Golf club

• US 10,583,335 B2
• Filed: 06/26/2018
• Issued: 03/10/2020
• Est. Priority Date: 05/21/2014
• Status: Active Grant

• Current Assignee: Taylor Made Golf Co., Inc.
• Original Assignee: Taylor Made Golf Co., Inc.
• Inventors: Wester, Christian Reber, Sargent, Nathan T., Nielson, Joseph Reeve, Harbert, Christopher John, Jeon, Hong G.
• Primary Examiner(s): Dennis, Michael D
• Application Number:
  US16/019,186
• Publication Number:
  US 20180318667A1
• Time in Patent Office: 623 Days
• CPC Class Codes: A63B 2053/0491 with added weights, e.g. changeable, replaceable
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 53/0408 characterised by specific dimensions, e.g. thickness
• CPC Class Codes: A63B 53/0416 Heads having an impact surface provided by a face insert
• CPC Class Codes: A63B 53/042 the face insert consisting of a material different from that of the head
• CPC Class Codes: A63B 53/0433 with special sole configurations
• CPC Class Codes: A63B 53/045 Strengthening ribs
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: A63B 53/06 adjustable
• CPC Class Codes: A63B 60/00 Details or accessories of golf clubs, bats, rackets or the like
• CPC Class Codes: A63B 60/002 Resonance frequency related characteristics
• CPC Class Codes: A63B 60/02 Ballast means for adjusting the centre of mass A63B60/24, A63B60/54 take precedence
• CPC Class Codes: A63B 60/52 with slits

Abstract

In one embodiment the golf club head includes three main components, a frame component, a rear cap component, and a striking plate.

In another embodiment the club head may also comprise a front component, which is manufactured as a single unitary piece, and a rear cap component. The front component may also be overmolded by a thermoplastic polymeric outer portion which may or may not cover the striking face and which provides additional reinforcement at the load bearing sections of the club head and allows a more facile connection to the rear cap component.

In another embodiment, a club head having a main body, crown insert, sole insert and metal face plate frame is formed by forming the sole insert and crown insert from a polymeric material using a thermoforming or thermosetting process and then injection molding the main body over the sole insert, crown insert and metal face plate frame.

Claims

1. A golf club head comprising:

a main body formed from a thermoplastic material suitable for injection molding;

at least one composite insert joined to the main body; and

a metal face plate frame joined to the main body and including a peripheral edge, the metal face plate frame being distinct from the main body and configured to receive a face plate;

wherein the main body is injection molded around the metal face plate frame and mechanically captures the peripheral edge of the metal face plate frame; and

wherein the thermoplastic material of the main body has a mass that is at least 20% of the mass of the entire club head; and

wherein the thermoplastic material of the main body is a first thermoplastic composite material, and the at least one insert includes a second thermoplastic composite material, the first and second thermoplastic composite materials each having a matrix material compatible with one another to facilitate injection molding the main body over the at least one composite insert.

2. The golf club head of claim 1, wherein the thermoplastic material of the main body has a mass that is at least 30% of the mass of the entire club head.

3. The golf club head of claim 1, wherein the at least one composite insert includes a continuous fiber thermoplastic composite material.

4. The golf club head of claim 1, wherein the at least one composite insert is one of a crown insert, a sole insert or both a crown insert and a sole insert.

5. The golf club head of claim 1, wherein the main body extends over and at least partially overlies a face-side-most surface of the metal face plate frame.

6. A golf club head comprising:

a main body having a crown opening, a sole opening, and a face opening, the main body comprising a first thermoplastic composite material suitable for injection molding; and

at least one composite insert configured as a crown insert joined to the main body and overlying the crown opening, or configured as a sole insert joined to the main body and overlying the sole opening, the at least one composite insert including a second thermoplastic composite material; and

a metal face plate frame joined to the main body and including a peripheral edge, the metal face plate frame being distinct from the main body and configured to receive a face plate;

wherein the main body is injection molded around the metal face plate frame and mechanically captures the peripheral edge of the metal face plate frame; and

wherein the first and second thermoplastic composite materials each have a matrix material compatible with each other to facilitate injection molding the main body around the at least one composite insert.

7. The golf club head of claim 6, wherein the first thermoplastic composite material of the main body comprises chopped fibers.

8. The golf club head of claim 6, wherein the second thermoplastic composite material of the at least one composite insert includes a continuous fiber thermoplastic composite material.

9. The golf club head of claim 6, wherein:

the at least one composite insert is a crown insert that overlies the crown opening; and

the golf club head further comprises a sole insert that overlies the sole opening.

10. The golf club head of claim 6, wherein the main body at least partially overlies a face-side-most surface of the metal face plate frame.

11. The golf club head of claim 6, wherein the main body has a thickness of about 0.75 mm to about 3 mm, and the at least one composite insert has a thickness of about 0.5 mm to about 1.5 mm.

12. The golf club head of claim 6, wherein the first thermoplastic material of the main body has a mass that is at least 20% of the mass of the entire club head.

13. The golf club head of claim 6, wherein the at least one composite insert is configured as both a crown insert and a sole insert.

14. A golf club head comprising:

a main body formed from a first thermoplastic composite material suitable for injection molding;

at least one composite insert joined to the main body, the at least one insert including a second thermoplastic composite material; and

a metal face plate frame joined to the main body and including a peripheral edge, the metal face plate frame being distinct from the main body and defining an opening configured to receive a face plate;

wherein the main body is injection molded around the metal face plate frame and mechanically captures the peripheral edge of the metal face plate frame; and

wherein the first and second thermoplastic composite materials each have a matrix material compatible with one another to facilitate injection molding the main body over the at least one composite insert.

15. The golf club head of claim 14, wherein the first thermoplastic composite material of the main body comprises chopped fibers.

16. The golf club head of claim 14, wherein the second thermoplastic composite material of the at least one composite insert includes a continuous fiber thermoplastic composite material.

17. The golf club head of claim 14, wherein:

the at least one composite insert is a crown insert that overlies the crown opening; and

the golf club head further comprises a sole insert that overlies the sole opening.

18. The golf club head of claim 14, wherein the main body has a thickness of about 0.75 mm to about 3 mm, and the at least one composite insert has a thickness of about 0.5 mm to about 1.5 mm.

19. The golf club head of claim 14, wherein the first thermoplastic material of the main body has a mass that is at least 20% of the mass of the entire club head.

20. The golf club head of claim 14, wherein the at least one composite insert is configured as both a crown insert and a sole insert.