Golf club head with improved striking face

Abstract

A golf club head with an improved striking face is disclosed herein. More specifically, the present invention utilizes an innovative die quenching method that can alter the Young's modulus of the material of the striking face. The striking face portion of the present invention generally created from an α+β titanium alloy such as SP 700 that contains a β rich alloy composition to create more phase change in the alloying elements. In a preferred embodiment, the die quenching process could create a localized change in the material's Young's modulus throughout different regions of the striking face, resulting in a change in the Young's modulus of the material within the same striking face.

Description

FIELD OF THE INVENTION

The present invention relates generally to a golf club head with an improved striking face. More specifically, the present invention relates to a striking face of a golf club head manufactured utilizing an innovative quenching method that alters the Young's modulus of the material. The striking face portion in accordance with the present invention is generally created from a beta rich, near beta α+β titanium alloy such as SP 700 that will yield a reduced Young's modulus of the material to improve the performance of the striking face. The present invention could even create a change in the Young's modulus of the striking face while maintain the same alloy to further improve the performance of the striking face.

BACKGROUND OF THE INVENTION

In order to improve the performance of a golf club, club designers are constantly struggling to achieve a golf club with higher performance. One of the recent trends in improving golf club performance has been focused on improving the striking face of a metalwood golf club head.

The striking face of a metalwood golf club head is one of the most important component of a golf club head, as it is the only part that comes in contact with the golf ball. In order to maximize the performance of a golf club head, golf club designers have experimented with variables such as improving the coefficient of restitution (COR) as well as increasing the size of the “sweet zone”. The “sweet zone”, as generally known in the golf industry, relates to the zone of substantially uniform high initial velocity or a high COR. These concepts of “sweet zone” and COR have already been discussed by U.S. Pat. No. 6,605,007 to Bissonnette et al., and the disclosure of which is hereby incorporated by reference in its entirety.

One of the ways to create a larger “sweet zone” is illustrated in U.S. Pat. No. 8,318,300 to Schmitt et al., wherein a frontal wall of the striking face has a variable thickness. More specifically, U.S. Pat. No. 8,318,300 discussed how a golf club having a variable thickness will resist cracking bucking, and to efficiently transmit impact forces to the head top wall.

U.S. Pat. No. 7,682,262 to Soracco et al. expands upon the above basic concept of a variable face thickness by going on to establish the concept of “flexural stiffness”, wherein different flexural stiffness in the striking face can be achieved by different materials, different thicknesses, or a combination of both different material and different thicknesses.

Despite all of the advances in attempting to improve the performance of the striking face of the golf club head, none of the references are capable of adjusting the performance of the striking face without varying the material or thickness, both of which have some minor drawbacks. Varying the material of the striking face would require a bonding process to occur at the striking face portion, which could potentially crack when subjected to the high impact forced with a golf ball. Varying the thickness of the striking face, although eliminates the problem with cracking, would require additional mass at the striking face portion by thickening up certain parts of the striking face.

More importantly, none of the prior art recognize the ability to alter the Young's modulus of the same material used for the striking face portion to improve upon the performance of the golf club head.

Hence, based on the above it can be seen, there exists a need for an ability to alter the performance of a striking face of a golf club head that takes advantage of the inherent material property of the material by altering its Young's modulus. More specifically, there is a need in the field for a striking face of a golf club head wherein the Young's modulus of the striking face could be changed independent or in combination with the adjustment in altering the thickness.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention is a golf club head comprising of a striking face portion and an aft portion attached to the rear of the striking face portion. The striking face portion is made out of an α-β titanium having a Molybdenum Equivalency between 4.0 and 9.75 and wherein at least a portion of the striking face portion has a Young's modulus of less than about 90 GPa.

In another aspect of the present invention is a method of manufacturing a golf club head comprising the step of heating a striking face portion that is made of an α-β titanium alloy to a temperature that is 25-100° C. below a β-transus temperature of a material used to make said striking face portion and subsequently quenching the striking face portion using a die via conduction by maintaining the die in direct contact with the striking face portion for greater than about 15 seconds. The resulting face insert portion will comprise of at least one phase that is a body centered cubic β structure and where at least a portion of the striking face portion has a Young's modulus of less than about 90 GPa.

These and other features, aspects and advantages of the present invention will become better understood with references to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

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.

FIG. 1 shows a perspective view of a golf club head in accordance with the present invention;

FIG. 2 shows a frontal view of a golf club head in accordance with the present invention, allowing cross-sectional line A-A′ to be shown;

FIG. 3a shows a perspective view of prior art face insert;

FIG. 3b shows a cross-sectional view of the prior art face insert shown in FIG. 3a;

FIG. 3d shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 3b;

FIG. 3c shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 3b;

FIG. 4a shows a perspective view of a different prior art face insert;

FIG. 4b shows a cross-sectional view of the prior art face insert shown in FIG. 4a;

FIG. 4c shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 4;

FIG. 4d shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 4b;

FIG. 5a shows a perspective view of a face insert with a die in accordance with an exemplary embodiment of the present invention;

FIG. 5b shows a cross-sectional view of the face insert shown in FIG. 5a;

FIG. 5c shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 5b;

FIG. 5d shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 5b;

FIG. 6a shows α phase diagram of a titanium alloy used for the face insert in accordance with an exemplary embodiment of the present invention;

FIG. 6b shows the crystalline structure of the titanium alloy used for the face insert in accordance with an exemplary embodiment of the present invention;

FIG. 7a shows a perspective view of a face cup with a die in accordance with an exemplary embodiment of the present invention;

FIG. 7b shows a cross-sectional view of the face cup shown in FIG. 7a;

FIG. 7c shows the Young's modulus profile of the prior art face cup across the cross-sectional area shown in FIG. 7b;

FIG. 7d shows the Flexural Stiffness profile of the prior art face cup across cross-sectional area shown in FIG. 7b;

FIG. 8a shows a perspective view of a face insert with a die in accordance with an exemplary embodiment of the present invention;

FIG. 8b shows a cross-sectional view of the face insert shown in FIG. 8a;

FIG. 8c shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 8b;

FIG. 8d shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 8b;

FIG. 9a shows a perspective view of a face insert with a die in accordance with an exemplary embodiment of the present invention;

FIG. 9b shows a cross-sectional view of the face insert shown in FIG. 9a;

FIG. 9c shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 9b;

FIG. 9d shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 9b;

FIG. 10a shows a perspective view of a face insert with a die in accordance with an exemplary embodiment of the present invention;

FIG. 10b shows a cross-sectional view of the face insert shown in FIG. 10a;

FIG. 10c shows the Young's modulus profile of the prior art face insert across the cross-sectional area shown in FIG. 10b;

FIG. 10d shows the Flexural Stiffness profile of the prior art face insert across cross-sectional area shown in FIG. 10b;

FIG. 11a shows a perspective view of a face cup with a die in accordance with an alternative embodiment of the present invention;

FIG. 11b shows a cross-sectional view of the face cup shown in FIG. 11a;

FIG. 11c shows the Young's modulus profile of the prior art face cup across the cross-sectional area shown in FIG. 11b; and

FIG. 11d shows the Flexural Stiffness profile of the prior art face cup across cross-sectional area shown in FIG. 11b.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of 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.

Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any or all of the problems discussed above or may only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below.

FIG. 1 of the accompanying drawings shows a perspective view of a golf club head 100 in accordance with the present invention. The golf club head 100 may generally have a body 102 portion and a striking face 104 portion, wherein the striking face 104 may further comprise of a face insert 106. The face insert 106 of the golf club head 100 may generally have a variable Young's modulus changing radially from the center 108 of the striking face 104. In an alternative embodiment of the present invention, the striking face 104 may utilize a face cup construction instead of a face insert 106 while still maintaining a variable Young's modulus that changes radially from the center 108 of the striking face.

The face insert 106 of the striking face 104, as discussed in this exemplary embodiment, may generally be comprised of a β rich α+β titanium material such as SP-700. A β rich titanium material is preferred because the change in Young's modulus of the face insert 106 contemplated by the present invention is achieved through the phase changes of the titanium between α and β phases via a heat treatment and quenching process. More information regarding the preferred material of SP-700 can be found in JFE's technical report titled Advantages of High Formability SP 700 Titanium Alloy and Its Applications (March 2005), the disclosure of which is incorporated by reference in its entirety. However, there are numerous other alloys that could potentially exhibit such a behavior which can generally be described as being near β titanium alloys. The nomenclature of titanium alloys as α or β is based on which phase is predominantly present in the alloy at room temperature. As can be expected an α titanium alloy has predominantly α phase present at room temperature. Conversely, a β alloy has predominantly β phase present at room temperature. And a α-β alloy has both phases present in significant quantities. It should be pointed out that for most titanium alloys of importance, β phase is not the equilibrium phase at room temperature as per the thermodynamic principles; it is in fact α phase. The reason β phase remains at room temperature is because the transformation of β to α is suppressed due to rapid cooling or quenching. Certain elements such as Mo, V, Cr, Fe, Ni, Co, Mn, Nb, Ta and W tend to stabilize the β phase and therefore alloying of titanium with such elements allows the alloy to be cooled slowly while still retaining β phase. When a titanium alloy containing significant amount of β phase is heated to elevated temperature, the β phase transforms into the equilibrium α phase. Thus the β phase in most titanium alloys is considered as metastable. It is possible to alloy the titanium to such an extent, that the β phase becomes the equilibrium phase and such an alloy cannot be heated to elevated temperature to transform into α. Alloys belonging to this category are not part of this invention. The discussion above relating to the transformation and stability of β phase can be described by a parameter called “Molybdenum Equivalency” summarized by Eq. (1) belowMo-Eq=% Mo+0.2% Ta+0.28% Nb+0.4% W+0.67% V+1.25% Cr+1.25% Ni+1.7% Mn+1.7% Co+2.5% Fe  Eq. (1)where % indicates the weight percent of that element in the alloy.

A Mo-Eq greater than about 10 is considered necessary for retaining all the β phase at room temperature. A titanium alloy is considered near β alloy when the Mo-Eq. is close to 10 but not more than 10, although a clear definition of near β titanium alloy is not available, for the purpose of this discussion, a Mo-Eq of greater than about 10 can be considered a β rich alloy. For this invention it is speculated that alloys having Mo-Eq in the range 4-9.5 are suitable for die quenching to obtain the low Young's modulus discussed above. It should be pointed out that Young's modulus will depend on the alloying element and not strictly on the Mo-Eq. For example, it is possible to achieve a Mo-Eq. of 9 by alloying titanium with 9 wt % of Mo or 3.6 wt % of Fe. The resulting Young's modulus however is not the same for both alloys.

The Young's modulus of the face insert 106 that changes radially from the center may not does not require the Young's modulus of the face insert 106 to be different at each and every section that shifts away from the center 108 of the striking face 104. Rather, the radial change in Young's modulus, as referred to by the present invention, could alternatively be described as a mere change of the Young's modulus of the face insert 106 at different locations. The face insert 106, as described in the present embodiment, may generally be comprised of a single alloy such as SP-700 Titanium as described above, however, other alloys capable of α and β phase transformation may also be used without departing from the scope and content of the present invention.

FIG. 2 of the accompanying drawings shows a frontal view of a golf club head 200 in accordance with the present invention, allowing cross-sectional line A-A′ to be shown. FIG. 2, in addition to showing the striking face 204 with a face insert 206, also show a central zone 201, an intermediate zone 203, and an outer zone 205. The location and size of the central zone 201, the intermediate zone 203, and outer zone 205 shown here in FIG. 2 are not critical and are not drawn to scale. The illustration here serves the purpose of illustrating the relationship of the zones relative to one another, as the zones will be referred to later with respect to the varying Young's modulus of the striking face 204.

In order to understand the need for a striking face 204 of a golf club head to have a varying Young's modulus that changes radially from the central zone 201, the intermediate zone 203, and the outer zone 205, a brief background discussion regarding the development of prior art striking face of a golf club may be beneficial. FIGS. 3a, 3b, 3c, and 3d of the accompanying drawings does that by showing a prior art face insert 306 together with its Young's modulus and Flexural Stiffness (FS) profiles across a horizontal cross-section. FIG. 3a of the accompanying drawings shows a perspective view of a face insert 306 in accordance with a prior art golf club head with a constant thickness across the entire face insert 306. FIG. 3b shows a cross-sectional view of a face insert 306 taken horizontally from a heel to toe direction of the striking face 204 passing through the face center 208 as illustrated by cross-sectional line A-A′ shown in FIG. 2. As previously mentioned, the thickness of the face insert 306 in this prior art embodiment may generally have a constant thickness d1 of about 2.5 mm. Because it is desirable for the face insert 306 of a striking face to be flexible to increase the coefficient of restitution upon impact with a golf ball, it is generally desirable to have a face with a low Young's modulus with a high tensile strength paired with a low yield strength. FIG. 3c shows the Young's modulus of this prior art face insert 306 being constant at approximately 110 GPa across the entire width of the face insert 306. Finally, FIG. 3d of the accompanying drawing shows a graph of the Flexural Stiffness of the face insert 306 across the cross-section shown in FIG. 3b. The concept of flexural stiffness is defined by the following formula as shown by Eq. (2):FS=E*t³  Eq. (2)where,

• • E=Young's modulus of material, and
  • t=thickness of the material.The concept of determining the Flexural Stiffness of a striking face of a golf club has been discussed in commonly owned U.S. Pat. No. 6,605,007 to Bissonnette et al., the disclosure of which is incorporated by reference in its entirety.

Before the discussion moves away from the Young's modulus of a material, it is worthwhile to note here that the Young's modulus of a material such as a striking face of a golf club head may generally be measured using a non-destructive ultrasonic test equipment, as the Young's modulus of a material is related to its Poisson's Ratio, which is a function of the longitudinal and shear wave sound velocity. Numerous devices such as the Olympus Thickness Gauges 38DL Plus, 45MG with Single Element Software, or Model 35 DL can all be used. Alternatively, Olympus Flaw Detectors with velocity measurement capabilities such as the EPOCH series instruments or even Olympus Pulse/Receivers such as Model 5072PR or 5077PR can all be used without departing from the scope and content of the present invention.

Here, given that the Young's modulus of the face insert 306 is approximately 110 GPa and the thickness d1 of the face insert is about 2.5 mm, the Flexural Stiffness of this prior art face insert stay constant at approximately 1,700 kN-mm.

One factor useful to determine the ability of the face insert 306 to improve the coefficient of restitution over a greater area is to calculate the Flexural Stiffness Ratio of a the face insert 306, wherein the Flexural Stiffness Ratio is defined as follows by Eq. (3):

$\begin{array}{cc}\mathrm{Flexural}\mathrm{Stiffness}\mathrm{Ratio}=\frac{\mathrm{Peak}\mathrm{Flexural}\mathrm{Stiffness}}{\mathrm{Trough}\mathrm{Flexural}\mathrm{Stiffness}}& \left(\mathrm{Eq}.3\right)\end{array}$ Here, in this prior art embodiment, the Flexural Stiffness Ratio is 1, as the Flexural Stiffness of the entire prior art face insert 306 stays constant across the entire cross-section.

FIG. 4a through 4d of the accompanying drawings shows a different prior art face insert 406 intended to improve upon the prior art face insert 306 shown in FIG. 3, by creating a face insert 406 with a variable Flexural Stiffness. This prior art face insert 406 achieves this change in Flexural Stiffness by utilizing the commonly known technique of varying the thickness of the face insert 406. In FIG. 4b, the cross-sectional view of the face insert 406 is taken horizontally across the striking face, as indicated by cross-sectional line A-A′ shown in FIG. 2 is shown to more fully illustrate the change in thickness of the face insert 406. Here, the face insert 406 is thicker at the central zone and thinner around the intermediate and outer zones. More specifically, the outer zone may have a first thickness d1 of approximately 2.5 mm, while the central zone may have a second thickness d2 of approximately 3.5 mm. FIG. 4c shows that this prior art face insert 406 has a constant Young's modulus of approximately 110 GPa across the entire cross-section, yielding a Flexural Stiffness profile shown in FIG. 4d. The Flexural Stiffness profile of the variable thickness face insert 406 shown in FIG. 4d may have a Flexural Stiffness of approximately 1,700 kN-mm at the outer zones and gradually increasing to a Flexural Stiffness of about 4,700 kN-mm at the central zone, before tapering back to a Flexural Stiffness of approximately 1,700 kN-mm at the other outer zone. It is worth noting that in this exemplary embodiment, the change in the Flexural Stiffness of the prior art face insert 406 is achieved by changing the thickness “t” while keeping the Young's modulus of the material constant.

This prior art face insert 406, by incorporating a variable face thickness, has a Flexural Stiffness Ratio of 2.75, indicative of the fact that the central zone 401 is approximately 2.75 more compliant than the outer zone 405, as the peak Flexural Stiffness and the trough Flexural Stiffness occur at the central zone 401 and outer zone 405 respectively.

FIG. 5a through 5d shows a face insert 506 in accordance with an exemplary embodiment of the present invention with a die 510 used to help rapidly quench and cool the face insert 506 to promote the phase transformation of the face insert 506 discussed above. Although the conventional quenching process of a face insert 506 may generally be convection cooling with air, the current embodiment utilizes conduction cooling by placing the die 510 in direct contact with the face insert 506 to achieve the rapid quenching required. The phase transformation of this particular titanium material serves to retain the β phase titanium post heat treatment, which alter the Young's modulus of the material. In the exemplary embodiment, a face insert 506 of a golf club head's striking face is generally heat treated by first bring the temperature of the face insert above a β transus temperature and selectively quenching all or just a portion of the face insert 506 to preserve the β titanium body-centered cubic crystalline structure. The result of the present inventive methodology allows α phase change in the titanium material, thus lowering the Young's modulus of the material.

In one preferred embodiment, the SP-700 titanium face insert 506 may generally be heated 50 C below the β transus temperature to about 845° C. for a time period of 6 minutes. Subsequent to the heating phase, the die 510 is introduced to the face insert 506 for a duration of greater than approximately 5 seconds, more preferably greater than about 10 seconds, most preferably greater than about 15 seconds. This die 510 may generally have an internal geometry the mirrors the ultimate geometry of the face insert 506, as the die 510 can also help form the geometry of the face insert 506 by applying pressure to the face insert 506 similar to that of a forging process. In this exemplary embodiment of the present invention, the temperature of the die 510 is not controlled, however, in a more precise embodiment; the temperature of the die 510 could be maintained at a desired temperature without departing from the scope and content of the present invention. For example, in an alternative embodiment of the present invention, the face insert 506 could be heated up to the previously discussed temperature of about 845° C., then quenched by a die 510 that is maintained at a temperature of less than about 250° C., more preferably less than about 200° C., and most preferably less than about 150° C. without departing from the scope and content of the present invention.

The die 510 shown in this exemplary embodiment of the present invention may generally be created from a carbon steel type material with a bulk conductivity of approximately 16 W/mK to allow heat of the face insert 506 to be conducted away to the die 510. However, numerous other materials such as iron with a bulk conductivity of approximately 55 W/mK, Zinc with a bulk conductivity of approximately 112 W/mK, aluminum with a bulk conductivity of approximately 167 W/mK, copper with a bulk conductivity of approximately 388 W/mK, or even silver with a bulk conductivity of approximately 418 W/mK all without departing from the scope and content of the present invention. In fact. The material of the die 510 may generally have a bulk conductivity of greater than about 10 W/mK, more preferably greater than about 15 W/mK, and most preferably greater than about 20 w/mK.

FIG. 5b shows a cross-sectional view of the current inventive face insert 506. As it can be seen, the cross-sectional view of the face insert 506 does not differ very much from the prior art face insert 406 shown in FIG. 5b, as the thickness' are very similar with d1 being approximately 2.5 mm and d2 being approximately 3.5 mm. However, a closer examination of the Young's modulus of the face insert 506 shown in FIG. 5c and the Flexural Stiffness shown in FIG. 5d clearly shows that the present invention differs from the prior art. More specifically, FIG. 5c shows that due to the heat treatment discussed above, the Young's modulus of the face insert 506 has decreased significantly from about 110 GPa to less than about 90 GPa, more preferably less than about 85 GPa, and most preferably less than about 80 GPa. The effect of this reduced Young's modulus creates a Flexural Modulus that is less than about 3,900 kN-mm at the central zone and less than about 1,500 kN-mm at the outer zone, more preferably less than about 3,650 kN-mm at the central zone and less than about 1350 kN-mm at the outer zone, and most preferably less than 3,450 kN-mm at the central zone and less than about 1250 kN-mm at the outer zone as shown in FIG. 5d.

Here, in this current exemplary embodiment of the present invention, the face insert 506 may generally have a Flexural Stiffness Ratio of greater than about 2.60, more preferably greater than about 2.65, and most preferably greater than about 2.70, all without departing from the scope and content of the present invention. Notice here that the peak Flexural Stiffness occurs at the central zone 501 and the trough Flexural Stiffness occurs at the outer zone 505.

In order to provide a clearer explanation of the interaction between α and β phases within a Titanium alloy, FIGS. 6a and 6b are provided. FIG. 6a is an equilibrium phase diagram of the current titanium alloy illustrating relationship of the α and β phases as a function of temperature and composition. As it can be seen in FIG. 6a, an α-β titanium alloy may generally have more Hexagonal Close Packed (HCP) α phase at a lower temperature. As the alloy is heated, upon reaching the α-solvus temperature, the α phase starts to transform to β phase. At the β-transus temperature all the α phase has been transformed to β. FIG. 6b provides a closer graphical representation of the difference between a β phase BCC structure and an α phase HCP structure, giving a visual representation of the crystalline structure. As can be seen from FIG. 6a, that at any temperature between α-solvus and β-transus, the alloy will be a mixture of α and β phases. The relative amounts of the phases is determined by the composition and temperature of the alloy; higher the temperature more the amount of β. Experimentally it has been found that quenching from α+β phase field is better than quenching from above the β-transus. The Young's modulus in both the cases is very similar. Thus there is no advantage to quenching from above the β-transus temperature.

FIGS. 7a through 7d shows an alternative embodiment of the present invention wherein a face cup 706 is shown instead of a face insert 506 (shown in FIG. 5a). In this embodiment, the die 710 is used in the same way as previously discussed to cool the face cup 706 to create the change in Young's modulus that was previously discussed. Using the same method described above, the face cup 706 may achieve the same Young's modulus and Flexural Stiffness as a previously discussed. More specifically, FIG. 7b shows a cross-sectional view of the face cup 706 having a similar thickness at the ball striking region with d1 being approximately 2.5 mm and d2 being approximately 3.5 mm. Notice here in FIG. 7c, the Young's modulus of the face cup 706 has decreased dramatically to approximately less than about 90 GPa, more preferably less than about 85 GPa, and most preferably less than about 80 GPa. The effect of this reduced Young's modulus creates a Flexural Stiffness that is less than about 3,900 kN-mm at the central zone and less than about 1,500 kN-mm at the outer zone, more preferably less than about 3,650 kN-mm at the central zone and less than about 1350 kN-mm at the outer zone, and most preferably less than 3,450 kN-mm at the central zone and less than about 1250 kN-mm at the outer zone as shown in FIG. 7d.

Similar to the face insert 506 shown in FIG. 5, the face cup 706 may generally have a Flexural Stiffness Ratio of greater than about 2.60, more preferably greater than about 2.65, and most preferably greater than about 2.70, all without departing from the scope and content of the present invention.

FIG. 8a through 8d shows an alternative embodiment of the present invention wherein the die 810 may have an opening 812 to further manipulate the desired Flexural Stiffness of a face insert 806. Here, the opening 812 will allow the central portion 801 to maintain a high Flexural Stiffness while the intermediate zone 803 and the outer zone 805 may have a lower Flexural Stiffness due to the reduction in Young's modulus from the die quenching process. In order to illustrate this effect, FIGS. 8b through 8d are provided below. FIG. 8b, illustrates that the face insert 806 maintains a very similar geometry than all of the previous embodiments, however, a closer examination of the Young's modulus profile of the face insert 806 shows a dramatically different story, with a variable Young's modulus across the cross-section. More specifically, the central portion 801 may generally have a Young's modulus of greater than about 110 GPa, while the intermediate and outer zones 803 and 805 may generally have a lower Young's modulus of less than about 90 GPa, more preferably less than about 85 GPa, and most preferably less than about 80 GPa. The effect of this Young's modulus profile will yield a Flexural Stiffness of greater than about 4700 kN-mm at the central zone, and a Flexural Stiffness of less than about 1400 kN-mm, more preferably less than about 1350 kN-mm, and most preferably less than about 1250 kN-mm.

In this current exemplary embodiment, the maximum change in Young's modulus is greater than about 20 GPa, more preferably greater than about 25 GPa, and most preferably greater than about 30 GPa. Additionally, in this current embodiment, the Flexural Stiffness takes advantage of both the change in Young's modulus of the face insert 806 as well as the change in thickness, to create a Flexural Stiffness Ratio of greater than about 3.30, more preferably greater than about 3.50, most preferably greater than about 4.0.

FIG. 9a through 9d show a further alternative embodiment of the present invention, wherein a die 910 may have an opening 912 similar to the prior embodiment, but the boundaries of the die 910 do not extend to the boarders of the face insert 906, forming a circular doughnut shape. This particular doughnut shaped die can be used on a face insert 906 without a variable thickness to simulate the effect that increases ball speed across a greater portion of the face. In order to understand this embodiment, FIG. 9b show a cross-sectional view of the face insert 906 having a constant thickness d1 throughout. In one embodiment, the thickness d1 may generally be about 2.5 mm. FIG. 9c shows the effect of this alternative die 910 on the Young's modulus of the face insert 906, which yields a lower Young's modulus of about 70 GPa at portions wherein the die 910 comes into contact with the face insert 906 while maintaining a Young's modulus of about 110 GPa at portions wherein the conductive heat transfer did not take place. Finally, as shown in FIG. 9d, the Flexural Stiffness of this alternative embodiment at its peak near the central zone and the outer zone at approximately 1700 kN-mm while the intermediate zone has a Flexural Stiffness of less than about 1250 kN-mm.

Ultimately, the face insert 906 in accordance with this embodiment of the present invention may generally have a Flexural Stiffness Ratio of about 1.36. Notice in this embodiment, the peak Flexural Stiffness occurs at the center of the golf club, while the trough Flexural Stiffness occurs near an intermediate zone.

FIG. 10a through 10d of the accompanying drawings show an even further alternative embodiment of the present invention wherein a doughnut shaped die 1010 having an opening 1012 can be used in combination with a face insert 1006 that has a variable thickness. Having seen the cross-section of the face insert 1006 shown in FIG. 10b, the Young's modulus of a this face insert 1006 may generally change from about 70 GPa at portions where the die 1010 comes in contact with the face insert 1006 and about 110 GPa at portions wherein the conductive heat transfer did not take place as shown in FIG. 10c. Similarly, FIG. 10d shows the Flexural Stiffness of the face insert 1006 across the cross-section, having a peak Flexural Stiffness of about 4700 kN-mm and a trough Flexural Stiffness of about 1200 kN-mm, yielding a Flexural Stiffness Ratio of about 4.0.

FIGS. 11a through 11d of the accompanying drawings show an alternative embodiment of the present invention, wherein a face cup 1106 utilizes a top die 1110 and a bottom die 1120 to create an alternative Young's modulus profile. The top die 1110, as shown in the embodiment, may generally be ring shaped, allowing the Young's modulus of the perimeter of the face cup 1106 to be adjusted. Additionally, the bottom die 1120 utilizes a cup type geometry with an opening in the center to concentrate the quenching process near the perimeter of the face cup 1106. The resultant face cup, as it can be seen by the cross-sectional diagram in FIG. 11b, may look similar to previous face cup designs in terms of thickness, but will have a dramatically different Young's modulus profile as observed in FIG. 11c. More specifically, the perimeter of the face cup 1106 may have a Young's modulus of less than about 70 GPa, while the center of the face cup will maintain a Young's modulus of greater than about 110 GPa. Finally, FIG. 11d shows the Flexural Stiffness of the face cup 1106, indicates that the extreme perimeter of the face cup 1106 will generally have a Flexural Stiffness of less than about 1200 kN-mm, while the intermediate portion will generally have a Flexural Stiffness of less than about 1800 kN-mm, and the central portion having a Flexural Stiffness of greater than about 4700 kN-mm, yielding a Flexural Stiffness Ratio of about 4.0.

Although all of the proceeding discussion relates to the incorporation of the die quenching process on the striking face of a golf ball, the same process could be applied to different portions of the golf club head such as the crown, the sole, the hosel, or even the skirt all without departing from the scope and content of the present invention. Additionally, the same die quenching process discussed above is not limited to a metalwood type golf club, but could extend to cover iron type golf clubs as well without departing from the scope and content of the present invention.

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 aforementioned 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.

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.

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 portion made out of one unitary material; andan aft portion, attached to a rear of said striking face portion;wherein said striking face portion is made out of an α-β titanium having a Molybdenum Equivalency between 4.0 and 9.75, andwherein at least a portion of said striking face portion has a Young's modulus of less than about 90 GPa, andwherein said striking face portion has a variable Young's modulus of said unitary material across at least one cross-sectional area, independent of material thickness.

2. The golf club head of claim 1, wherein said Young's modulus of said striking face portion is less than about 85 GPa.

3. The golf club head of claim 2, wherein said Young's modulus of said striking face portion is less than about 80 GPa.

4. The golf club head of claim 1, wherein said striking face portion has a variable Young's modulus across at least one cross-sectional area.

5. The golf club head of claim 1, wherein said striking face portion has a striking face with a maximum change in Young's modulus of greater than about 20 GPa.

6. The golf club head of claim 5, wherein said striking face portion has a striking face with a maximum change in Young's modulus of greater than about 25 GPa.

7. The golf club head of claim 6, wherein said striking face portion has a striking face with a maximum change in Young's modulus of greater than about 30 GPa.

8. The golf club head of claim 1, wherein said striking face portion has a Flexural Stiffness Ratio of greater than about 2.6, said Flexural Stiffness Ratio defined as a peak Flexural Stiffness of said striking face portion divided by a trough Flexural Stiffness of said striking face.

9. The golf club head of claim 8, wherein said striking face portion has a Flexural Stiffness Ratio of greater than about 2.65.

10. The golf club head of claim 9, wherein said striking face portion has a Flexural Stiffness Ratio of greater than about 4.0.