Golf club head having a composite face insert

• US 7,850,546 B2
• Filed: 10/22/2009
• Issued: 12/14/2010
• Est. Priority Date: 05/21/2003
• Status: Expired due to Fees

• Current Assignee: Taylor Made Golf Co., Inc.
• Original Assignee: Taylor Made Golf Co., Inc.
• Inventors: Flukers, Jabaarr A., Ie, Citra A., Beach, Todd P., Chao, Bing-Ling, Vincent, Benoit
• Primary Examiner(s): Hunter; Alvin A
• Application Number:
  US12/589,484
• Publication Number:
  US 20100099513A1
• Time in Patent Office: 418 Days
• Field of Search: 473324-350
• 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 having a volume of at least 300 cc, comprising:

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

a face insert having at least a portion comprising prepreg plies having a fiber areal weight, the face insert closing the front opening of the body;

a metallic cap adhesively attached to the prepreg plies wherein the prepreg plies are configured to reinforce a majority of a metallic cap striking surface, the metallic cap abutting the transition edge to form a substantially flush golf club head front surface;

wherein the face insert'"'"'s total thickness is within a range of about 3.0 mm to about 4.5 mm, the golf club head having a coefficient of restitution of at least 0.79; and

the prepreg plies including carbon fiber reinforcement having a fiber areal weight of less than 100 g/m²;

2. A golf club head having a volume of at least 300 cc, comprising:

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

a face insert comprising prepreg plies having a fiber areal weight, the face insert attached at and closing the front opening of the body;

a metallic cap attached to the prepreg plies wherein the prepreg plies are configured to reinforce a majority of a metallic cap striking surface, the metallic cap abutting the transition edge to form a substantially flush golf club head front surface;

wherein the thickness of the prepreg plies is about 4.5 mm or less, and the thickness of the metallic cap is about 0.5 mm or less, and wherein the golf club head has a coefficient of restitution of at least 0.79, and wherein the metallic cap is formed with a density less than 5 g/cc. the cap covering a front surface of the prepreg plies and comprising a peripheral rim;

wherein the prepreg plies have a fiber areal weight of less than 100 g/m².

3. The golf club head of claim 2, wherein the prepreg plies have a fiber areal weight of less than 70 g/m².

4. A golf club head having a volume of at least 300cc, comprising:

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

a face insert comprising prepreg plies having a resin content of about 40%, the face insert attached at and closing the front opening of the body;

wherein the thickness of the prepreg plies is about 4.5 mm or less and the prepreg plies are configured to reinforce a majority of a cap striking surface, and wherein the golf club head has a coefficient of restitution of at least 0.79, wherein the body comprises an annular ledge extending around the periphery of the front opening, and wherein the face insert is coupled to the annular ledge; and

wherein the prepreg plies have a fiber areal weight of less than 100 g/m².

5. A golf club head having a volume of at least 300 cc, comprising:

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

a face insert comprising a plurality of stacked groups of 10 or more prepreg plies and the prepreg plies are configured to reinforce a majority of a cap striking surface, wherein each group of plies is arranged at a different orientation with respect to an adjacent group of plies, the face insert attached at and closing the front opening of the body;

wherein the thickness of the prepreg plies is about 4.5 mm or less, and wherein the golf club head has a coefficient of restitution of at least 0.79, wherein the body comprises an annular ledge extending around the periphery of the front opening, and wherein the face insert is coupled to the annular ledge; and

wherein the prepreg plies have a fiber areal weight of less than 100 g/m².