rear direction. Alternatively speaking, the x-axis may be defined as a horizontal axis tangent to a geometric center of the face with the positive direction towards a heel of the golf club head, a y-axis is a vertical axis orthogonal to the x-axis with a positive direction towards a top of the golf club head, and a z-axis being orthogonal to both the x-axis and the y-axis with a positive direction towards a front of the golf club head. The x-y-z coordinate system described above shall be the same for all subsequent discussions. For example, the x-y-z coordinate system may be used to describe the CG of the golf club head. The golf club head may have a CG-x, a CG-y, and a CG-z component corresponding to the x-, y-, and z-coordinates discussed herein.

[0048] FIG. 1 is a partial cross-sectional view of a golf club head in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Golf club head 100 may include a face 102. The face 102 may include front surface (at least shown as front surface 1004 in FIG. 10), voids 106, body 108, and rear surface (at least shown as rear surface 1310 in FIG. 13). Front surface (at least shown as front surface 1004 in FIG. 10) may refer to a frontal surface of face 102. Front surface (at least shown as front surface 1004 in FIG. 10) may be the striking surface intended to impact a golf ball and may be substantially planar. In some embodiments, front surface (at least shown as front surface 1004 in FIG. 10) may have a bulge and roll. The bulge may refer to a curvature between a heel-to-toe direction of face 102, or a horizontal curvature. The roll may refer to a curvature between a bottom-to-top direction of face 102, or a vertical curvature.

[0049] Rear surface (at least shown as rear surface 1310 in FIG. 13) may be the back surface of face 102. Rear surface (at least shown as rear surface 1310 in FIG. 13) may be the opposite surface of front surface (at least shown as front surface 1004 in FIG. 10). Rear surface (at least shown as rear surface 1310 in FIG. 13) may face an interior of golf club head 100.

[0050] Between front surface (at least shown as front surface 1004 in FIG. 10) and rear surface (at least shown as rear surface 1310 in FIG. 13) may be body 108. Body 108 may be the material between these two opposing surfaces. Front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and body 108 may include, or be, the same material. For example, the material may include metal, plastic, composite, and / or other materials. The metal may include tungsten, steel, titanium, aluminum, scandium, zinc, nickel, copper, iron, alloys, and / or other metals without departing from the spirit and scope of the presently disclosed technology. The plastic may include thermosets, thermoplastics, and / or other plastics. Composites may include a variety of materials known to those skilled in the art, including for example, graphite, carbon fiber, resins, ceramics, boron fiber, polymers, foams, and so on. In some embodiments, each of front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and body 108 may include, or be, different materials.

[0051] Body 108 may include voids 106. Voids 106 may be between front surface (at least shown as front surface 1004 in FIG. 10) and rear surface (at least shown as rear surface 1310 in FIG. 13). Voids 106 may be empty regions or chambers in body 108. Voids 106 may be channels. Voids 106 may be substantially cylindrical. In some embodiments, voids 106 may be substantially spherical, though it should be appreciated that voids 106 may be differently shaped, sized, and / or dimensioned without departing from the spirit and scope of the presently disclosed technology. Voids 106 may extend out radially from a point on face 102. For example, voids 106 may extend out radially from a geometric center, a sweet spot, and / or another point on face 102. Voids 106 may be fully contained by face 102. For example, no portion of void may extend beyond front surface (at least shown as front surface 1004 in FIG. 10), rear surface (at least shown as rear surface 1310 in FIG. 13), and / or sides of face 102. In some embodiments, these voids 106 may be referred to as internal voids. The presently disclosed technology may include a diameter-to-thickness ratio. A diameter-to-thickness ratio may be defined asDiameter-To-Thickness⁢ Ratio=a⁢ diameter⁢ of⁢ one⁢ of⁢ voids⁢ 106a⁢ thickness⁢ of⁢ golf⁢ club⁢ face⁢ 102In some embodiments, the diameter used or the diameter-to-thickness ratio may be based on a smallest void, a largest void, or another void. In embodiments, void may be selected in a cross-section along a thickest portion of face 102, a thinnest portion of face 102, and / or another portion of face 102. In some embodiments, the thickness of face 102 for the diameter-to-thickness ratio may be based on a thickest portion of face 102, a thinnest portion of face 102, and / or another portion of face 102. In some embodiments, the diameter-to-thickness ratio between about 0.5 and about 1.0. In some embodiments, a total void volume may be less than about 50% of the face volume. For example, it may be less than about 15% of the total face volume, which may include the void volume and the rest of the face volume. In an example, voids 106 may be between about 700 mm3 and about 1500 mm3, and the total face volume may be between about 5500 mm3 and about 8500 mm3. This ratio may provide a lighter face which may be more responsive for users. Each individual void may have a volume between about 0.025 mm3 and about 25.0 mm3. In some embodiments, each individual void may have a volume between about 0.05 mm3 and about 8.5 mm3. For example, cylindrical voids, as discussed herein, may be about 0.5 mm to about 5.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. Spherical voids may have diameters of about 0.25 mm to about 2.5 mm.FIG. 2 is a cross-sectional view of golf club face 202 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 202 may include voids 206 and body 208. Voids 206 may be a different pattern than other voids discussed herein. Voids 206 may be substantially spherical. Voids 206 may be distributed in a symmetrical pattern around a geometric center or another point on face 202. While nine voids 206 are illustrated, it should be appreciated that there may be more or fewer without departing from the spirit and scope of the presently disclosed technology. A total void volume may be less than about 10% of the face volume.

[0053] FIG. 3 is a cross-sectional view of golf club face 302 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 302 may include voids 306 and body 308. Voids 306 may be a different pattern than other voids discussed herein. Voids 306 may be substantially spherical. Voids 306 may be distributed in an elliptical-like pattern around a point on face 302. In some embodiments, some or each of the voids 306 may be differently shaped, sized, and / or dimensioned. For example, voids 306 closer to the center of the pattern may be larger while voids 306 on the edge of the distribution pattern may be smaller. Voids 306 may be spaced apart such that they are each at least one diameter length away from adjacent voids 306. In some embodiments, voids 306 may be spaced apart from each other at least one diameter length of the smallest void 306. In embodiments, voids 306 may be spaced apart from each other at least one diameter length of the largest void 306. In embodiments, voids 306 may be spaced apart from each other less than one diameter length away from adjacent voids 306. It should be appreciated that voids 306 may be differently spaced without departing from the spirit and scope of the presently disclosed technology.

[0054] FIG. 4 is a partial cross-sectional view of golf club head 400 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 402 may include voids 406 and body 408. Voids 406 may be a different pattern than other voids discussed herein. Voids 406 may be substantially cylindrical. Voids 406 may extend across a toeward surface of face 402. For example, toeward portions of voids 406 may be exposed to outside of golf club head 400. Voids 406 may loop around at heelward portions of voids 406. For voids 406 that loop back around, an individual void 406 may have a volume between about 125.0 mm3 and about 1000.0 mm3. For example, cylindrical voids 406, as discussed herein, may be about 10.0 mm to about 200.0 mm in length and have a diameter of about 0.25 mm to about 2.5 mm. In some embodiments, the cylindrical voids 406 may be between about 50.0 mm and about 100 mm across face 402 and then loop back across face 402 between about 50.0 mm and about 100 mm.

[0055] FIG. 5 is a partial cross-sectional view of golf club head 500 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 502 may include voids 506 and body 508. Voids 506 may be a different pattern than other voids discussed herein. Voids 506 may be substantially cylindrical. Voids 506 may extend across an entire heel-to-toe direction of face 502. For example, toeward portions of voids 506 may be exposed to outside of golf club head 500. Heelward portions of voids 506 may be exposed to other internal portions of golf club head 500 (e.g., toeward portion of a hosel). Face 502 may be solid from a central portion downward.

[0056] FIG. 6 is a partial cross-sectional view of golf club head 600 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 602 may include voids 606 and body 608. Voids 606 may be a different pattern than other voids discussed herein. Voids 606 may be substantially cylindrical. Voids 606 may extend across a toeward surface of face 602. For example, toeward portions of voids 606 may be exposed to outside of golf club head 600. A portion of voids 606 may extend across a top of face 602. For example, the top-most void 606 on the heel side may be exposed to outside of golf club head 600. Voids 606 on the toe-end of face 602 may loop around at heelward portions of voids 606. Voids 606 on the heel-end of face 602 may loop around at toeward portions of voids 606. A central region of face 602 may be voidless or otherwise free from voids 606. In other words, a central region of face 602 may be solid.

[0057] FIG. 7 is a partial cross-sectional view of golf club head 700 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 702 may include voids 706 and body 708. Face 702 may be the same as, or substantially similar to, face 602, except face 702 has more of a central region of face 702 that is solid. For example, a solid portion of face 702 may extend further heelward and toeward than the solid portion of face 602.

[0058] FIG. 8 is a partial cross-sectional view of golf club head 800 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 802 may include voids 806 and body 808. Voids 806 may be a different pattern than other voids discussed herein. Voids 806 may be substantially cylindrical. A first set of voids 806 along the top of face 802 may extend across a toeward surface of face 802 and a heelward surface of face 802. A second set of voids 806 along a bottom heelward section of face 802 may loop around at heelward portions of the second set of voids 806. A third set of voids 806 along a bottom toeward section of face 802 may loop around at toeward portions of the second set of voids 806. A small lower region of face 802 may be solid.

[0059] FIG. 9 is a partial cross-sectional view of golf club head 900 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 902 may include voids 906 and body 908. Face 902 may be the same as, or substantially similar to, face 802, except face 902 has less of a central region of face 902 that is solid. For example, a solid portion of face 902 may extend less downward than the solid portion of face 802. The set of voids 906 extending heel-to-toe direction across face 902 may be on an upper and lower section of face 902.

[0060] FIG. 10 is a perspective view of golf club head 1000 in accordance with one or more embodiments of the presently disclosed technology. Golf club head 1000 may include face 1002, which may include front surface 1004 and voids 1006. Voids 1006 may be exposed on a toeward side as discussed herein. In some embodiments, these exposed portions of voids 1006 may be plugged, sealed, injected, and / or covered with a material. The material may be metal, plastic, or a composite as discussed herein.

[0061] FIG. 11 is a partial cross-sectional view of golf club head 1100 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 1102 may include voids 1106 and body 1108. Voids 1106 may be a different pattern than other voids discussed herein. Voids 1106 may be substantially cylindrical. Voids 1106 may extend across the entire top-to-bottom direction of face 1102. For example, topward portions of voids 1106 may be exposed to outside of golf club head 1100. Bottomward portions of voids 1106 may be exposed to outside of golf club head 1100. It should be appreciated that based on the varied examples described herein, that the patterns, locations, shapes, number, offset, distribution, and / or other characteristics of the presently disclosed voids may vary without departing from the spirit and scope of the presently disclosed technology.

[0062] FIG. 12 is a cross-sectional view of golf club head 1200 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4. Golf club head 1200 may include face 1202, front surface 1204, voids 1206, body 1208, and rear surface 1210. Voids 1206 may be between front surface 1204 and rear surface 1210. In some embodiments, voids 1206 may be filled with a fill material (not shown). The fill material (not shown) may include metal, plastic, glass, polymer, or a composite as discussed herein. The fill material may be an artifact of the manufacturing process to form voids 1206. In some embodiments, the fill material may cause performance benefits by having different densities than the rest of face 1202 and / or golf club head 1200. Face 1202 may be similar to face 402.

[0063] FIG. 13 is a set of cross-sectional views of golf club faces 1302, 1342, and 1382 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line A-A′ of FIG. 4. Face 1302 may include front surface 1304, voids 1306, body 1308, rear surface 1310, and axis 1312. In some embodiments, voids 1306 may be centered along axis 1312. Axis 1312 may represent a midplane of face 1302, that is a geometric middle or center plane of face 1302.

[0064] Face 1342 may include front surface 1344, fill material 1347, body 1348, and / or rear surface 1350. Face 1342 may be the same as, or substantially similar to, face 1302. Fill material 1347 may include metal, plastic, glass, polymer, or a composite as discussed herein. Each of fill material 1347 may be a different material than other fill material 1347. In some embodiments, a set of fill material 1347 may be different from a second set of fill material 1347.

[0065] Face 1382 may include front surface 1384, voids 1386, body 1388, rear surface 1390, and axis 1392. Face 1382 may be the same as, or substantially similar to, face 1302 except voids 1386 are offset from axis 1392. In some embodiments, voids 1386 may be offset faceward. In embodiments, voids 1386 may be offset backward. The offset may be up to about 1.0 mm. In some embodiments, the offset may be up to about 0.1 mm. In embodiments, the offset may be about 0.05 mm. In some embodiments, In embodiments, the offset may be between about 0.025 mm to about 2.00 mm.

[0066] FIG. 14 is a rear view of golf club face 1402 in accordance with one or more embodiments of the presently disclosed technology. Face 1402 may be an initial face insert. Face 1402 may be just, or immediately, formed, casted, forged, formed, molded, additive manufactured. Face 1402 may include front surface 1404, body 1408, and / or rear surface 1410. Front surface 1404 may include first set of ribs 1414. First set of ribs 1414 may be distributed in a radial pattern extending away from a point on face 1402. As described herein, the initial face insert may include composite faces, metal faces, forged faces, cast faces, L cup face, C cup faces, and / or other types of faces without departing from the spirit and scope of the presently disclosed technology.

[0067] FIG. 15 is a cross-sectional view of golf club face 1502 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14. Face 1502 may be an initial face insert. Face 1502 may be the same as, or substantially similar to, face 1402. Face 1502 may include front surface 1504, body 1508, and rear surface 1510. Rear surface 1510 may include second set of ribs 1514. Body 1508 may extend between front surface 1504 and rear surface 1510.

[0068] FIG. 16 is a cross-sectional view of golf club face 1602 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line B-B′ of FIG. 14. Face 1602 may be an intermediate face insert. The intermediate face insert may be cooled. For example, the intermediate face insert may be formed by cooling, chilling, and / or resting the initial face insert. Face 1602 may include front surface 1604, voids 1606, body 1608, rear surface 1610, and ribs 1614. Face 1602 may be formed from face 1402 and / or face 1502. Cooling face 1402 or face 1502 may form voids 1606 in body 1608. Voids 1606 may be between the first set of ribs 1614 and the second set of ribs 1614. A height of ribs 1614, a dimension measuring perpendicularly away from face 1602, may determine a size, shape, and / or position of voids 1606 in body 1608. For example, taller ribs 1614 on front surface 1604 than ribs 1614 on rear surface 1610 may offset the position of voids 1606 more toward front surface 1604. For example, ribs 1614 may dissipate heat from body 1608 forming voids 1606. After the initial face insert is cast, ribs 1614 may act as cooling fins and cause voids 1606 in face 1602. In some embodiments, ribs 1614 may be made of a first material and rest of face 1602 may be made of a second material to change the dissipation rate of the heat from body 1608. For example, more thermally conductive materials may increase the dissipation rate while less thermally conductive materials may decrease the dissipation rate. Along this cross-section, voids 1606 may appear rectangular.

[0069] FIG. 17 is a cross-sectional view of golf club face 1702 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line C-C′ of FIG. 14. Face 1702 may be an intermediate face insert. Face 1702, including front surface 1704, voids 1706, body 1708, rear surface 1710, and ribs 1714 may be the same as, or substantially similar to, face 1602, including front surface 1604, voids 1606, body 1608, rear surface 1610, and ribs 1614. Along this cross-section, voids 1706 may appear circular.

[0070] FIG. 18 is a rear view of golf club face 1802 in accordance with one or more embodiments of the presently disclosed technology taken along line B-B′ of FIG. 14. Face 1802 may be a final face insert. The final face insert may be formed by removing the first set of ribs and the second set of ribs. In some embodiments, polishing and / or other finishing techniques may be applied to face 1802 to form the final face insert. Face 1802 may include front surface 1804, body 1808, and rear surface 1810. The final face insert may be visually indistinguishable from traditional faces.

[0071] FIG. 19 is a cross-sectional view of golf club face 1902 in accordance with one or more embodiments of the presently disclosed technology taken substantially along a midplane parallel to front surface (at least shown as front surface 1004 in FIG. 10). Face 1902 may be a final face insert. Face 1902 may include voids 1906 and / or body 1908. Voids 1906 may correspond to the rib shapes, sizes, dimensions, and / or locations. For example, face 1902 may be formed from face 1402.

[0072] FIG. 20 is a cross-sectional view of golf club face 2002 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line D-D′ of FIG. 18. Face 2002 may be a final face insert. Face 2002 may include front surface 2004, voids 2006, body 2008, and / or rear surface 2010. Body 2008 may include voids 2006. Voids 2006 may be between front surface 2004 and rear surface 2010. Along this cross-section, voids 2006 may appear rectangular.

[0073] FIG. 21 is a cross-sectional view of golf club face 2102 in accordance with one or more embodiments of the presently disclosed technology taken substantially along line E-E′ of FIG. 18. Face 2102 may be a final face insert. Face 2102, including front surface 2104, voids 2106, body 2108, and rear surface 2110 may be the same as, or substantially similar to, face 2002, including front surface 2004, voids 2006, body 2008, and rear surface 2010. Along this cross-section, voids 2106 may appear circular.

[0074] FIG. 22 illustrates an example flow diagram 2200 for making a face insert in accordance with one or more embodiments of the present disclosure. The operations of flow diagram 2200 presented below are intended to be illustrative. In some embodiments, flow diagram 2200 may be accomplished with additional operations not described and / or without one of the operations discussed. Additionally, the order in which the operations of method 2200 are illustrated in FIG. 22 and described below is not intended to be limiting.

[0075] In some embodiments, at least some operations of method 2200 may be implemented in a processing device (e.g., a physical computer processor, a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and / or other mechanisms for electronically processing information). The processing device may include a device executing some or all of the operations of method 2200 in response to instructions stored electronically on an electronic storage medium. The processing device may include a device configured through hardware, firmware, and / or software to be specifically designed for execution of operations of method 2200.

[0076] 2202 may include forming an initial face insert. Forming may include casting, forging, forming, molding, additive manufacturing, welding, brazing, polishing, bonding, and / or adhering materials into a shape to intended golf club face specification values. The initial face insert may include an initial front surface, an initial rear surface opposite the initial front surface, and an initial body extending between the initial rear front surface and the initial rear surface. In some embodiments, forming the initial face insert may include fill material such as glue, metals, plastics, and / or other materials to help form the voids discussed herein. As described herein, the initial face insert may include composite faces, metal faces, forged faces, cast faces, L cup face, C cup faces, and / or other types of faces without departing from the spirit and scope of the presently disclosed technology. 2202 may be fully or partially performed by hand or without computer and / or automated aid. In some embodiments, 2202 may be performed by a physical computer processor configured by machine-readable instructions. For example, a computer-aided manufacturing (CAM) tool may convert a design into a set of instructions for a computer numerical control (CNC) device to form the initial face insert. Any of these devices and / or tools may be configured to communicate with a system to form the initial face insert. Forming the initial face insert may include casting, forging, forming, molding, additive manufacturing, welding, brazing, polishing, bonding, adhering, and / or other manufacturing techniques used to form face inserts and / or golf club heads. The physical computer processor may be developed to form the initial face insert.

[0077] 2204 may include forming an intermediate face insert. Forming the intermediate face insert may include cooling, chilling, or otherwise forming the intermediate face insert. 2204 may be fully or partially performed by hand or without computer and / or automated aid. In some embodiments, 2204 may be performed by a physical computer processor configured by machine-readable instructions as discussed herein, including, for example, a CNC device. This may include a physical computer processor developed to remove manufacturing components, move manufacturing components, cool the initial face insert, and / or otherwise form the intermediate face insert.

[0078] 2206 may include forming a final face insert. Forming the final face insert may include removing a portion of the intermediate face insert. For example, this may be accomplished by grinding, machining, and / or otherwise removing a portion of the intermediate face insert. In some embodiments, this may include removing the ribs discussed herein. 2206 may be fully or partially performed by hand or without computer and / or automated aid. In embodiments, 2206 may be performed by a physical computer processor configured by machine-readable instructions as discussed herein, including, for example, a CNC device. This may include a physical computer processor developed to remove or otherwise form the final face insert.

[0079] Other than in at least some of the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, moment of inertias, center of gravity locations, loft, angles, various ratios, and others in the aforementioned portions of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear in the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the above specification and appended claims are approximations that may vary depending upon the desired properties sought to be obtained by the presently disclosed technology. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0080] In some examples, substantially parallel may be defined to include zero degrees, or between zero degrees and one degree, or between zero degrees and two degrees, or between zero degrees and five degrees, or between zero degrees and ten degrees of deviation from being exactly parallel to the disclosed front surface. Substantially may be defined to be a value within 10% of the identified value.

[0081] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the presently disclosed technology are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.

[0082] While various embodiments of the disclosed technology have been described above, it should be appreciated these are examples only, and not limiting. Likewise, the various figures may depict an example configuration or structure to aid in understanding the features and functionality that can be included in the disclosed technology. The presently disclosed technology is not intended to be restricted to the illustrated example configurations and structures, and the desired features can be implemented with a variety of alternative configurations and structures. It may be apparent to one of skill in the art how alternative embodiments can be implemented to impart the desired features of the presently disclosed technology. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the presently disclosed technology.

[0083] While the presently disclosed technology may be described herein in terms of various exemplary embodiments, it should be understood that the various features described in any individual embodiment is not limited to its particular embodiment, and can be applied, whether alone or in combinations with features of other embodiments, to another embodiment, whether or not such an embodiment is described herein or described as part of a single embodiment. Thus, the breadth and scope of the presently disclosed technology should not be limited to any of the above-described exemplary embodiments.

[0084] Words, phrases, and their variations that are used herein, unless otherwise expressly stated, should be construed as open ended, not as limiting. For example, the term “include” should be read to mean “include, without limitation”; the term “example” should be read to mean the following provides exemplary instances, not an exhaustive or limiting list thereof; “a” or “an” should be read as meaning “at least one,”“one or more” etc.; and “traditional,”“normal,” and similar terms should not be construed as limiting to a given time period, but should be read to encompass traditional, normal, like technologies that may be known now or at any future point; and a heel-to-toe direction should be read as meaning either the toe-to-heel direction or the heel-to-toe direction, a bottom-to-top direction should be read as meaning either the bottom-to-top direction or the top-to-bottom direction, and a back-to-front direction should be read as meaning either a back-to-front direction or a front-to-back direction. In addition, references herein to technologies that would be apparent or known to one of ordinary skill in the art includes such technologies that are apparent or known to one of ordinary skill in the art now or at any time in the future.

[0085] The presence of words and phrases such as “one or more,”“at least,”“not limited to,” or other similar phrases shall not be read to necessarily mean that the narrower case is intended in instances where such broadening phrases may be absent. The presence of words such as “first,”“second,” or other similar words shall not be read to mean that there can only be one or two elements.

Examples

Embodiment Construction

[0045]Existing ways to form golf club faces are generally cast or forged to form a solid face. However, the shape, volume, and / or other characteristics of many golf club faces are very limited to maintain golf club head characteristics. These existing golf club faces However, these existing methods fail to improve structural integrity and / or durability while improving CG, MOI, and / or other characteristics.

[0046]The presently disclosed technology described herein contemplates a golf club head, such as an iron, a fairway wood, a driver, or another type of golf club head, that includes a face with voids. The voids may provide mass redistribution benefits, durability benefits, structural integrity benefits, and / or other golf club performance benefits. The voids may allow for further adjustment of CG and / or MOI of the golf club head. The voids may provide for increased ball speed. The voids may also improve sound and feel. The voids may be filled with fill material, as will be discussed ...

Claims

1. A golf club face comprising:a front surface to impact a golf ball;a rear surface; anda plurality of two or more voids between the front surface and the rear surface distributed in a pattern.

2. The golf club face of claim 1, wherein each of the plurality of two or more voids have a volume of between about 0.05 mm3 to about 8.5 mm3.

3. The golf club face of claim 1, wherein each of the plurality of two or more voids are spherical.

4. The golf club face of claim 1, wherein the plurality of two or more voids are distributed radially around a center of the golf club face.

5. The golf club face of claim 1, wherein each of the plurality of two or more voids are cylindrical.

6. The golf club face of claim 5, wherein each of the plurality of two or more voids extend across the golf club face horizontally.

7. The golf club face of claim 5, wherein each of the plurality of two or more voids extend across the golf club face vertically.

8. The golf club face of claim 3, wherein each of the plurality of two or more voids are spaced apart by at least 1 diameter length from a center of adjacent ones of the plurality of two or more voids.

9. The golf club face of claim 1, wherein at least some of the plurality of two or more voids have different volumes.

10. The golf club face of claim 1, wherein each of the plurality of two or more voids extend radially outward from a center of the golf club face.

11. The golf club face of claim 1, wherein the golf club face further comprises a fill material to fill each of the plurality of two or more voids.

12. The golf club face of claim 1, wherein the plurality of two or more voids are offset toward the front surface from a midplane.

13. The golf club face of claim 1, wherein the golf club face has a diameter-to-thickness ratio between about 0.5 to about 1.0, wherein the diameter-to-thickness ratio is defined asDiameter-To-Thickness⁢ Ratio=a⁢ diameter⁢ of⁢ one⁢ of⁢ the⁢ multiple⁢ voidsa⁢ thickness⁢ of⁢ the⁢ golf⁢ club⁢ face.

14. A golf club head comprising:a face, wherein the face comprises:a front surface to impact a golf ball;a rear surface opposite the front surface; anda body extending between the front surface and the rear surface, wherein the body comprises a plurality of two or more voids distributed in a pattern.

15. The golf club head of claim 14, wherein each of the plurality of two or more voids have a volume of between about 0.05 mm3 to about 25.0 mm3.

16. The golf club head of claim 14, wherein each of the plurality of two or more voids are spherical.

17. The golf club head of claim 14, wherein at least some of the plurality of two or more voids have different volumes.

18. The golf club head of claim 14, wherein the plurality of two or more voids are offset toward the front surface from a midplane between about 0.025 mm to about 2.00 mm.

19. A method of forming voids in a golf club face, the method comprising:forming an initial face insert, wherein the initial face insert comprises:an initial front surface, wherein the initial front surface comprises a first set of ribs;an initial rear surface opposite the initial front surface, wherein the initial rear surface comprises a second set of ribs opposite the first set of ribs; andan initial body extending between the initial front surface and the initial rear surface; andcooling the initial face insert to form an intermediate face insert thereby forming a plurality of two or more voids in an intermediate body between the first set of ribs and the second set of ribs.

20. The method of claim 19, further comprising removing the first set of ribs and the second set of ribs to form a final face insert, wherein the final face insert comprises:a front surface intended to impact a golf ball;a rear surface opposite the front surface; anda body extending between the front surface and the rear surface, wherein the body comprises the plurality of two or more voids.

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