Golf club head

Abstract

A golf club head includes a center of gravity spaced less than 5 mm from a vertical center plane that is perpendicular to a striking face plane and extends through a striking face center. The golf club head also includes a first component having a first melting point and a first density and a second component having a second melting point higher than the first melting point and a second density less than the first density. And the second component (i) is at least partially encapsulated by the first component, (ii) extends into a hosel portion below a hosel bore, and (iii) has a mass less than about 5 g.

Description

BACKGROUND

This disclosure relates generally to the field of golf clubs. More particularly, it relates to a golf club head with an insert in at least the hosel portion of the club head.

A goal of golf club head design is to align the club head's center of gravity with the location on the striking face most likely to come into contact with the golf ball during a swing. This increases shot accuracy and helps ensure that as much energy as possible from the golfer's swing is transferred to the golf ball at impact, thereby resulting in a favorable golf shot.

SUMMARY

But this goal can often be difficult to achieve within the constraints of a given mass budget. This is especially true in connection with “player” iron-type golf club heads, in which the center of gravity of the club head is naturally biased toward the heel side from face center due to the shaping and weight of the heel and hosel portions. Golfers who use these club heads also often enjoy their more traditional look, and these golfers may thus object to changes designed to beneficially alter the weight profile of the club head but that also cause the club head to diverge from this traditional look. For example, perimeter weighting may be added to an iron or wedge-type golf club head to increase its moments of inertia and thereby add “forgiveness” on off-center hits, but the appearance of such a cavity-back club head can be off-putting for players who prefer the appearance of blade-type irons and wedges. A need thus exists for a design that discretely moves weight from one portion of the club head to another so as to move the center of gravity closer to where the golf ball is likely to be struck, most likely the face center of the club head, while also providing forgiveness on off-center hits.

A golf club head according to one or more aspects of the present disclosure thus includes, when oriented in a reference position, a striking face having a face center and defining a face plane; a vertical center plane that is perpendicular to the face plane and extends through the face center; a sole portion; a top portion; a heel portion; a toe portion opposite the heel portion; a hosel portion extending from the heel portion and comprising a hosel bore with an open end for receiving a shaft and a bottom surface, the hosel bore defining a central hosel axis; and a center of gravity spaced less than 5 mm from the vertical center plane. The golf club head may also include a first component of a first material having a first melting point and a first density and a second component having a second melting point higher than the first melting point and a second density less than the first density, the second component (i) being at least partially encapsulated by the first component, (ii) extending into the hosel portion below the hosel bore, and (iii) having a mass less than about 5 g.

A method of manufacturing a golf club head in accordance with one or more aspects of the present disclosure may in turn include steps of: (a) forming an auxiliary component with an auxiliary material; (b) encapsulating, by an investment casting process, the auxiliary component within a golf club head body comprising a primary material; and (c) removing a portion of the auxiliary component to create a hosel bore with an open end and a bottom surface such that an uppermost extent of the auxiliary component is below the bottom surface. The primary material may have a first melting point and a first density, and the auxiliary material may have a second melting point greater than the first melting point and a second density less than the first density. And the golf club head may further include: a striking face having a face center and defining a face plane; a vertical center plane substantially perpendicular to the face plane and passing through the face center; and a center of gravity located less than 5 mm from the vertical center plane.

And another golf club head according to one or more aspects of the present disclosure may include a golf club head main body and an auxiliary component. The golf club head main body may in turn include a striking face having a face center and defining a face plane; a vertical center plane that is perpendicular to the face plane and extends through the face center; a sole portion; a top portion; a heel portion; a toe portion opposite the heel portion; a hosel extending from the heel portion and comprising a hosel bore with an open end and a bottom surface, the hosel bore defining a central hosel axis; and a first material having a first melting point and a first density. The auxiliary component may in turn include a heel portion comprising a second material having a second melting point higher than the first melting point and a second density less than the first density; an upper extent located below the bottom surface of the hosel bore; and a toe portion connected to the heel portion and comprising a third material having a density greater than the first density. And a center of gravity of this golf club head may be located less than 5 mm from the vertical center plane.

These and other features and advantages of the golf club heads and manufacturing methods thereof according to the various aspects of the present disclosure will become more apparent upon consideration of the following description, drawings, and appended claims. The description and drawings described below are for illustrative purposes only and are not intended to limit the scope of the present invention in any manner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a front elevation view of an exemplary golf club head in accordance with one or more aspects of the present disclosure;

FIG. 2 shows a rear schematic view of the exemplary golf club head of FIG. 1;

FIG. 3 shows a heel-side elevation view of an exemplary golf club head in accordance with one or more aspects of the present disclosure;

FIG. 4 shows a cross-section of the golf club head of FIG. 3 along the line IV-IV;

FIG. 5 shows a front perspective view of the golf club head of FIG. 3 with the hosel removed;

FIG. 6 shows a cross-section of the golf club head of FIG. 5 along the line VI-VI;

FIG. 7 shows an exemplary method of manufacturing the golf club head of FIG. 3;

FIG. 8 shows a close-up view of the insert within the golf club head of FIG. 3;

FIG. 9 shows overlapping club heads as part of a method of designing the insert of FIG. 8;

FIG. 10 shows a golf club head resulting from a second step of the method of FIG. 7;

FIG. 11 shows a golf club head resulting from a third step of the method of FIG. 7;

FIG. 12 shows a golf club head resulting from a fourth step of the method of FIG. 7;

FIG. 13 shows an exemplary method of manufacturing a golf club head in accordance with one or more aspects of the present disclosure;

FIG. 14 shows a golf club head resulting from a fourth step of the method of FIG. 13;

FIG. 15 shows a rear cutaway view of a golf club head in accordance with one or more aspects of the present disclosure;

FIG. 16 shows a heel-side cutaway view of the golf club head of FIG. 15;

FIG. 17 shows a rear schematic view of the golf club head of FIG. 15;

FIG. 18 shows a cross-section of the golf club head of FIG. 17 along the line XVIII-XVIII; and

FIG. 19 shows a cross-section of the golf club head of FIG. 17 along the line XIX-XIX.

DETAILED DESCRIPTION OF EMBODIMENTS

Shown in FIGS. 1 and 2 is a golf club head 100 in accordance with one or more aspects of the present disclosure. A main body of this golf club head may be bounded by a toe portion 110, a heel portion 120 opposite the toe portion, a top portion 130, and a sole portion 140 opposite the top portion. A hosel portion 150 for securing the club head to an associated shaft (not shown) may extend from the heel portion, and the hosel portion may in turn define a virtual central hosel axis 152.

The club head may further include a striking face 160 at a front portion thereof. The striking face is the substantially planar exterior surface part of the front portion that generally conforms to a virtual striking face plane and that is arranged to contact a golf ball at a factory-designated loft angle taken between the striking face plane and the central hosel axis. The striking face may be formed with surface features that increase traction between the striking face and a struck golf ball to ensure both good contact with the ball (for example, in wet conditions) and impart a degree of spin to the ball, e.g., for stability in flight or to control better the rest position of a struck golf ball once it has returned to the ground by way of backspin. Included in these surface features may be a plurality of substantially parallel horizontal grooves or score lines 162 as well as other surface features (not shown) that form a texture pattern. The striking face may include a face center 164. Face center, as used herein, refers to the point on the striking face of the club head that is halfway between the heel-most extent and the toe-most extent of the score lines 162, and halfway between the topmost extent and sole-most extent of the score lines. In a golf club head where score lines extend to about a toe-side edge of the striking face, the toe-most extent of the score lines is defined by a virtual vertical plane extending through an apex of the golf club head's top portion. A virtual vertical center plane 166 perpendicular to the face plane may project through the face center in the front-to-rear direction of the club head, and a center of gravity 170 of the golf club head may be spaced from that virtual vertical center plane. In FIG. 1, for example, the center of gravity may be spaced heelward from the virtual vertical center plane. The center of gravity may be spaced by a distance 172 less than 5 mm from the virtual vertical center plane, and in more preferred embodiments, it may be spaced less than 2 mm from that virtual vertical center plane.

The golf club head is shown in FIG. 1 as being in the “reference position.” As used herein, “reference position” denotes a position of a golf club head, e.g., the club head of FIG. 1, in which the sole portion of the club head contacts a virtual ground plane 10 such that the virtual central hosel axis 152 of the hosel portion lies in a virtual vertical hosel plane and the score lines 162 are oriented horizontally relative to the ground plane. Unless otherwise specified, all club head dimensions described herein are taken with the club head in the reference position.

The golf dub head of FIGS. 1 and 2 preferably comprises an iron-type dub head such as a wedge-type dub head, and it may preferably have a loft angle of no less than 40°. More preferably, the golf club head may be a traditional blade-type club head, which may otherwise be referred to as a “player”-type club head by certain golfers. As such, and as shown in FIG. 2, a rear 180 of the club head may include an upper blade portion 182 and a lower muscle portion 184. The upper blade portion may preferably comprise a substantially planar surface, and it may thus preferably lack any perimeter-weighting features. The muscle portion may project rearward from the upper blade portion. Mass of the golf club head may be generally concentrated in the muscle portion, so the center of gravity 170 may be located soleward of the face center. And as shown in FIG. 2 specifically, moment of inertia (“MOI”) Izz 186 of the golf club head may be measured about a virtual vertical axis 187 passing through the center of gravity, and MOI Ixx 188 of the golf club head may be measured about a virtual horizontal axis 189, parallel to the ground plane, that likewise passes through the center of gravity. As known to those of ordinary skill in the art, MOI is generally correlated with increasing the club head's natural resistance to rotation about a certain axis on off-centered golf ball impacts.

The golf club head of one or more aspects of this disclosure preferably has an internal structure that, compared to other “player”-type golf club heads, discretely moves weight from the heel portion or lower hosel portion to the sole/muscle portion or to the top of the hosel portion, thereby moving the center of gravity closer to the face center, i.e., where experienced golfers are more likely to hit the golf ball on the striking face, and correspondingly increasing both vertical (Izz) and horizontal (Ixx) MOI. Exemplary golf club heads having such an internal structure are described below. Each of these exemplary club heads may include the main body structure described above in connection with FIGS. 1 and 2.

FIG. 4 shows a cross-section of a golf club head according to one aspect of the present disclosure taken along line IV-IV in FIG. 3. As shown, the hosel portion 150 of this club head may include a hosel bore 154 extending a depth 155 into the hosel portion from an open, topmost end 156 of the hosel portion. This bore may possess a top inner diameter 157 and a bottom inner diameter 158, which may be the same or may be different. And the hosel bore may terminate at its bottom at a metal shelf 159 that projects inward toward the virtual central hosel axis. The hosel portion sidewall (as well as the remainder of the golf club head main body) may constitute a first component preferably formed of a primary material such as steel and/or a material having a density no less than 8 g/cm³ and/or a melting point below 1600° C. And a minimum thickness 151 of the hosel portion sidewall, preferably measured at a bottom of the hosel bore, may be sufficient to ensure structural integrity of the hosel portion without negatively affecting vibrational feedback on golf shots. For example, this minimum thickness may be no less than 0.5 mm, and more preferably no less than 0.75 mm.

Soleward of the bottom of the hosel bore may be an insert 190 that serves as a second, or auxiliary, component. The insert may include a substantially cylindrical portion 192 (FIG. 8) with a central axis that is coaxial with the virtual central hosel axis. The insert may also include a heel portion shaped to generally conform to a heel contour of the golf club head. This insert may be formed of an auxiliary material such as a ceramic, and it may preferably have a melting point higher than that of the first component and a density less than that of the first component. As such, the insert may have a mass less than about 5 g in the golf club head, and relative to the overall mass of the golf club head, the mass of the insert may be less than 1.5%. This insert may by composed of at least 60% aluminum oxide (Al₂O₃). More specifically, this ceramic insert may be composed of 20% SiO₂, 10% ZrO₂, and 70% Al₂O₃, although each of these percentages may vary by up to about 10%. By adjusting the ceramic composition, material properties of the insert may be tuned to achieve a weight distribution target, e.g., increased moment of inertia, lower and/or centered center of gravity location, or a particular vibrational frequency upon impact. The insert may also possess the following properties: (i) a bonding strength of 15 MPa; (ii) a porosity of no more than 40%, preferably 30%; (iii) absorption of 30%; (iv) a melting point greater than 2500° C.; and (v) a density no greater than 3 g/cm³, preferably no greater than 2 g/cm³. But like the composition of the insert, the insert's bonding strength, porosity, absorption, and density may vary to achieve a particular weight distribution target.

As shown in FIG. 6, which shows a cross-section taken at the line VI-VI in FIG. 5, the insert 190 may extend from the hosel portion into the heel portion of the golf club head. And this insert may impact various MOI values of the golf club head. For example, vertical MOI Izz may be greater than 3,000 g*cm², and horizontal MOI Ixx may be greater than 1,000 g*cm².

FIGS. 7-12 show an exemplary method 200 of forming the golf club head of FIGS. 3-6. In a first step 210, the insert may be formed by, e.g., injection molding. FIG. 8 shows one embodiment of the insert 190 after this first forming step. This insert may preferably be designed by overlaying various club lofts in a computer-assisted design (“CAD”) program and selecting an overlapping region of those club heads while accounting for necessary constraints such as minimal steel wall thickness for integrity of the hosel and/or heel portions. For example, FIG. 9 shows an insert formed in an overlapping area of club heads having lofts of 46°, 54°, and 64°. This design process may ease manufacturing concerns and provide various cost benefits since a new insert is not required to be designed for each golf club head loft and sole shape. In one or more embodiments, a minimum steel wall thickness is no less than 0.5 mm and more preferably no less than 0.75 mm.

In the second step 220 shown in FIG. 7, the golf club head main body may then be formed, e.g., by investment casting, around the insert 190 so to encapsulate the insert therein. The result of this step is shown in FIG. 10, in which the insert is shown to extend not only below the bottom metal shelf 159 of the hosel bore but also through the hosel bore and beyond the opening at the topmost end 156 of the hosel portion 150. The upper part 194 of the insert, i.e., the portions extending beyond the topmost opening of the hosel portion and extending into the hosel bore, may then be removed in the third step 230 shown in FIG. 7 by, e.g., machining. As shown in FIG. 11, which shows the result of this third step, the hosel bore 154 and topmost end 156 of the hosel portion may now be open so as to be able to receive a golf club shaft, and the insert 190 may extend soleward of the metal shelf 159 delimiting the bottom of the hosel bore. As also shown in FIG. 11, the insert may not extend beyond the heel-most extent 163 of the score lines formed on the striking face. Preferably, the insert may extend to about the heel-most extent of those score lines. This ensures that the insert does not extend into the hitting zone of the striking face, which may minimize any change to traditional feel and sound of the golf club head at impact with the golf ball. And in the final step 240 of FIG. 7, the result of which is shown in FIG. 12, an insert cap 196 may be introduced into the hosel bore so as to rest on the metal shelf 159. This insert cap, which may be formed of Al or ABS plastic, may provide a protective barrier between a tip end of the shaft and the topmost end of the insert. In other embodiments, the insert cap may not be necessary, as the topmost end of the insert is covered by an epoxy layer when the tip end of the shaft is affixed in the hosel bore. By thus forming the main body of the golf club head around the insert, space that would otherwise be filled by denser metallic material is instead occupied by, e.g., a ceramic material. Mass is thus selectively removed from the hosel and heel portions, thereby accomplishing the goal of moving the center of gravity closer to the face center.

Other exemplary club heads are seen as being within the spirit and scope of the present invention. For example, as shown in FIG. 13 and like the method of FIG. 7, an insert 390 may first by formed at a first step 310 by, e.g., injection molding, and the main body of the golf club head may then be formed around the insert at a second step 320 by, e.g., investment casting. But at a third step 330, instead of removing only the upper part of the insert so as to form the hosel bore of the hosel portion, more of the insert may be removed so as to form an internal cavity below the hosel bore. More specifically, and as shown in FIG. 14, part 392, e.g., at least 50% by volume, or all of the insert may be removed by, e.g., mechanical agitation, chemical etching, or electrolytic etching, to form the internal cavity. In some aspects, the insert may be comprised of a material having high solubility in water or aqueous solutions. In such aspects, the insert may be easily dissolved out of the golf club head to form the cavity. This cavity may then be filled at the fourth step 340 in FIG. 13 by injecting therein material such as a polymer foam that later solidifies. This fourth step may thus introduce a vibration dampening material within the club head or allow tuning of the location of the center of gravity by, e.g., varying the density of the polymer material. And as in the method of FIG. 7, an insert cap may then be introduced at a fifth step 350 into the hosel bore so as to rest on the metal shelf delimiting the bottom of the hosel bore.

Yet other exemplary club heads are considered as being within the spirit and scope of the present invention. For example, although FIGS. 10-12 and 14 show the insert as extending only to the heel-most extent of the score lines, this need not be the case. Indeed, as shown in the exemplary golf club head 400 of FIGS. 15-19, the insert 490 may extend farther into the sole portion or to the toe portion of the golf club head. This insert may in fact extend the entire distance from the heel to the toe. Such a configuration may be more feasible in “game-improvement” type golf club heads, which generally have a larger sole volume to accommodate such an insert. The golfer using a “game-improvement” club head may also find less objectionable any changes in sound and/or feel that result from the insert extending into the striking face. In fact, the presence of the insert may provide a vibrational dampening effect and improve feel on off-center impacts. And as shown in FIG. 19, which shows a cross-section taken along the line XIX-XIX of the golf club head of FIG. 17, a high density portion 492 may be co-molded with or otherwise located within the insert at the toe portion. This high density portion may be a metallic material, e.g., a tungsten alloy, and it may have a density greater than 10 g/cm³. Including such a high density portion in the insert may be beneficial because it can add mass to the toe portion of the golf club head to increase MOI, it can improve feel of the golf club head upon striking a golf ball, and it may ultimately reduce manufacturing costs.

In the foregoing discussion, the present invention has been described with reference to specific exemplary aspects thereof. However, it will be evident that various modifications and changes may be made to these exemplary aspects without departing from the broader spirit and scope of the invention. Accordingly, the foregoing discussion and the accompanying drawings are to be regarded as merely illustrative of the present invention rather than as limiting its scope in any manner.

Claims

1. A golf club head that, when oriented in a reference position, comprises: a striking face having a face center and defining a face plane;a vertical center plane that is perpendicular to the face plane and extends through the face center;a sole portion;a top portion;a heel portion;a toe portion opposite the heel portion;a hosel portion extending from the heel portion and comprising a hosel bore with an open end for receiving a shaft and a bottom surface, the hosel bore defining a central hosel axis;a rear surface opposite the striking face that, along a heel-to-toe direction, is substantially flat from a heel-most extent of the golf club head to a toe-most extent of the golf club head;a center of gravity spaced less than 5 mm from the vertical center plane;a moment of inertia about a vertical axis extending through the center of gravity, Izz, greater than 3,000 g*cm2; anda moment of inertia about a horizontal axis extending through the center of gravity, Ixx, greater than 1,000 g*cm2,wherein the golf club head comprises a first component comprised of a first material having a first melting point and a first density and a second component having a second melting point higher than the first melting point and a second density less than the first density, the second component (i) being at least partially encapsulated by the first component, (ii) extending into the hosel portion below the hosel bore, and (iii) having a mass less than about 5 g.

2. The golf club head of claim 1, wherein the first component encapsulates substantially the entirety of the second component and defines a minimum surrounding wall thickness that is no less than 0.5 mm.

3. The golf club head of claim 2, wherein the minimum surrounding wall thickness is no less than 0.75 mm.

4. The golf club head of claim 1, wherein the golf club head further comprises an overall mass and the mass of the second component is less than 1.5% of the overall mass of the golf club head.

5. The golf club head of claim 1, wherein the second component comprises a porosity of no more than 40%.

6. The golf club head of claim 1, further comprising a cap in communication with the bottom surface of the hosel bore.

7. The golf club head of claim 1, wherein the second component further comprises a substantially cylindrical portion defining a second central axis coaxial with the central hosel axis.

8. The golf club head of claim 7, wherein the striking face includes a plurality of horizontally extending score lines and the second component extends to about a heel-most extent of the score lines in the heel-to-toe direction.

9. A method of forming a golf club head comprising the steps of: (a) forming an auxiliary component with an auxiliary material;(b) encapsulating, by an investment casting process, the auxiliary component within a golf club head body comprising a primary material; and(c) removing a portion of the auxiliary component to create a hosel bore with an open end and a bottom surface such that an uppermost extent of the auxiliary component is below the bottom surface,wherein the primary material has a first melting point and a first density and the auxiliary material has a second melting point greater than the first melting point and a second density less than the first density,wherein the golf club head includes: a striking face having a face center and defining a face plane;a vertical center plane substantially perpendicular to the face plane and passing through the face center;a rear surface opposite the striking face that, along a heel-to-toe direction, is substantially flat from a heel-most extent of the golf club head to a toe-most extent of the golf club-head;a center of gravity located less than 5 mm from the vertical center plane;a moment of inertia about a vertical axis extending through the center of gravity, Izz, greater than 3,000 g*cm2; anda moment of inertia about a horizontal axis extending through the center of gravity, Ixx, greater than 1,000 g*cm2.

10. The method of claim 9, wherein forming the auxiliary component comprises an injection molding process.

11. The method of claim 9, wherein a minimum surrounding wall thickness of the encapsulating auxiliary component is no less than 0.5 mm.

12. The method of claim 11, wherein the minimum surrounding wall thickness is no less than 0.75 mm.

13. The method of claim 9, wherein a mass of the auxiliary component is less than 1.5% of an overall mass of the golf club head.

14. The method of claim 9, wherein the auxiliary component comprises a porosity no more than 40%.

15. The method of claim 9, further comprising inserting a cap in communication with the bottom surface of the hosel bore.

16. The method of claim 9, further comprising the steps of forming an internal cavity by removing at least 50% by volume of the auxiliary component by a process selected from the group consisting of mechanical agitation, chemical etching, and electrolytic etching; andinjecting a polymeric material into the internal cavity.

17. A golf club head that, when oriented in a reference position, comprises: a golf club head main body comprising: a striking face having a face center and defining a face plane;a vertical center plane that is perpendicular to the face plane and extends through the face center;a sole portion;a top portion;a heel portion;a toe portion opposite the heel portion;a hosel extending from the heel portion and comprising a hosel bore with an open end and a bottom surface, the hosel bore defining a central hosel axis;a rear surface opposite the striking face that, along a heel-to-toe direction, is substantially flat from a heel-most extent of the golf club head to a toe-most extent of the golf club head; anda first material having a first melting point and a first density;a center of gravity located less than 5 mm from the vertical center plane;a moment of inertia about a vertical axis extending through the center of gravity, Izz, greater than 3,000 g*cm2;a moment of inertia about a horizontal axis extending through the center of gravity, Ixx, greater than 1,000 g*cm2; andan auxiliary component comprising: a heel portion comprising a second material having a second melting point higher than the first melting point and a second density less than the first density;an upper extent located below the bottom surface of the hosel bore; anda toe portion connected to the heel portion and comprising a third material having a density greater than the first density.