Golf club head with a multi-material face cup

Abstract

A golf club head having a face cup made of multiple materials attached to an aft body. More specifically, the face cup has a composite inner core which improves mass properties in the golf club head. The face cup also has a metallic outer cover which improves abrasion resistance, durability, surface finishing, and bonding techniques.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to a new and improved golf club head having a multi-material face cup for improved weight distribution, durability, surface finishing, and bonding techniques.BACKGROUND OF THE INVENTION

[0002] With the development of the modern day oversized metalwoods, the performance capabilities of these types of golf clubs have increased dramatically over their predecessor, “the persimmon wood”. One of the ways these metalwood type golf clubs have been performing better than their predecessors is in the increase in overall distance, generally attributed to the inherent elastic deformation of thin metallic metal materials used by these metalwoods. Another way the metalwood type golf clubs have been outperforming their predecessors is in the increase in overall forgiveness of the golf club head, generally attributed to the increase in the moment of inertia of the golf club head itself. The moment of inertia refers to the ability of the golf club head to resist undesirable twisting upon impact with a golf ball, as such a twisting movement will generally change the face angle of the golf club head away from the intended target line, sending the golf ball away from the intended target.

[0003] More recently, various metalwoods have utilized composite materials in forming components of the golf club head. However, composite materials have several drawbacks from metallic materials including being susceptible to abrasion, having lower durability, being more vulnerable under high temperatures, and being more difficult to apply certain cosmetic features.

[0004] Hence, it can be seen from the above there is a need for a golf club head design that improves upon the shortcomings of previous golf club head designs that utilize composite materials, particularly around the striking face.BRIEF SUMMARY OF THE INVENTION

[0005] In some aspects, the techniques described herein relate to a golf club head including: a striking face configured to contact a golf ball; a crown; a sole opposite the crown; a skirt between the crown and the sole; a toe portion; a heel portion opposite the toe portion; and a hosel at the heel portion configured to connect to a shaft, wherein a forward portion of the golf club head defines a face cup and a rearward portion of the golf club head defines an aft body, wherein the aft body is located rearward of the face cup and is bonded to the face cup to form an interior cavity within the golf club head, wherein the hosel is connected to the face cup, wherein the face cup includes the striking face, a front portion of the crown, a front portion of the sole, a front portion of the skirt, a front portion of the toe portion, and a front portion of the heel portion, and wherein the face cup includes an inner core and an outer cover located exterior of the inner core.

[0006] In some aspects, the techniques described herein relate to a golf club head including: a striking face configured to contact a golf ball; a crown; a sole opposite the crown; a skirt between the crown and the sole; a toe portion; a heel portion opposite the toe portion; and a hosel at the heel portion configured to connect to a shaft, wherein a forward portion of the golf club head defines a face cup and a rearward portion of the golf club head defines an aft body, wherein the aft body is located rearward of the face cup and is bonded to the face cup to form an interior cavity within the golf club head, wherein the hosel is connected to the face cup, wherein the face cup includes the striking face, a front portion of the crown, a front portion of the sole, a front portion of the skirt, a front portion of the toe portion, and a front portion of the heel portion, wherein the face cup includes an inner core and an outer cover located exterior of the inner core, wherein the inner core and the outer cover are made of different materials, and wherein the outer cover spans over the striking face, the front portion of the crown, the front portion of the sole, the front portion of the skirt, the front portion of the toe portion, and the front portion of the heel portion.

[0007] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other features and advantages of the invention will be apparent from the following description of the invention as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

[0009] FIG. 1 of the accompanying drawings shows an exploded perspective view of a golf club head in accordance with an exemplary embodiment of the present invention; and

[0010] FIG. 2 of the accompanying drawings shows a cross-sectional view of the golf club head of FIG. 1.DETAILED DESCRIPTION OF THE INVENTION

[0011] The following detailed description describes the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

[0012] FIG. 1 of the accompanying drawings shows an exploded perspective view of a golf club head 100 in accordance with an embodiment of the present invention. As shown in FIG. 1, the golf club head 100 includes a striking face 103 configured to contact a golf ball, a crown 105, a sole 107 opposite the crown 105, a skirt 109 between the crown 105 and the sole 107, a toe portion 111, a heel portion 113 opposite the toe portion 111, and a hosel 115 at the heel portion 113 adapted to connect to a shaft (not shown). The golf club head 100 is further defined by a face cup 120 at a forward portion of the golf club head 100 and an aft body 130 located rearward of the face cup 120, wherein the hosel 115 is connected to the face cup 120. The face cup 120 is bonded to the aft body 130 to form an interior cavity 140 within the golf club head 100. The face cup 120 includes the striking face 103, a front portion of the crown 105, a front portion of the sole 107, a front portion of the skirt 109, a front portion of the toe portion 111, and a front portion of the heel portion 113. A crown transition 122 is defined between the striking face 103 and the front portion of the crown 105. A leading edge 124 is defined between the striking face 103 and the front portion of the sole 107.

[0013] FIG. 2 of the accompanying drawings shows a cross-sectional view of the golf club head 100 through a vertical plane extending through a face center of the striking face 103. As shown in FIG. 2, the face cup 120 comprises an inner core 126 and an outer cover 128. The outer cover 128 may cover an entirety of an outer surface of the inner core 126. The inner core 126 is made of a composite material which is either thermoplastic or thermoset. This allows for weight savings over an entirely metal face cup which permits discretionary mass to be placed elsewhere in the golf club head 100 to manipulate center of gravity location and moment of inertia properties. The outer cover 128 is made of titanium, steel, or aluminum. The outer cover 128 provides abrasion resistance for the inner core 126 over the striking face 103, leading edge 124, and front portion of the sole 107 which are most prone to impacts during a golf swing. The outer cover 128 increases durability of the face cup 120 which is particularly critical over the crown transition 122 and the leading edge 124 which are higher stress areas because of their shaper curves. A further benefit of the outer cover 128 being metallic is in adding surface texture and / or cosmetic decoration to the striking face 103 which is more difficult to do on a composite surface. The outer cover 128 can withstand high temperatures required for coating or paint application that may be too high for epoxy or other polymers in a composite material. The inner core 126 has a thickness between 2.5 mm and 6.0 mm, most preferably between 3.5 mm and 4.5 mm. The outer cover 128 has a thickness between 0.1 mm and 1.5 mm, most preferably between 0.2 mm and 0.4 mm. The outer cover 128 also provides increased characteristic time and / or coefficient of restitution performance for the golf club head 100.

[0014] In one embodiment of the present invention, the outer cover 128 is forged or stamped into shape. The outer cover 128 may be used as a mold for forming the inner core 126 which would help ensure proper fitting between the two components. Pre-preg plies of composite material may be positioned within the outer cover 128 and cured in place to form the inner core 126. Alternatively, a flowable thermoplastic or thermoset material may be inserted within the outer cover 128 and cured in place to form the inner core 126. In another embodiment, the inner core 126 may be formed independently of the outer cover 128 then bonded to the outer cover 128. The outer cover 128 may go through a finishing process such as plating, painting, laser etching, or other decorative and / or protective surface treatment prior to being bonded to the inner core 126 to prevent the finishing process from degrading the bond between the inner core 126 and the outer cover 128.

[0015] Other than in the operating example, 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, draft angles, various performance 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 attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. 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.

[0016] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention 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.

[0017] It should be understood, of course, that the foregoing relates to exemplary embodiments of the present invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. A golf club head comprising:a striking face configured to contact a golf ball;a crown;a sole opposite said crown;a skirt between said crown and said sole;a toe portion;a heel portion opposite said toe portion; anda hosel at said heel portion configured to connect to a shaft,wherein a forward portion of said golf club head defines a face cup and a rearward portion of said golf club head defines an aft body,wherein said aft body is located rearward of said face cup and is bonded to said face cup to form an interior cavity within said golf club head,wherein said hosel is connected to said face cup,wherein said face cup includes said striking face, a front portion of said crown, a front portion of said sole, a front portion of said skirt, a front portion of said toe portion, and a front portion of said heel portion, andwherein said face cup comprises an inner core and an outer cover located exterior of said inner core.

2. The golf club head of claim 1, wherein said inner core and said outer cover are made of different materials.

3. The golf club head of claim 1, wherein said inner core is made of composite material and said outer cover is made of metal.

4. The golf club head of claim 3, wherein said outer cover is made of titanium, steel, or aluminum.

5. The golf club head of claim 4, wherein said inner core has a thickness between 2.5 mm and 6.0 mm.

6. The golf club head of claim 5, wherein said inner core has a thickness between 3.5 mm and 4.5 mm.

7. The golf club head of claim 4, wherein said outer cover has a thickness between 0.1 mm and 1.5 mm.

8. The golf club head of claim 7, wherein said outer cover has a thickness between 0.2 mm and 0.4 mm.

9. The golf club head of claim 4, wherein said outer cover covers an entirety of an outer surface of said inner core.

10. The golf club head of claim 4, wherein said inner core is cured within said outer cover.

11. A golf club head comprising:a striking face configured to contact a golf ball;a crown;a sole opposite said crown;a skirt between said crown and said sole;a toe portion;a heel portion opposite said toe portion; anda hosel at said heel portion configured to connect to a shaft,wherein a forward portion of said golf club head defines a face cup and a rearward portion of said golf club head defines an aft body,wherein said aft body is located rearward of said face cup and is bonded to said face cup to form an interior cavity within said golf club head,wherein said hosel is connected to said face cup,wherein said face cup includes said striking face, a front portion of said crown, a front portion of said sole, a front portion of said skirt, a front portion of said toe portion, and a front portion of said heel portion,wherein said face cup comprises an inner core and an outer cover located exterior of said inner core,wherein said inner core and said outer cover are made of different materials, andwherein said outer cover spans over said striking face, said front portion of said crown, said front portion of said sole, said front portion of said skirt, said front portion of said toe portion, and said front portion of said heel portion.

12. The golf club head of claim 11, wherein said inner core forms an interior portion of said striking face, said front portion of said crown, said front portion of said sole, said front portion of said skirt, said front portion of said toe portion, and said front portion of said heel portion.

13. The golf club head of claim 12, wherein said inner core is made of composite material and said outer cover is made of metal.

14. The golf club head of claim 13, wherein said outer cover is made of titanium.

15. The golf club head of claim 14, wherein said inner core has a thickness between 2.5 mm and 6.0 mm.

16. The golf club head of claim 15, wherein said inner core has a thickness between 3.5 mm and 4.5 mm.

17. The golf club head of claim 14, wherein said outer cover has a thickness between 0.1 mm and 1.5 mm.

18. The golf club head of claim 17, wherein said outer cover has a thickness between 0.2 mm and 0.4 mm.

19. The golf club head of claim 18, wherein said inner core is cured within said outer cover.

20. The golf club head of claim 18, wherein said inner core is bonded to said outer cover,wherein said outer cover undergoes a surface treatment prior to being bonded to said inner core, andwherein said inner core is cured prior to being bonded to said outer cover.

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