Golf club head having a composite face insert

• US 20070293349A1
• Filed: 08/21/2007
• Published: 12/20/2007
• Est. Priority Date: 05/21/2003
• Status: Active Grant

• Current Assignee: Taylor Made Golf Co., Inc.
• Original Assignee: Taylor Made Golf Co., Inc.
• Inventors: Chao, Bing-Ling, Vincent, Benoit, Beach, Todd, Ie, Citra, Flukers, Jabaarr
• Granted Patent: US 7,628,712 B2
• Time in Patent Office: Days
• US Class Current: 473/342
• CPC Class Codes: A63B 2209/02 with reinforcing fibres, e.g. carbon, polyamide fibres
• CPC Class Codes: A63B 2209/023 Long, oriented fibres, e.g. wound filaments, woven fabrics, mats
• CPC Class Codes: A63B 53/0408 characterised by specific dimensions, e.g. thickness
• CPC Class Codes: A63B 53/0412 Volume
• CPC Class Codes: A63B 53/0416 Heads having an impact surface provided by a face insert
• CPC Class Codes: A63B 53/0425 the face insert comprising two or more different materials
• CPC Class Codes: A63B 53/0466 wood-type
• CPC Class Codes: Y10T 156/1062 Prior to assembly

Abstract

A golf club head having a composite face insert attached to a metallic body is provided. The club head preferably has a volume of at least 200 cc and provides superior durability and club performance. The face insert includes prepreg plies having a fiber areal weight (FAW) of less than 100 g/m². The face insert preferably has a thickness less than 4 mm and a mass at least 10 grams less than an insert of equivalent volume formed of the metallic material of the body of the club head. A metallic cap with a peripheral rim is also provided to protect the ends of the composite material of the face insert. Related methods of manufacturing and alternative materials are disclosed. The resin content of the prepreg plies can be controlled through management of the timing and environment in which the resultant prepreg plies are cured and soaked.

Claims

1. :

A golf club head, comprising;

a body defining a front opening; and

a face insert comprising prepreg plies having a fiber areal weight of less than 100 g/m², the face insert attached at and closing the front opening of the body;

wherein the face insert'"'"'s total thickness is within a range of about 1 mm to about 8 mm.

2. :

A golf club head as defined in claim 1, wherein the face insert comprises a cap formed of a material with a density less than 5 g/cc, the cap covering a front surface of the prepreg plies and comprising a peripheral rim.

34. :

The golf club head of claim 1, wherein the thickness of the face insert is non-constant.

35. :

The golf club head of claim 1, wherein the thickness of the face insert is less than 5 mm.

36. :

The golf club head of claim 35, wherein the thickness of the face insert is less than 3.5 mm.

37. :

The golf club head of claim 1, wherein the prepreg plies have a fiber areal weight of less than 70 g/m².

38. :

The golf club head of claim 37, wherein the prepreg plies have a fiber areal weight of less than 50 g/m².

39. :

The golf club head of claim 1, further comprising a cap covering at least a portion of the face insert.

40. :

The golf club head of claim 39, the face insert having a front surface and a side edge, the cap covering at least a portion of the side edge.

41. :

The golf club head of claim 39, the face insert having a front surface and a side edge, the cap extending across at least a portion of the front surface.

42. :

The golf club head of claim 41, wherein the cap is comprised of a metallic material.

43. :

The golf club head of claim 42, wherein the cap is comprised of a titanium alloy.

44. The golf club head of claim 41, wherein the cap is comprised of an injection-molded plastic.

45. :

The golf club head of claim 1, wherein the body comprises an annular ledge extending around a periphery of the front opening, and wherein the face insert is coupled to the annular ledge.

46. :

The golf club head of claim 1, wherein the body is comprised of at least one material selected from the group consisting of a titanium alloy, a steel alloy, and a composite material.

3. :

A golf club head having a volume of at least 200 cc, comprising;

a body having a crown, a skirt, and a sole, the body defining a front opening; and

a face insert having at least a portion comprising prepreg plies having a fiber areal weight of less than 100 g/m², the face insert closing the front opening of the body;

wherein the face insert'"'"'s total thickness is within a range of about 1 mm to about 8 mm, the golf club head having a coefficient of restitution of at least 0.79.

4. :

A golf club head as defined in claim 3, wherein;

the prepreg plies include carbon fiber reinforcement having a fiber areal weight of about 70 g/m²; and

the face insert'"'"'s total thickness is within a range of about 3 mm to about 4 mm.

5. :

A golf club head as defined in claim 3, wherein the prepreg plies have a fiber areal weight of less than 70 g/m2.

6. :

A golf club head as defined in claim 5, wherein;

the prepreg plies include carbon fiber reinforcement having a fiber areal weight of about 50 g/m²; and

the face insert'"'"'s total thickness is within a range of about 2.5 mm to about 4 mm.

7. :

A golf club head as defined in claim 5, wherein the body is at least partly formed of a metallic material and the mass of the face insert is at least 10 grams less than an equivalent volume of the metallic material of the body.

8. :

A golf club head as defined in claim 3, wherein the face insert comprises a metallic cap adhesively attached to the prepreg plies.

9-33. -33. (canceled)