WEIGHTED IRON SET

Abstract

The present invention is direct to a set of golf clubs comprising long irons, mid-irons and short irons. The invention contemplates the use of titanium or steel for the main body portion and a tungsten weight member coupled to the toe and a tungsten heel weight member coupled in a hosel cavity.

Description

TECHNICAL FIELD OF THE INVENTION

The present invention generally relates to sets of iron golf clubs, and more particularly, to sets of iron golf clubs that are comprised of significant tungsten weighting.

BACKGROUND OF THE INVENTION

In conventional sets of “iron” golf clubs, each club includes a shaft with a club head attached to one end and a grip attached to the other end. The club head includes a face for striking a golf ball. The angle between the face and a vertical plane is called “loft.” In general, the greater the loft is of the golf club in a set, the greater the launch angle and the less distance the golf ball is hit.

A set of irons generally includes individual irons that are designated as number 3 through number 9, and a pitching wedge. The iron set is generally complimented by a series of wedges, such as a lob wedge, a gap wedge, and/or a sand wedge. Sets can also include a 1 iron and a 2 iron, but these clubs are generally sold separate from the set. Each iron has a shaft length that usually decreases through the set as the loft for each club head increases, from the long irons to the short irons. The length of the club, along with the club head loft and center of gravity impart various performance characteristics to the ball's launch conditions upon impact. The initial trajectory of the ball generally extends between the impact point and the apex or peak of the trajectory. In general, the ball's trajectory for long irons, like the 3 iron, is a more penetrating, lower trajectory due to the lower launch angle and the increased ball speed off of the club. Short irons, like the 8 iron or pitching wedge, produce a trajectory that is substantially steeper and less penetrating than the trajectory of balls struck by long irons. The highest point of the long iron's ball flight is generally lower than the highest point for the short iron's ball flight. The mid irons, such as the 5 iron, produce an initial trajectory that is between those exhibited by balls hit with the long and short irons.

SUMMARY OF THE INVENTION

The present invention is directed to a set of golf clubs comprising at least a first club head having a loft between about 15 and 25 degrees (long irons), a second club head having a loft of between about 26 and 35 degrees (mid irons), and a third club head having a loft of about 36 degrees or greater (short irons). Within the set, the first, second and third club heads each have a heel, a toe, a topline, a sole, a hosel and a front face having a face center. Each of the club heads has a club head mass that is different than the other club head mass by at least 5 grams. Further, the set includes at least one club head that has a tungsten heel member and a tungsten toe member that together comprise more that 50% of the club head mass. More preferably, each of the long irons and the mid irons are comprised of tungsten weight members that are at least 50% of the club head mass.

The present invention is also directed to a set of irons where the long and mid irons each have a tungsten heel member and a tungsten toe member, wherein the tungsten heel member plus the tungsten toe member weigh 135 grams or greater. Preferably, the long and mid irons are comprised of titanium and tungsten and the tungsten portion forms more than 25% of the club heads' volume. In a preferred embodiment, the short iron is comprised of titanium and steel and the steel portion comprises between 50% and 70% of the club head mass.

The present invention is also directed to a set of golf clubs comprising at least a first club head having a loft between about 15 and 25 degrees, a second club head having a loft of between about 26 and 35 degrees, and a third club head having a loft of about 36 degrees or greater, where each club head has a club head mass that is different than the one preceding it by at least 5 grams and at least one club head is comprised of a steel body member and a steel face insert that together comprise less than 75 percent of the overall club head mass. Preferably, the club head includes a tungsten heel member and a tungsten toe member that together comprise more that 25% of the club head mass. More preferably, the tungsten heel member plus the tungsten toe member weigh 70 grams or greater.

In a preferred embodiment of the invention, the long irons and mid irons are comprised of steel and tungsten and the tungsten portion forms at least about 20 percent of the club heads' solid volume. Still further, at least one short iron can be comprised of steel and tungsten and the tungsten portion comprises at least about 20 percent of the club head mass.

The present invention also contemplates a set of golf clubs comprising at least a long iron having a first blade length, a first hosel length and a first scoreline width, a mid iron having a second blade length, a second hosel length and a second scoreline width, and a short iron having a third blade length, a third hosel length and a third scoreline width, where the blade lengths are approximately constant and the second hosel length is greater than the first hosel length and the third hosel length is greater than the second hosel length. Also the second scoreline width is preferably less than the first scoreline width and the third scoreline width is preferably less than the second scoreline width. In a preferred embodiment, the long iron has a first toe height, the mid iron has a second toe height greater than the first toe height and the short iron has a third toe height greater than the second toe height. Still further, the long iron can have a first sole width, the mid iron can have a second sole width less than the first sole width and the short iron can have a third sole width less than the second sole width.

In the preferred embodiment of the current invention, the long iron has a first tungsten toe member, the mid iron has a second tungsten toe member with greater mass than the first tungsten toe member and at least one short iron has a third tungsten toe member with greater mass than the second tungsten toe member. Conversely, in the preferred embodiment, the long iron has a first tungsten heel member and the mid iron has a second tungsten heel member with less mass than the first tungsten heel member.

The present invention is also directed to a set of golf clubs comprising at least a first club head having a loft between about 15 and 25 degrees, a second club head having a loft of between about 26 and 35 degrees, and a third club head having a loft of about 36 degrees or greater, wherein each club head having a club head mass that is different than the previous club head by at least 5 grams, and wherein at least one of the club heads includes a weight member formed of tungsten and coupled to the toe that comprises 15%-25% of the club head mass. More preferably, the weight member is coupled to the golf club to form a portion of the back surface, the toe surface and the sole surface via a mechanical fastener. The club head can also include an indentation that forms a wall surrounding a portion of the weight member that has an angle between about 10 degrees and 60 degrees such that the weight member is press fit against the wall when the mechanical fastener is tightened. The club can also include a bottom surface and an adhesive tape is juxtaposed the bottom surface and the weight member. In a most preferred embodiment, the mechanical fastener is inserted through a face side of the club and extends through an aperture in the club and the club and the weight member form a paint fill edge that surrounds the weight member perimeter.

The present invention is also directed to a set of golf clubs comprising at least a first club head having a loft between about 15 and 25 degrees and a first club head mass, a second club head having a loft of between about 26 and 35 degrees and a second club head mass, and a third club head having a loft of about 36 degrees or greater and a third club head mass, wherein at least one of the clubs is formed with a body made of steel comprising a heel, a toe, a topline, a sole, a hosel, a front face insert and a back wall forming a hollow cavity therebetween. The club head further comprises a toe weight member formed of tungsten coupled to a toe portion of the hollow cavity that is about 25%-35% of the club head mass and a heel weight member formed of tungsten that is coupled into a hosel cavity formed in a front, lower portion of the hosel. The heel weight member is preferably enclosed in the hosel cavity by a steel cover member that forms at least a front portion of the hosel.

In a preferred embodiment of the present invention, both the first and second club heads have toe weight members that are at least 65 grams. Moreover, the first club head has a Moment of Inertia about the y-axis through the face center of greater than 250 kg-mm². Preferably, the first club head also has a Center of Gravity that is less than 18 mm from a ground surface when the club head is in the standard address position and is greater than 6 mm from the face center toward the back surface. Further still, in a preferred embodiment, the first club head has a Moment of Inertia about the y-axis of greater than 250 kg-mm² and a blade length of less than 82 mm. Even more preferably, the irons have a blade length that is less than 78 mm.

In a preferred embodiment of the present invention, the Center of Gravity depth from the face center toward the back wall of the hollow irons is almost 1/10 the blade length. Still further, within the set, the Moment of Inertia for the long irons is less than the Moment of Inertia for the mid irons and the Moment of Inertia for the short irons. Within the set, the Center of Gravity for the mid irons is preferably less than 19 mm from a ground surface when the club head is in the standard address position and the Center of Gravity for the short irons is greater than 19 mm from a ground surface when the club head is in the standard address position. More preferably, each of the club heads has a Center of Gravity height from the ground that increases with loft through the set.

Preferably, the present invention comprises at least three hollow long irons, each having a loft of between 15 and 25 degrees, and a combined mass of the toe weight member located in a hollow cavity and the heel weight member located in a lower portion of the hosel that increases with loft. Moreover, the Moment of Inertia about the y-axis for the long irons increases with loft.

The present invention is also directed to a set of hollow irons where the sole has a sole width and a face insert includes a face insert sole portion that extends in a front-to-back direction from a leading edge toward the back wall a distance that is at least 25% of the sole width. It is also preferred that the face insert sole portion extend from the heel toward the toe and has a length in a heel-to-toe direction that is between 50% and 80% of the blade length. It is preferred that the face insert has a face center thickness of 1.8 mm or less and has an Ultimate Tensile Strength of 2300 MPa or greater. More particularly, it is preferred that the face insert has a face center thickness of 1.75 mm or less and has a Fatigue Strength of greater than 800 MPa.

In an alternate embodiment of the present invention, the toe weight member is further comprised of a main supported portion, defined as a portion of the toe weight member that contacts a striking face, and an unsupported extension portion, extending toeward from the main supported portion, wherein the unsupported extension of the toe weight member does not contact the striking face.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a back view of an iron according to the present invention;

FIG. 2 is a perspective view of the iron in FIG. 1;

FIG. 3 is a front view of a long iron according to another embodiment of the present invention;

FIG. 4 is a front view of a long iron body member according to the present invention;

FIG. 5 is a front view of a mid-iron body member according to the present invention;

FIG. 6 is a front view of a short iron body member according to the present invention;

FIG. 7 is a front view of another embodiment of a short iron body member according to the present invention;

FIG. 8 is an exploded view of an iron according to the present invention;

FIG. 9 is a cross-sectional view of the iron in FIG. 8;

FIG. 10 is an exploded view of an iron according to the present invention;

FIG. 11 is a cross-sectional view of the iron in FIG. 10;

FIG. 12 is an exploded view of an iron according to the present invention;

FIG. 13 is a cross-sectional view of the iron in FIG. 12;

FIG. 14 is an exploded view of an iron according to the present invention;

FIG. 15 is a cross-sectional view of the iron in FIG. 14;

FIG. 16 is an exploded view of an iron according to the present invention;

FIG. 17 is an exploded view of an iron according to the present invention;

FIG. 18 is a back view of an iron according to the present invention;

FIG. 19 is an exploded view of the iron in FIG. 18;

FIG. 20 is a back view of an iron according to the present invention;

FIG. 21 is an exploded view of the iron in FIG. 20;

FIG. 22 is a side view of the iron in FIGS. 20 and 21;

FIG. 23 is a back view of an iron according to the present invention;

FIG. 24 is an exploded view of the iron in FIG. 23 from a heel perspective;

FIG. 25 is an exploded view of the iron in FIG. 23 from a sole perspective;

FIG. 26 is a back view of an iron according to the present invention;

FIG. 27 is an exploded view of the iron in FIG. 26 from a toe perspective;

FIG. 28 is an exploded view of the iron in FIG. 26 from a sole perspective;

FIG. 29 is an exploded view of the iron in FIG. 26 from a back perspective;

FIG. 30 is a back view of an iron according to the present invention;

FIG. 31 is a top view of the iron in FIG. 30;

FIG. 32 is a toe view of the iron in FIG. 30;

FIG. 33 is an exploded view of a portion of the iron in FIG. 30 from a heel perspective;

FIG. 34 is a front view of the iron in FIG. 30;

FIG. 35 is an exploded view of a portion of the iron in FIG. 30 from a toe perspective;

FIG. 36 is a cross-sectional view of the iron in FIG. 30 from a front perspective;

FIG. 37 is a cross-sectional view of second embodiment of the iron in FIG. 30 from a front perspective;

FIG. 38 is a cross-sectional view of the second embodiment of the iron in FIG. 30 from a toe perspective;

FIG. 39 is a cross-sectional view of the second embodiment of the iron in FIG. 30 from a heel perspective;

FIG. 40 is a top view of an iron according to the present invention;

FIG. 41 is a toe view of the iron in FIG. 40;

FIG. 42 is a cross-sectional view of the iron in FIG. 40 from a front perspective

FIG. 43 is an exploded view of a portion of the iron in FIG. 40 from a heel perspective;

FIG. 44 is an exploded view of a portion of the iron in FIG. 40 from a toe perspective;

FIG. 45 is a rear view of a golf club head in accordance with an alternative embodiment of the present invention;

FIG. 46 is a frontal view of a toe weight member in accordance with an alternative embodiment of the present invention;

FIG. 47 is an exploded cross-sectional view of a golf club head in accordance with an alternative embodiment of the present invention; and

FIG. 48 is a cross-sectional view of a golf club head in accordance with an alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in the accompanying drawings and discussed in detail below, the present invention is directed to an improved set of iron-type golf clubs, wherein the clubs have tungsten weight members that form a significant portion of the club heads' mass.

Referring to FIGS. 1 and 2, an iron 10 has a heel 12, a toe 14, a hosel 16, a back cavity 18 a top line 20 and a sole 22. The iron is comprised of two main components, the main body 24 and the weight members 26. The iron includes a hosel axis 32 and a Y-axis 34 that extends vertically through a face center FC. The main body 24 is formed from titanium, or more preferably, a titanium alloy. For at least the long irons and mid irons, the weight members include a toe weight member 28 and a heel weight member 30 that are formed from tungsten or more preferably a tungsten alloy having a specific gravity of 15 g/cm3 or greater. Thus, the main body 24 will have a specific gravity of about 4-5 g/cm3 and the weight members 26 will have a specific gravity of about 15-20 g/cm3.

Table I provides exemplary, non-limiting dimensions for the various measurements of clubs according to the Example of the invention. It is fully intended that all of the dimensions set forth below can be adjusted such that the overall objective of the individual irons is met.

TABLE I
Club Number	3	4	5	6	7	8	9	P
loft	21	24	27	30	34	38	42	46
Mass	238	245	252	259	266	274	282	286
Ti (g)	103	100	102	109	116	94	102	106
W (g)	135	145	150	150	150
Steel (g)						180	180	180
Ti %	43.3	40.8	40.5	42.1	43.6	34.3	36.2	37.1
W %	56.7	59.2	59.5	57.9	56.4
Steel %						65.7	63.8	62.9
Ti vol. (cm3)	22.9	22.2	22.7	24.2	25.8	20.9	22.7	23.6
W vol. (cm3)	9.0	9.7	10	10	10
Steel Vol. (cm3)						24	24	24

Referring to the data in Table I above, the set of irons according to the present invention can be separated into long irons that have a loft of between about 15 and 25 degrees, mid irons that have a loft of between about 26 and 35 degrees and short irons that have a loft of about 36 or greater. The total mass of the clubs increases throughout the set from about 235 grams to about 290 grams. Each club is preferably about 5 grams or more greater in mass than the previous iron. As shown, for example, the 4 iron is 7 grams greater than the 3 iron. Thus, the mass increases through the set.

Each of the irons includes a titanium body member. The long irons and the mid irons preferably have tungsten weight members 28 and 30 as shown in FIGS. 1 and 2. In the long irons, the titanium body member 24 has a mass that is less than about 120 grams and more particularly, about 100 grams. The toe weight member 28 and heel weight member 30 preferably have a mass of about 130 grams to 150 grams. Thus, the tungsten weight members are greater than 50% of the total club mass.

In the mid irons, the titanium body member 24 has a mass that is less than about 120 grams and more particularly, about 100 grams to about 115 grams. The tungsten toe weight member 28 and heel weight member 30 preferably have a mass of about 140 grams to 160 grams, and more particularly about 150 grams. Thus, the tungsten weight members are greater than 50% of the total club mass. Also, the tungsten weight members 28 and 30 have greater mass than the tungsten weight members 28 and 30 for the long irons.

In the short irons, the titanium body member 24 has a mass that is less than about 120 grams and more particularly, about 90 grams to about 110 grams. The toe weight member 28 and heel weight member 30 are preferably made of steel and preferably have a mass of about 160 grams to 200 grams, and more particularly about 180 grams. Thus, the steel weight members are greater than 50% of the total club mass. Also, the steel weight members 28 and 30 have greater mass than the tungsten weight members 28 and 30 for the long irons and of the mid irons.

TABLE II
Club Number	2	3	4	5	6	7	8	9	P
loft	17	20	23	26	29	33	37	41	45
Total Mass (g)	234	239	246	252	256	267	274	282	286
Body Mass (g)	116	117	118	118	132	139	164	170	240
Face Mass (g)	34	37	38	38	38	39	41	41	41
Toe W (g)	38	45	50	55	61	60	61	63
Heel W (g)	34	32	31	31	20	20
Steel Mass %	70	68	67	66	68	70	78	78	100
W Mass %	30	32	33	34	32	30	22	22
Steel vol. %	80	79	78	77	80	81	86	86	100
W vol. %	20	21	22	23	20	19	14	14

TABLE III
Club
Number	2	3	4	5	6	7	8	9	P
loft	17	20	23	26	29	33	37	41	45
Blade	77.6	77.6	77.6	77.6	77.6	77.6	77.6	77.6	77.6
Length
(mm)
Toe	51.9	52.3	52.8	53.3	53.8	54.3	54.9	55.4	55.8
Height
(mm)
Scoreline	53.2	53.0	52.8	52.7	52.5	52.3	52.2	52	51.8
Width
(mm)
Scoreline	17.3	17.5	17.7	17.8	18	18.2	18.3	18.5	18.7
to Toe
(mm)
Hosel	62	63	64	65	66	67	68	69	70
Length
(mm)
Sole Width	19.7	19.4	19.0	18.5	18.0	17.4	16.8	16.1	15.4
(mm)

As shown in FIG. 3 and set forth in Table III above, another embodiment of the present invention includes a set of irons that have a substantially constant Blade Length (BL) throughout the set. The BL is defined at the length from the hosel axis (HA) intersection with the ground plane to the end of the toe. However in this set, the Toe Height (TH) progressively increases through the set. Thus, the TH of the mid iron is greater than the TH of the long iron and the TH of the short iron is greater than the TH of the mid iron and the long iron. The TH is defined as the maximum length from the leading edge to the top of the toe in the plane parallel to the face plane and perpendicular to the scorelines. Preferably, the TH increases by about at least 0.3 mm per club, and most preferably at least 0.4 mm per club. Also, the TH preferably increases at least 1 mm per club (or about 4 degrees of loft) for the short irons and only 0.3-0.6 mm per club for the long and mid irons.

Furthermore, even though the BL remains substantially constant through the set, the scoreline width (SLW) progressively decreases through the set and the scoreline to toe width (SLTW) progressively increases through the set. More particularly, the SLW decreases by at least about 0.1 mm per club (or per 4 degrees of loft). Thus, the SLW for the long iron is greater than the SLW for the mid iron and the SLW for the mid iron is greater than the SLW for the short iron. Moreover, because the SLTW progressively increases through the set, the non-grooved toe area increases throughout the set.

Still further, in this preferred embodiment of the present invention, the distance of the center of gravity from the face center progressively increases through the set. Thus, CG-Xfc progressively increases from less than 2 mm from the face center in the long irons to about 3 mm from the face center towards the hosel in the short irons.

Another aspect of the present invention is that the hosel length HL increases through the set. Preferably, the hosel length increases by about 1 mm/club (or per 4 degrees of loft) such that the HL of the mid irons is greater than the HL of the long irons and the HL of the short irons is greater than the HL of the mid irons. Also, the sole width, not shown in the figures because it is the width of the sole at the center of the club head perpendicular to the front view shown in FIG. 3, decreases through the set. Thus, the sole width of the mid irons is less than the sole width of the long irons and greater than the sole width of the short irons. Preferably, the sole width decreases by about 0.3 mm/club (or per 4 degrees of loft).

As shown in FIGS. 4-7 and set forth in the table above, the set includes a long iron 100, a mid iron 200, a first short iron 300 and a second short iron 400. In FIG. 4, the long iron 100 includes a body member 110, heel 112, a toe 114, a hosel 116 and a sole 118. The iron body 110 includes an insert aperture 120 and a hollow portion 122. A face insert, not shown, is welded to the insert aperture 120 to enclose the hollow portion 122. Both the body member 110 and the face insert are preferably formed of steel. Inside the hollow portion 122, a tungsten toe weight member 124 and a tungsten heel weight member 126 are located proximate the toe 114 and the heel 112, respectively, to create a high moment of inertia. As shown in Table II above, the body member 110 preferably has a mass of about 110 grams to 120 grams and the face insert has a mass of about 30 grams to 45 grams. In the long irons 100, the toe weight member 124 preferably has a mass of about 35 to 55 grams. Preferably, the toe weight member 124 mass increases with each club by about 5 grams per club. The heel weight member 126 is preferably about 30 grams to 35 grams and preferably decreases by about 1 or 2 grams per club. Preferably, the tungsten mass of the toe weight member 124 and the heel weight member 126 are at least 25% of the total club head mass and at least 15% of the total club head solid volume. More particularly, the toe weight member 124 and the heel weight member comprise about 30% of the total mass or more and 20% of the total solid volume. Preferably, the toe weight member 124 has greater mass than the heel weight member 126.

As shown in FIG. 5 and set forth in Table II above, the set includes a mid iron 200 that includes a body member 210, heel 212, a toe 214, a hosel 216 and a sole 218. The iron body 210 includes an insert aperture 220 and a hollow portion 222. A face insert, not shown, is welded to the insert aperture 220 to enclose the hollow portion 222. Both the body member 210 and the face insert are preferably formed of steel. Inside the hollow portion 222, a tungsten toe weight member 224 and a tungsten heel weight member 226 are located proximate the toe 214 and the heel 212, respectively, to create a high moment of inertia. As shown in Table II above, the body member 210 preferably has a mass of about 115 grams to 145 grams and the face insert has a mass of about 30 grams to 45 grams. In the mid irons 200, the toe weight member 224 preferably has a mass of about 50 to 70 grams. Preferably, the toe weight member 224 mass increases with each club by about 5 grams per club. The heel weight member 226 is preferably about 35 grams or less and preferably decreases per club. Preferably, the tungsten mass of the toe weight member 224 and the heel weight member 226 are at least 25% of the total club head mass and at least 15% of the total club head solid volume. More particularly, the toe weight member 224 and the heel weight member 226 comprise about 30% of the total mass or more and about 20% of the total solid volume. Preferably, the toe weight member 224 has greater mass than the heel weight member 226, and more preferably, is about twice the amount of mass.

As shown in FIG. 6 and as set forth in Table II above, the set can include a short iron 300 that includes a body member 310, heel 312, a toe 314, a hosel 316 and a sole 318. The iron body 310 includes an insert aperture 320 and a hollow portion 322. A face insert, not shown, is welded to the insert aperture 320 to enclose the hollow portion 322. Both the body member 310 and the face insert are preferably formed of steel. Inside the hollow portion 322, a tungsten toe weight member 324 is located proximate the toe 314, to create a high moment of inertia. As shown in Table 11 above, the body member 310 preferably has a mass of about 150 grams to 200 grams and the face insert has a mass of about 30 grams to 45 grams. In the short iron 300, the toe weight member 324 preferably has a mass of about 55 to 70 grams. Preferably, the tungsten mass of the toe weight member 324 is at least 20% of the total club head mass and at least 10% of the total club head solid volume.

As shown in FIG. 7 and as set forth in Table II above, the set can include a short iron 400 that includes a body member 410, heel 412, a toe 414, a hosel 416 and a sole 418. The iron body 410 includes an insert aperture 420. A face insert, not shown, is welded to the insert aperture 420. The short iron 400 is preferably substantially solid and does not contain tungsten weight members.

Referring now to FIGS. 8-19, the present invention also includes a number of ways to attach the tungsten weight to a club head such that the weight and the head can be manufactured and finished separately. Preferably, the club head frame is cast or forged and then polished. The weight can be manufactured out of 17 g/cm3 tungsten and polished. After both components are polished, the weight member can be attached to the body via a mechanical fastener as discussed in more detail below.

As shown in FIG. 8, the iron body 500, includes a heel 512, a toe 514, a hosel 516 and a sole 518 and is preferably formed by forging steel or titanium as discussed above. The club head also includes a toe weight member 528 that is coupled to the body 500 by a mechanical fastener 530. The body 500 includes an indentation 532 on the toe 514 and sole 518 for receiving the weight member 528. The indentation 532 includes an inner wall 534 that surrounds a portion of the weight member 528 and a receptacle 536 for coupling with the mechanical fastener 530. In this embodiment, the receptacle 536 is a threaded aperture. As shown in the cross-sectional view of FIG. 9, the wall 534 is formed at an angle α such that the weight member is press fit into the indentation 532 when the mechanical fastener is tightened. Preferably, the angle α is between about 10 degrees and 60 degrees. The weight member 528 and the indentation 532 form a bottom interface 538. In a preferred embodiment, an adhesive tape may be applied at this interface to further secure the weight member 528 to the body 500. The body 500 also includes a back surface 510 and the weight member 528 has an outer surface 540. The outer surface of the weight member 528 preferably creates a lower portion of the toe 514, an outer, toe portion of the sole 518 and a portion of the back surface 510 for maximum MOI efficiency. In the preferred embodiment shown in FIGS. 8 and 9, the body 500 also includes a front surface 542 for welding the front face to, not shown. Further, a paint fill edge 544 can be formed in the weight member 528, the body 500 or both, as shown, to finish the club head and provide a visual separation of the weight member 528.

As discussed above, the toe weight member 528 preferably has a mass of about 35 to 65 grams. Preferably, the toe weight member 528 mass increases with each club by about 5 grams per club through at least a portion of the set. The club can further include a heel weight member that is not shown that is preferably about 30 grams to 35 grams and preferably decreases by about 1 or 2 grams per club through at least a portion of the set. A heel weight can be attached in the same manner as the toe weight member shown or can be placed behind the face insert as discussed above with respect to FIGS. 4 and 5. Preferably, the tungsten mass of the toe weight member 528 and the heel weight member are at least 25% of the total club head mass and at least 15% of the total club head solid volume. As set forth in Table II, and for all the embodiments, the toe weight member is preferably between about 15% and 25% of the total club mass.

As shown in FIG. 10, the iron body 600, includes a heel 612, a toe 614, a hosel 616 and a sole 618 and is preferably formed by forging steel or titanium as discussed above. The club head also includes a toe weight member 628 that is coupled to the body 600 by a mechanical fastener 630. Like the embodiment in FIG. 8, the body 600 includes an indentation 632 on the toe 614 and sole 618 for receiving the weight member 628. The indentation 632 includes an inner wall 634 that surrounds a portion of the weight member 628 and a receptacle 636 for coupling with the mechanical fastener 630. In this embodiment, the indentation 632 further includes a conical collar 637. As shown in the cross-sectional view of FIG. 11, the conical collar 637 is formed at an angle β such that the weight member is press fit into the indentation 632 when the mechanical fastener is tightened. Again, the weight member 628 and the indentation 632 form a bottom interface 638 that can include an adhesive tape juxtaposed the interface to further secure the weight member 628 to the body 600. As above, the outer surface of the weight member 628 preferably creates a lower portion of the toe 614, an outer portion of the sole 618 and a portion of the back surface 610 for maximum MOI efficiency. The body 600 also includes a front surface 642 for welding the front face, not shown, to and a paint fill edge 644 can be formed in the weight member 628, the body 600 or both, as shown, to finish the club head and provide a visual separation of the weight member 628.

Even with the additional conical collar 637, the toe weight member 628 preferably has a mass of about 35 to 55 grams and the toe weight member 628 mass increases with each club by about 5 grams per club. Preferably, the tungsten mass of the toe weight member 628 and any heel weight member are at least 25% of the total club head mass and at least 15% of the total club head solid volume.

FIG. 12 is an exploded view of another embodiment of the present invention. The iron body 700, includes a heel 712, a toe 714, a hosel 716 and a sole 718 and is preferably formed by forging steel or titanium as discussed above. The club head 700 also includes a toe weight member 728 that is coupled to the body 700 by a mechanical fastener 730. Like the embodiment in FIG. 8, the body 700 includes an indentation 732 on the toe 714 and sole 718 for receiving the weight member 728. The indentation 732 includes an inner wall 734 that surrounds a portion of the weight member 728. In this embodiment, as shown in FIG. 13, a threaded receptacle member 736 is inserted into the body 700 through the face side of the body 700 for coupling with the mechanical fastener 730. In this embodiment, the receptacle member 736 is covered from view when the face member, not shown, is welded to the face securing surface 742. As shown in the cross-sectional view of FIG. 13, the fastener 730 and the receptacle member 736 capture the weight member 728 to the body 700. Again, the weight member 728 and the indentation 732 form a bottom interface 738 that can include an adhesive tape juxtaposed the interface to further secure the weight member 728 to the body 700. As above, the outer surface of the weight member 728 preferably creates a lower portion of the toe 714, an outer portion of the sole 718 and a portion of the back surface 710 for maximum MOI efficiency. The body 700 also includes a paint fill edge 744 can be formed in the weight member 728, the body 700 or both, as shown, to finish the club head and provide a visual separation of the weight member 728.

Referring to FIGS. 14 and 15, another embodiment of the present invention is an iron body 800 including a heel 812, a toe 814, a hosel 816 and a sole 818. The iron 800 further comprises a toe weight member 828 that is secured to the body 800. In this embodiment, the weight member 828 is secured to the body 800 by a mechanical fastener 830 that is inserted through the face of the iron 800. The iron body 800 can be formed by casting, but is preferably forged. An aperture 804 is formed in the back wall 806 and the weight member 828 is attached to the back wall 806 via the mechanical fastener 830 that is inserted through the face. Then, a face member can be welded to the face retaining surface 842.

As in the other embodiments, the toe weight member 828 preferably has a mass of about 35 to 55 grams. Preferably, the toe weight member 828 mass increases with each club by about 5 grams per club. The club can further include a heel weight member that is not shown that is preferably about 30 grams to 35 grams and preferably decreases by about 1 or 2 grams per club. A heel weight can be attached in the same manner as the toe weight member shown or can be placed behind the face insert as discussed above with respect to FIGS. 4 and 5. Preferably, the tungsten mass of the toe weight member 828 and the heel weight member are at least 25% of the total club head mass and at least 15% of the total club head solid volume. In yet another embodiment, the body 800 can include a hosel weight instead of a heel weight to further increase the MOI about the horizontal axis.

Referring to FIG. 16, another embodiment of the present invention is an iron body 900 including a heel 912, a toe 914, a hosel 916 and a sole 918. The iron 900 further comprises a toe weight member 928 that is coupled to the body 900. In this embodiment, the weight member 928 is coupled to the body 900 by a mechanical fastener 930 that is nut fastener inserted through the face of the iron 900 that tightens onto a threaded portion 931 of the weight member 928. The iron body 900 can be formed by casting, but is preferably forged. An aperture is formed in the back wall 906 and the weight member 928 is attached to the back wall 906 via the mechanical fastener 930 that is inserted through the face. Then, a face member can be welded to the face retaining surface.

Referring to FIG. 17, another embodiment of the present invention is an iron body 1000 including a heel 1012, a toe 1014, a hosel 1016 and a sole 1018. The iron 1000 further comprises a toe weight member 1028 that is coupled to the body 1000. In this embodiment, the weight member 1028 is coupled to the back surface 1006 of the body 1000 by a plurality of mechanical fasteners 1030 that are inserted through the back cavity 1020 of the iron 1000. More particularly, a plurality of apertures 1004 can be formed in a bottom surface 1008 of the back cavity 1020 such that the threaded fasteners 1030 can couple to the weight member 1028. The iron body 1000 can be formed by casting, but is preferably forged. As shown, a face member can be welded to the face retaining surface, but this embodiment can also allow for the face to be integrally formed with the body 1000.

Referring to FIGS. 18 and 19, another embodiment of the present invention is an iron body 1100 including a heel 1112, a toe 1114, a hosel 1116 and a sole 1118. The iron 1100 further comprises a toe weight member 1128 that is coupled to the body 1100. In this embodiment, the weight member 1128 is coupled to the body 1100 by a mechanical fastener 1130 that provides an abutting lock. More particularly, a recess 1104 is formed in an outer surface 1108 of the iron body 1100 and the weight member 1128 such that the head of the threaded fastener 1030 can couple the weight member 1128 to the back surface 1106 of the body 1100. A retaining wall 1134 surrounds the weight member 1128 such that the weight member 1128 is press fit when the fastener member 1130 is secured in the recess 1104. The iron body 1100 can be formed by casting, but is preferably forged. As shown, a face member can be welded to the face retaining surface, but this embodiment can also allow for the face to be integrally formed with the body 1100.

Referring to FIGS. 20, 21 and 22, another embodiment of the present invention is a set of golf clubs comprising at least a long iron having a loft between about 15 and 25 degrees and a first club head mass, a mid iron having a loft of between about 26 and 35 degrees and a second club head mass, and a short iron having a loft of about 36 degrees or greater and a third club head mass. The long iron, for example, comprises a steel body 1200 that comprises a heel 1212, a toe 1214, a topline 1220, a sole 1218, and a hosel 1216. A front face insert 1210 and a back wall 1224 form a hollow cavity 1226 therebetween.

Preferably, the iron body is cast with the main cavity 1226 and the hosel cavity 1232. The front face insert 1210 is preferably stamped from a high strength sheet metal and is welded to the body after a toe weight member 1228 is secured with in the hollow cavity 1226. A heel weight member 1230 is inserted into the face side of the hosel cavity 1232 and then a hosel cover member 1234 is welded to the front portion of the hosel 1216 to secure the heel weight member 1230 within the hosel cavity 1232.

The toe weight member 1228 is formed of tungsten and is coupled to a toe portion of the hollow cavity 1226. Preferably, as set forth in Table IV below, the toe weight member 1228 is greater than about 65 grams and comprises about 25%-35% of the long iron club head mass. The long iron head further comprises the heel weight member 1230, also formed of tungsten, that is about 10 to 20 grams and is coupled into the hosel cavity 1232 formed in the front, lower portion of the hosel 1216. Preferably, the heel weight member 1230 comprises about 5%-10% of the long iron head mass. In this embodiment, the heel weight member 1230 is preferably secured in the hosel cavity 1232 by a steel cover member 1234 that forms at least a front portion of the hosel 1216.

In the preferred set, the mid iron has the same or similar construction as the long iron, and thus, similarly comprises a steel, hollow body with a heel, a toe, a topline, a sole, and a hosel. As set forth in Table IV below, the toe weight member for at least one of the mid irons is also formed of greater than 65 grams of tungsten and comprises about 25%-35% of the mid iron head mass.

The club heads according to the present invention have high Moment of Inertias. Because they have such large tungsten weight members, the Moment of Inertia about the y-axis (34 shown in FIG. 2), MOIy, is greater than 250 kg-mm² for all of the irons. Still further, the irons in the preferred set as presented in Tables IV and V below are not oversized. That is, the blade length is less than 82 mm. Thus, the MOIy to blade length ratio is very high. More particularly, the MOIy to blade length ration is greater than 3 kg-mm, and more preferably, between about 3.1 kg-mm and 3.5 kg-mm.

Moreover, because the mid irons and the long irons are hollow, the Center of Gravity is relatively deep. More particularly, the Center of Gravity depth from the face center, CGzFC, is preferably greater than 6 mm for all of the irons. In a preferred embodiment, the CGzFC can be around 8 mm for the long irons. Preferably, the CGzFC is almost 1/10 of the blade length for the long irons.

Also, the Center of Gravity from the ground, CGy, is very low through the set. As set forth in Table V below, preferably, the CGy is less than 18 mm from a ground surface for the long irons and less than 19 mm for the mid irons and short irons when the club head is in the standard address position.

TABLE IV
Club Number	3	4	5	6	7	8	9	P
loft	19	22	25	28	3	35	39	43
Total Mass (g)	239	247	254	261	268	274	284	286
Body Mass (g)	85	86	87	118	261	267	278	280
Face Mass (g)	58	58	58	56
Toe W (g)	67	74	77	73
Heel W (g)	14	15	18
Steel Mass %	60	58	57	67
W Mass %	34	36	37	28

TABLE V
Club
Number	3	4	5	6	7	8	9	P
Blade	81	81	81	80	80	80	80	80
Length
(mm)
Toe	31	31.5	32	32.3	32.7	33.3	34	34.5
Height
(mm)
Scoreline	54.5	54.3	54.1	54	53.8	53.6	53.3	53.1
Width
(mm)
Sole Width	16.8	16.3	15.8	15.3	14.8	14.65	14.5	14.35
Center
(mm)
CGy (mm)	17.75	17.8	17.9	18	18.4	18.6	18.7	18.7
MOIy	257	259	266	261	260	262	267	274
(kg · mm2)

Referring to FIGS. 23 through 25, another embodiment of the present invention is a set of golf clubs comprising at least a long iron having a loft between about 15 and 25 degrees and a first club head mass, a mid iron having a loft of between about 26 and 35 degrees and a second club head mass, and a short iron having a loft of about 36 degrees or greater and a third club head mass. The long iron, preferably, comprises a steel body 1300 that comprises a heel 1312, a toe 1314, a topline 1320, a sole 1318, and a hosel 1316. A front face insert 1310 and a back wall 1324 form a hollow cavity 1326 therebetween.

Preferably, the iron body is cast to form the hollow cavity 1326 and a hosel cavity 1332. The front face insert 1310 is preferably stamped from a high strength sheet metal and is welded to the body after a toe weight member 1328 is secured with in the hollow cavity 1326. As shown in the Tables II and IV above and Table VI below, it is important for the face member to be light weight to create a high MOI. Preferably, the face member 1310 has a mass of less than 45 grams, and more preferably, has less mass that the toe weight member 1328. It is even more preferred that the face insert mass is less than % the mass of the toe weight member 1328. In a preferred embodiment, the face member 1310 is formed from steel having an Ultimate Tensile Strength of greater than 2000 MPa. In the most preferred embodiment, the face insert 1310 is formed to a thickness t of 1.8 mm or less and has an Ultimate Tensile Strength of 2300 MPa or greater. In one embodiment, the long irons can be formed with a face insert 1310 stamped from AerMet 340 with the face insert 1310 having a thickness t of about 1.75 mm or less when measure at the center of the face. The face insert 1310 preferably has a uniform thickness, but may have a thinner perimeter region surrounding a thicker center with a smooth transition zone connecting the center to the perimeter. In this embodiment, the center section is at least 10% thicker than the perimeter region. The face insert material for either embodiment preferably has a Fatigue Strength of greater than 800 MPa, and more preferably, greater than about 900 MPa, which is extremely important for the durability of the iron.

A heel weight member 1330 is inserted into the face side of the hosel cavity 1332 and then a hosel cover member 1334 is welded to the front portion of the hosel 1316 to secure the heel weight member 1330 within the hosel cavity 1332. The toe weight member 1328 is formed of tungsten and is coupled to a toe portion of the hollow cavity 1326. Preferably, as set forth in Table VI below, the toe weight member 1328 is greater than about 65 grams and comprises about 25%-40% of the long iron club head mass. The long iron head further comprises the heel weight member 1330, also formed of tungsten, that is about 10 to 25 grams and is coupled into the hosel cavity 1332 formed in the front, lower portion of the hosel 1316. Preferably, the heel weight member 1330 comprises about 5%-10% of the long iron head mass and the mass increases with loft through the set. In this embodiment, the heel weight member 1330 is preferably secured in the hosel cavity 1332 by a steel cover member 1334 that forms at least a front, lower portion of the hosel 1316.

As shown in FIG. 24, the face insert 1310 includes a face insert sole portion 1340 that extends from the leading edge 1342 toward the back wall 1324. Preferably, the face insert sole portion 1340 extends in the front-to-back direction from the leading edge 1342 a distance d_fisp that is at least 25% or the sole width distance. Moreover, it is preferred that the face insert sole portion 1340 extends from the heel 1312 toward the toe 1314. Preferably, the face insert sole portion 1340 has a length d_fiht in the heel-to-toe direction that is between 50% and 80% of the blade length. This enables the face insert 1310 to form a majority of the front portion of the sole, but allows the body portion of the sole 1318 to hold the toe weight member 1328.

The toe weight member 1328 can also be formed of two portions, the toe extremity portion 1328a and the toe central portion 1328b. In order to maximize the MOI of the iron, it is preferred that the toe extremity portion 1328a has a first width t_tw1 and the toe central portion 1328b has a second width t_tw2 that is less than the first width. More preferably, the first width t_tw1 is at least 50% greater than the second width t_tw2.

In the preferred set, the mid iron has the same or similar construction as the long iron, and thus, similarly comprises a steel, hollow body with a heel, a toe, a topline, a sole, and a hosel. As set forth in Table VI below, the toe weight member for at least one of the mid irons is also formed of greater than 65 grams of tungsten, and more preferably greater than 90 grams of tungsten. The toe weight member 1328 for the mid iron preferably comprises about 25%-40% of the mid iron head mass.

The club heads according to the present invention have high Moment of Inertias. Because they have such large tungsten weight members, the Moment of Inertia about the y-axis (34 shown in FIG. 2), MOIy, is greater than 230 kg-mm² for all of the irons. Still further, the irons in the preferred set as presented in Tables VI and VII below have small blade lengths, that is less than 82 mm and more preferably less than 78 mm. Thus, the MOIy to blade length ratio is very high. More particularly, the MOIy to blade length ration is greater than about 3 kg-mm, and more preferably, between about 3.0 kg-mm and 3.5 kg-mm.

Moreover, because the mid irons and the long irons are hollow, the Center of Gravity is relatively deep. More particularly, the Center of Gravity depth from the face center toward the back wall 1324, CGz, is preferably greater than 6 mm for all of the irons. In a preferred embodiment, the CGz can be between 6 mm and 6.5 mm through the set. Preferably, the CGz is almost 1/10 of the blade length for the long irons.

Also, the Center of Gravity from the ground, CGy, is very low through the set. As set forth in Table V below, preferably, the CGy is less than about 18 mm from a ground surface for the long irons and less than about 19 mm for the mid irons and greater than about 19 mm for the short irons when the club head is in the standard address position.

TABLE VI
Club Number	3	4	5	6	7	8	9	P
loft	20	23	26	29	32	36	40	44
Total Mass (g)	239	245	251	258	265	274	281	286
Body Mass (g)	89	89	93	94	94	117	281	286
Face Mass (g)	42	42	42	43	44	41
Toe W (g)	88	87	93	91	97	83
Heel W (g)	17	23	20	25	27	28
Steel Mass %	55	53	54	53	52	58	100	100
W Mass %	44	45	45	45	47	41

TABLE VII
Club
Number	3	4	5	6	7	8	9	P
Blade	76	76	76	76	75	75	75	75
Length
(mm)
Toe	51	51	51	53	53	53	55	56
Height
(mm)
Scoreline	53	53	52	52	52	52	52	51
Width
(mm)
Sole Width	17	17	16	16	16	15	15	15
Center
(mm)
CGy (mm)	18.1	18.2	18.4	18.5	18.6	18.9	19.4	19.2
CGz (mm)	6.4	6.3	6.3	6.2	6.15	6.05	6.35	6.35
MOIy	231	237	230	236	240	249	232	239
(kg · mm2)

Referring to FIGS. 26 through 29 and Tables VIII and IX below, another embodiment of the present invention is a set of golf clubs comprising at least a long iron having a loft between about 15 and 25 degrees and a first club head mass, a mid iron having a loft of between about 26 and 35 degrees and a second club head mass, and a short iron having a loft of about 36 degrees or greater and a third club head mass. The long iron, preferably, comprises a steel body 1400 that comprises a heel 1412, a toe 1414, a topline 1420, a sole 1418, and a hosel 1416. A front face insert 1410 and a back wall 1424 form a hollow cavity 1426 therebetween and a medallion 1444 is secured to the outer surface of the back wall 1424. In a preferred embodiment, the medallion 1444 can also cover one or more apertures 1446 in the back wall 1424.

Preferably, the iron body 1400 of at least the long iron is cast to form the hollow cavity 1426 and a hosel cavity 1432 located below the hosel 1416. The front face insert 1410 is preferably stamped from a high strength sheet metal and is welded to the body after a toe weight member 1428 is secured within the hollow cavity 1426 and a heel weight member 1430 is secured in the hosel cavity 1432. As shown in the Tables II, IV and VI above and Table VIII below, it is important for the face member to be light weight to create a high MOIy. Preferably, the face member 1410 has a mass of less than 55 grams, and more preferably, has less mass that the toe weight member 1428. In a preferred embodiment, the face member 1410 is formed from steel having an Ultimate Tensile Strength of greater than 2000 MPa. In the most preferred embodiment, the face insert 1410 is formed to a thickness t of 1.8 mm or less and has an Ultimate Tensile Strength of 2300 MPa or greater. In one embodiment, the long irons and mid irons can be formed with a face insert 1410 stamped from AerMet 340 with the face insert 1410 having a thickness t of about 1.8 mm or less when measure at the center of the face and the short irons can be formed with a face insert 1410 having a thickness t of 2.0 mm or less. The face insert 1410 preferably has a uniform thickness, but may have a thinner perimeter region surrounding a thicker center with a smooth transition zone connecting the center to the perimeter. In this embodiment, the center section is at least 10% thicker than the perimeter region. The face insert material for either embodiment preferably has a Fatigue Strength of greater than 800 MPa, and more preferably, greater than about 900 MPa, which is important for the durability of the iron.

As stated above, the heel weight member 1430 is inserted into the hosel cavity 1432 which is cast into the lower portion of the hosel 1416. In FIG. 27, the arrow 1432a points to the hosel cavity 1432, which is located under the hosel 1416. The heel weight member 1430 is formed from tungsten having a specific gravity of about 15-20 g/cm³ and is an arcuate weight member having an arc angle α of about 5 degrees to about 60 degrees. More preferably, the heel weight member has an arc angle α of about 20 degrees to about 45 degrees. The heel weight member 1430 also has an inner arc radius R of between about 10 mm and about 50 mm. More preferably, the arc radius R of the heel weight member 1430 is between about 15 mm and 40 mm and is less than ½ the blade length. The heel weight member 1430 also includes welding grooves 1431 as a welding area to secure the heel weight member 1430 within the hosel cavity 1432. When the heel weight member 1430 is inserted into the hosel cavity 1432, preferably at least 80% of the heel weight mass is located further heelward (in the x direction) of the heel-side front wall 1436. More preferably, the all of the heel weight member mass is located heelward of the heel-side front wall 1436 such that the shaft axis SA intersects the heel weight member 1430 below the hosel 1416.

The toe weight member 1428 is also formed of tungsten having a specific gravity of about 15-20 g/cm³ and is coupled to a toe portion of the hollow cavity 1426. The toe weight member 1428 is preferably located in the lower (y direction) toe portion of the hollow cavity 1426. Preferably, the toe weight member includes welding grooves 1429 for securing the weight member to the iron body 1400 before the face insert 1410 is welded to the body 1400.

Preferably, as set forth in Table VIII below, the toe weight member 1428 is greater than about 65 grams and comprises about 25%-40% of the long iron club head mass and mid iron club head mass. The long iron head and mid iron head further comprises the heel weight member 1430, also formed of tungsten that is about 10 to 25 grams for the long iron and 25 to 40 grams for the mid irons. As stated above, the heel weight members 1430 are coupled into the hosel cavity 1432 formed in the lower, front portion of the iron body 1400 below the hosel 1416 such that the shaft axis SA intersects the heel weight member 1430. Preferably, the heel weight member 1430 comprises about 5%-10% of the long iron head mass and comprises about 8%-15% of the mid iron head mass. Preferably, the mass of the heel weight members increases with loft through the set. In this embodiment, the heel weight member 1430 is preferably secured in the hosel cavity 1432 by a weld bead formed in the weld groove 1431.

As shown in FIGS. 28 and 29, the face insert 1410 includes a face insert sole portion 1440 that extends from the leading edge 1442 toward the back wall 1424 (in the z direction). Preferably, the face insert sole portion 1440 extends in the front-to-back direction from the leading edge 1442 a distance d_fisp that is at least 25% of the sole width. Moreover, it is preferred that the face insert sole portion 1440 extends from the heel-side front wall 1436 toward the toe 1414 (the x direction). Preferably, the face insert sole portion 1440 has a length d_fiht in the heel-to-toe direction that is between 50% and 80% of the blade length. This enables the face insert 1410 to form a majority of the front portion of the sole, but allows the body portion of the sole 1418 to hold the toe weight member 1428.

In the preferred set, the mid iron has the same or similar construction as the long iron, and thus, similarly comprises a steel, hollow body with a heel, a toe, a topline, a sole, and a hosel. As set forth in Table VIII below, the toe weight member for at least one of the mid irons is also formed of greater than 65 grams of tungsten, and more preferably greater than 70 grams of tungsten. The toe weight member 1428 for the mid iron preferably comprises about 25%-40% of the mid iron head mass. The mass of the toe weight member preferably increases with loft through the set as set forth in Table VIII below. Within the preferred set, there are preferably at least two long irons and two mid irons that include toe weights 1428 and the mass of the toe weights increases with loft. Also, within the preferred set, there are preferably at least two long irons and two mid irons that include heel weights 1430 and the mass of the heel weights increases with loft.

The club heads according to the present invention have high Moment of Inertias. Because they have such large tungsten weight members, the Moment of Inertia about the y-axis (34 shown in FIG. 2), MOIy, is greater than 230 kg-mm² for all of the irons, and more preferably, greater than about 260 kg-mm² for all of the irons. Still further, the irons in the preferred set as presented in Tables VIII and IX below have medium blade lengths, that is between 80 mm and 84 mm. Thus, the MOIy to blade length ratio is very high. More particularly, the MOIy to blade length ration is greater than about 3 kg-mm, and more preferably, between about 3.0 kg-mm and 3.5 kg-mm.

The club heads according to the present invention have more consistent Moment of Inertias about the shaft axis (SA shown in FIG. 26). Because the tungsten heel weight members 1430 are located in the hosel cavity 1432 such that the shaft axis SA intersects the heel weight members 1430, the Moment of Inertia about the shaft axis, MOI_SA, is less than 700 kg-mm² for all of the irons, and more preferably, between about 650 kg-mm² and 700 kg-mm² for all of the irons. More particularly, the long irons have a MOI_SA that is with 10% of the MOI_SA for the mid irons and more preferably within 5%. Preferably, [(mid iron MOI_SA−long iron MOI_SA)/mid iron MOI_SA]*100<5. Also, the mid irons have a MOI_SA that is within 10% of the MOI_SA for the short irons and more preferably within 5%. Preferably, [(short iron MOI_SA−mid iron MOI_SA)/short iron MOI_SA]*100<5. Still further, the long irons have a MOI_SA that is with 10% of the MOI_SA for the short irons and more preferably within 5%. Preferably, [(short iron MOI_SA−long iron MOI_SA)/short iron MOI_SA]*100<5.

Moreover, because the mid irons and the long irons are hollow, the Center of Gravity is relatively deep. More particularly, the Center of Gravity depth from the face center toward the back wall 1424 (in the z direction), CGz, is preferably greater than 6 mm for all of the irons. In a preferred embodiment, the CGz can be between 7.5 mm and 8.5 mm through the set. Preferably, the CGz is almost 1/10 of the blade length for the long irons and mid irons.

Also, the Center of Gravity from the ground, CGy, is very low through the set. As set forth in Table IX below, preferably, the center of gravity in the y direction, CGy, is less than about 18 mm from a ground surface for the long irons and less than about 19 mm for the mid irons and short irons when the club head is in the standard address position.

TABLE VIII
Club Number	4	5	6	7	8	9	P	W
loft	21	24	27	30	34	38	43	48
Total Mass (g)	245	252	259	265	273	281	286	289
Body Mass (g)	93	93	93	93	218	224	228	231
Face Mass (g)	52	52	52	52	50	51	51	51
Toe W (g)	68	72	75	78
Heel W (g)	22	25	28	31
Medallion (g)	3.5	3.5	3.5	3.5	3.3	3.3	3.3	3.3
Steel Mass %	59	58	56	58	98	98	98	98
W Mass %	37	38	40	41

TABLE IX
Club
Number	4	5	6	7	8	9	P	W
Blade	83	83	82	82	82	8	81	81
Length
(mm)
Toe	55	55	55	56	56	56	57	57
Height
(mm)
Scoreline	54	54	54	54	54	53	53	53
Width
(mm)
Sole Width	22	21	21	20	20	19	19	18
Center
(mm)
CGy (mm)	17.7	17.8	17.9	18.0	18.3	18.5	18.6	18.6
CGz (mm)	7.5	7.5	7.4	7.4	7.8	7.9	8.0	8.2
MOIy	270	275	284	290	274	279	284	288
(kg · mm2)
MOISA	658	667	674	678	677	684	685	690
(kg · mm2)

Referring to FIGS. 30-38, another embodiment of the present invention is a set of golf clubs comprising at least a long iron having a loft between about 15 and 25 degrees and a first club head mass, a mid iron having a loft of between about 26 and 35 degrees and a second club head mass, and a short iron having a loft of about 36 degrees or greater and a third club head mass. The long iron, for example, comprises an iron body 1500 that is preferably formed from steel and comprises a heel 1512, a toe 1514, a topline 1520, a sole 1518, and a hosel 1516. A front face insert 1510, preferably formed from titanium such as 15-3-3-3, and a back wall 1524, preferably formed from a composite, a thermoplastic compound such as PEEK, PSU or PPS, or a light weight material having a specific gravity of less than 1.6, form a hollow cavity 1526 therebetween. In the preferred set, the mid iron has the same or similar construction as the long iron.

Preferably, the iron body 1500 is cast with the hollow cavity 1526 and the hosel cavity 1532. However, the hosel bore 1517 and the hosel cavity 1532 can be machined. The front face insert 1510 can also be formed from stamped, high strength sheet metal and welded to the body 1500 after a toe weight member 1528 is secured with in the hollow cavity 1526. A heel weight member 1530 is inserted into the hosel cavity 1532, and optionally, a hosel cover member can be welded to the front portion of the hosel 1516 to secure the heel weight member 1530 within the hosel cavity 1532.

The toe weight member 1528 is formed of tungsten and is coupled to a toe portion of the hollow cavity 1526. Preferably, as set forth in Table X below, the toe weight member 1528 is greater than about 65 grams and comprises about 25%-35% of the long iron club head mass. The long iron head further comprises the heel weight member 1530, also formed of tungsten, that is about 10 to 20 grams and is coupled into the hosel cavity 1532 formed in the lower portion of the hosel 1516 such that the heel weight member 1530 is intersected by the shaft axis SA. In this embodiment, the shaft is inserted to the upper hosel bore 1517. Preferably, the heel weight member 1530 comprises about 5%-10% of the long iron head mass.

With reference to FIGS. 33, 35 and 36, the iron body 1500 preferably includes a body insert groove 1550 that extends across the topline, 1520, the toe 1514 and the sole 1518 and a face insert tongue 1551 that fits within the body insert groove 1550. Moreover, the iron body 1500 includes a body insert tongue 1552 on the heel side of the face and a face insert groove 1553 on the heel side of the face insert 1510 that couples to the body insert tongue 1552. The coupling of the tongue and grooves facilitates a better welding of the face insert 1510 when the face insert 1510 is made from the same material as the iron body 1500, either steel or titanium, or facilitates brazing if the iron body 1500 is steel and the face insert 1510 is titanium. Preferably, the face insert 1510 is formed of titanium and has a face thickness of between about 2 mm and 2.5 mm.

Referring to FIGS. 37-39, the iron body 1500 can further comprise a second heel weight member 1531 coupled in the hollow cavity 1526. In the most preferred embodiment, the iron body 1500 comprises a first heel weight member 1530 that is intersected by the shaft axis SA and a second heel weight member 1531 that is located in the hollow cavity 1526. The second heel weight member 1531 preferably has greater mass that the first heel weight member 1530. Moreover, the first heel weight member 1530 and the second heel weight member 1531 combined have a mass of greater than about 20 grams and more preferably between about 20 and 30 grams. Still further, the first heel weight member 1530 and the second heel weight member are preferably spaced apart by distance d_HW of no more than 10 mm and preferably less than 5 mm.

The club heads according to the present invention have high Moment of Inertias. Because they have such large tungsten weight members, the Moment of Inertia about the y-axis (34 shown in FIG. 2), MOIy, is greater than 250 kg-mm² for all of the irons and more preferably greater than 280 kg-mm². Still further, the blade length is preferably greater than 82 mm, but the MOIy to blade length ration is greater than 3 kg-mm, and more preferably, between about 3.4 kg-mm and 4 kg-mm. Still further, the Moment of Inertia about the shaft axis MOI_sa is greater than 600 kg-mm² and, more preferably, between about 610 and 700 kg-mm².

Moreover, as shown in FIG. 32 and because the mid irons and the long irons are hollow, the Center of Gravity CG is relatively deep and low. More particularly, the iron body 1500 has a Center of Gravity depth from the face center FC, CGz, that is preferably greater than 6 mm for all of the irons. In a preferred embodiment, the CGz can be around 8 mm for the long irons. Preferably, the CGz is approximately 1/10 of the blade length for the long irons. Also, the Center of Gravity from the ground, CGy, is very low through the set. Preferably, the CGy is less than 18 mm from a ground surface for the long irons and less than 19 mm for the mid irons and short irons when the club head is in the standard address position.

Referring to FIGS. 40-44, another embodiment of the present invention is a set of golf clubs comprising at least a long iron having a loft between about 15 and 25 degrees and a first club head mass, a mid iron having a loft of between about 26 and 35 degrees and a second club head mass, and a short iron having a loft of about 36 degrees or greater and a third club head mass. The long iron, for example, comprises an iron body 1600 that is preferably formed from steel and comprises a heel 1612, a toe 1614, a topline 1620, a sole 1618, and a hosel 1616. A front face insert 1610, preferably formed from titanium, and a back wall 1624, preferably formed from a composite, thermoplastic compound or light weight material having a specific gravity of less than 1.6, form a hollow cavity 1626 therebetween. In the preferred set, the mid iron has the same or similar construction as the long iron.

Preferably, the iron body 1600 is cast with the hollow cavity 1626 and the hosel cavity 1632. However, the hosel bore 1617 and the hosel cavity 1632 can be machined. The front face insert 1610 can also be formed from stamped, high strength sheet metal and welded to the body 1600 after a toe weight member 1628 is secured with in the hollow cavity 1626. A heel weight member 1630 is inserted into the hosel cavity 1632, and optionally, a hosel cover member can be welded to the front portion of the hosel 1616 to secure the heel weight member 1630 within the hosel cavity 1632. Although not shown, the iron body 1600 can include a second heel weight member secured in the heel side of the hollow cavity 1626.

The toe weight member 1628 is formed of tungsten and is coupled to a toe portion of the hollow cavity 1626. Preferably, as set forth in Table X below, the toe weight member 1628 is greater than about 65 grams and comprises about 25%-35% of the long iron club head mass. Preferably, the mass of the toe weight member 1628 is greater than the mass of the face insert 1610. The long iron head further comprises the heel weight member 1630, also formed of tungsten, that is about 10 to 20 grams and is coupled into the hosel cavity 1632 formed in the lower portion of the hosel 1616 such that the heel weight member 1630 is intersected by the shaft axis SA. In this embodiment, the shaft is inserted to the upper hosel bore 1617. Preferably, the heel weight member 1630 comprises about 5%-10% of the long iron head mass.

With reference to FIGS. 43 and 44, the iron body 1600 preferably includes a body insert groove 1650 that extends across the topline 1620 and the sole 1618 and a face insert tongue 1651 that fits within the body insert groove 1650. Moreover, the iron body 1600 includes a body insert tongue 1652 on the toe side and heel side of the face and a corresponding face insert groove 1653 on the toe side and heel side of the face insert 1610 that couples to the body insert tongue 1652. The coupling of the tongue and grooves facilitates a better welding of the face insert 1610 when the face insert 1610 is made from the same material as the iron body 1600, either steel or titanium, or facilitates brazing if the iron body 1600 is steel and the face insert 1610 is titanium. Preferably, the face insert 1610 has a face thickness of between about 2 mm and 2.5 mm and if formed of a titanium alloy such as 15-3-3-3.

Moreover, as shown in FIG. 41 and because the mid irons and the long irons are hollow, the Center of Gravity CG is relatively deep and low. More particularly, the iron body 1600 has a Center of Gravity depth from the face center FC, CGz, that is preferably greater than 6 mm for all of the irons. In a preferred embodiment, the CGz can be around 9 mm for the long irons. Preferably, the CGz is approximately 1/10 of the blade length for the long irons. Also, the Center of Gravity from the ground, CGy, is very low through the set. Preferably, the CGy is less than 18 mm from a ground surface for the long irons and less than 19 mm for the mid irons and short irons when the club head is in the standard address position.

The following tables demonstrate the properties of the irons discussed above with steel bodies 1500, 1600, titanium face inserts 1510, 1610 brazed to the steel bodies, tungsten weights 1528, 1530, 1531, 1628, 1630 and a composite or thermoplastic backwall 1524, 1624.

	TABLE X
	Club	1600	1500
	loft	20	22
	Total Mass (g)	245	241
	Ti Mass (g)	36	86
	Steel Mass (g)	99	22
	Toe W (g)	76	101
	Heel W (g)	20	11
	Heel W2 (g)		16
	Steel Mass %	40	9
	W Mass %	39	53

	TABLE XI
	Club	1600	1500
	Blade Length (mm)	85	83
	Toe Height (mm)	53	50
	Scoreline Width (mm)	55	57
	Sole Width Center (mm)	22	27
	CGy (mm)	18	17
	CGz (mm)	7	9
	MOIy	312	317
	(kg-mm2)

FIG. 45 of the accompanying drawings shows a rear view of a golf club head 4500, with the sole cover 4635 (shown in FIG. 46) in accordance with a further alternative embodiment of the present invention. In this alternate embodiment of the present invention, the body portion 4510 has a heel, a toe, a topline, a sole, and a hosel which forms the main chassis of the golf club head 4500. Although some of the previous embodiments of the present invention may have utilized a titanium face insert, the present invention has a striking face that is formed out of steel like the remainder of the body portion 4510 and is generally formed as a unitary forged body with the remainder of the body portion 4510 to create the consistency and feel associated with a forged golf club head 4500. However, it should be noted that the striking face could be formed separately from the body portion 4510, out of the same material or even a different material, all without departing from the scope and content of the present invention.

With the sole cover 4735 (shown in FIG. 47) removed, the toe weight member 4528 and the heel weight member 4530 are now visible for the sake of illustration. It should be noted here that the heel weight member 4530 has a shape and geometry that is consistent with the various heel weight members previously, and the hosel axis still intersects the heel weight member 4530 below the hosel. The toe weight member 4528, on the other hand, differs from previously shown toe weight members 4528 in that it has an unsupported extension portion 4528-b, that separates the toe weight member 4528 into a main supported portion 4528-a and the aforementioned unsupported extension portion 4528-b.

In order to provide a better explanation of the unique toe weight member 4528 shown here in FIG. 45, FIG. 46 is provided in an attempt to illustrate how the toe weight member 4528 is divided into its main supported portion 4528-a and its unsupported extension portion 4528-b. FIG. 46 of the accompanying drawings shows an enlarged frontal view of a toe weight member 4628 in accordance with this alternative embodiment of the present invention. In this perspective view shown in FIG. 46, the toe weight member 4628 is divided into a main supported portion 4628-a and an unsupported extension portion 4628-b, separated by the bifurcation line 4633. The bifurcation line 4633 here is an imaginary line created at the transition between the main supported portion 4628-a. This imaginary bifurcation line is created by the toeward most point of the weight member 4628 that still come in contact with the striking face. Consequently, as the definition suggests, the unsupported extension portion 4628-b extends toeward from the main supported region 4628-a and does not contact the striking face of the golf club head. Utilizing this unsupported extension portion 4628-b of the toe weight member 4628 allows the center of gravity 4637 of the toe weight member 4628 to be located toeward of the bifurcation line 4633, which helps its structural integrity in being retained within the lower cavity of the golf club head. In addition to helping preserve the structural integrity, the unsupported extension portion 4628-b of the toe weight member 4628 reduces stresses in the striking face of the golf club head as it impacts a golf ball. Reducing stress in the striking face portion of the golf club head is critical to the performance of the golf club head, as it balances the need for increased moment of inertia of the golf club head with the increased stress created when the tungsten toe weight member 4628 touches the rear of the striking face.

FIG. 47 of the accompanying drawings shows an exploded perspective view of a golf club head 4700 in accordance with this alternative embodiment of the present invention. In this exploded perspective view shown in FIG. 47, we can see that the heel weight member 4730 and the toe weight member 4728 are both attached to the lower heel and toe portion of the body portion 4710 of the golf club head 4700 respectively. These high density heel weight member 4730 and toe weight member 4728 may generally be brazed to the rear surface of the striking face utilizing alignment indicators, with both of these weights being cradled by the sole cover 4735.

FIG. 48 of the accompanying drawings shows a cross-sectional view of a golf club head 4800 taken along the middle of the golf club head 4800 in order to illustrate the relationship between the unsupported extension portion 4828-b of the toe weight member 4828 and the striking face to be shown more clearly. In this cross-sectional view, we can see that the toe weight member 4828, including the unsupported extension portion 4828-b, does not extend all the way into the center of the face, which is where this cross-sectional view is provided. Based on this view, we can see that the main supported portion 4828-a of the toe weight member 4828 is in direct contact with the rear surface of the striking face, while the unsupported extension portion 4828-b of the same to weight member 4828 does not actually come in contact with the striking face but is separated by a distance d1. The distance d1 of separation, in this embodiment of the present invention may generally be greater than about 0.05 mm, more preferably greater than about 0.075 mm, and most preferably greater than about 0.1 mm, all without departing from the scope and content of the present invention.

While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives stated above, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Therefore, it will be understood that the appended claims are intended to cover all modifications and embodiments which would come within the spirit and scope 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 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.

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 y-axis extending vertically through a face center of the club head and a Moment of Inertia about said y-axis,a body comprising a heel, a toe, a topline, a sole, and a hosel;a striking face, located at a frontal portion of said golf club head;a toe weight member formed of tungsten and is coupled in a lower toe portion of said body and has a toe weight member mass that comprises greater than about 15% of a club head mass of said golf club head, anda heel weight member formed of tungsten and coupled in a lower hosel portion of said body and has a heel weight member mass that comprises between about 5% and about 10% of said club head mass of said golf club head,wherein said toe weight member further comprises; a main supported portion, defined as a portion of said toe weight member that contacts said striking face, andan unsupported extension portion, extending toeward from said main supported portion, wherein said unsupported extension portion of said tow weight member does not contact with said striking face.

2. The golf club head of claim 1, wherein said Moment of Inertia about said y-axis is greater than about 230 kg-mm2.

3. The golf club head of claim 2, wherein said Moment of Inertia about said y-axis is greater than about 280 kg-mm2.

4. The golf club head of claim 3, wherein said golf club head has a Moment of Inertia about a shaft axis that is between about 610 kg-mm2 and 700 kg-mm2.

5. The golf club head of claim 4, said striking face has a thickness of less than about 1.8 mm.

6. The golf club head of claim 5, wherein said unsupported extension portion of said toe weight member is separated from said striking face by a distance d1 of greater than about 0.05 mm.

7. The golf club head of claim 6, wherein said unsupported extension portion of said toe weight member is separated from said striking face by said distance d1 of greater than about 0.075 mm.

8. The golf club head of claim 7, wherein said unsupported extension portion of said toe weight member is separated from said striking face by said distance d1 of greater than about 0.1 mm.

9. The golf club head of claim 8, wherein a center of gravity of said toe weight member is located toeward of a bifurcation line within said toe weight member, wherein said bifurcation line is defined as a plane that separates said main supported portion of said toe weight member and said unsupported extension portion of said toe weight member.

10. The golf club head of claim 9, wherein said toe weight member has a specific gravity of between about 15 g/cm3 and about 20 g/cm3.

11. A golf club head comprising: a y-axis extending vertically through a face center of the club head and a Moment of Inertia about said y-axis,a body comprising a heel, a toe, a topline, a sole, and a hosel;a striking face, located at a frontal portion of said golf club head;a toe weight member formed of tungsten and is coupled in a lower toe portion of said body, anda heel weight member formed of tungsten and coupled in a lower hosel portion of said body,wherein said toe weight member further comprises; a main supported portion, defined as a portion of said toe weight member that contacts said striking face, andan unsupported extension portion, extending toeward from said main supported portion, wherein said unsupported extension portion of said tow weight member does not contact with said striking face, andwherein said unsupported extension portion of said toe weight member is separated from said striking face by a distance d1 of greater than about 0.05 mm.

12. The golf club head of claim 11, wherein said unsupported extension portion of said toe weight member is separated from said striking face by said distance d1 of greater than about 0.075 mm.

13. The golf club head of claim 12, wherein said unsupported extension portion of said toe weight member is separated from said striking face by said distance d1 of greater than about 0.1 mm.

14. The golf club head of claim 11, wherein said toe weight member has a toe weight member mass that comprises greater than about 15% of a club head mass of said golf club head.

15. The golf club head of claim 14, wherein said toe weight member mass comprises greater than about 20% of a club head mass of said golf club head.

16. The golf club head of claim 15, wherein said toe weight member mass comprises greater than about 25% of a club head mass of said golf club head.

17. The golf club head of claim 14, wherein said Moment of Inertia about said y-axis is greater than about 230 kg-mm2.

18. The golf club head of claim 17, wherein said Moment of Inertia about said y-axis is greater than about 280 kg-mm2.

19. The golf club head of claim 18, wherein said golf club head has a Moment of Inertia about a shaft axis that is between about 610 kg-mm2 and 700 kg-mm2.

20. A golf club head comprising: a y-axis extending vertically through a face center of the club head and a Moment of Inertia about said y-axis,a body comprising a heel, a toe, a topline, a sole, and a hosel;a striking face, located at a frontal portion of said golf club head;a toe weight member formed of tungsten and is coupled in a lower toe portion of said body and has a toe weight member mass that comprises greater than about 15% of a club head mass of said golf club head, anda heel weight member formed of tungsten and coupled in a lower hosel portion of said body,wherein said toe weight member further comprises; a main supported portion, defined as a portion of said toe weight member that contacts said striking face, andan unsupported extension portion, extending toeward from said main supported portion, wherein said unsupported extension portion of said tow weight member does not contact with said striking face, and