JP2020075102A - Golf club heads - Google Patents

Abstract

To provide golf club heads having cast components, and related methods for manufacturing such golf club heads.SOLUTION: A cast cup can include a forward portion of a golf club head, including a hosel, a face portion, a crown forward portion, a sole forward portion, a heel forward portion and a toe forward portion. A rear ring can be formed separately from the cast cup and coupled to heel and toe portions of the cast cup to form a metallic club head body, such that the club head body defines a hollow interior region, a crown opening and a sole opening. The cast cup and rear ring can be cast from titanium alloys. Composite crown and sole inserts can then be coupled to the crown opening and sole opening. The face portion of the cast cup can desirably have a complex geometry. The rear surface of the face portion of the cast cup can be modified before the rear ring is attached.SELECTED DRAWING: None

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part application of US patent application Ser. Claims the benefit of application No. 62 / 543,778, both of which are incorporated herein by reference in their entirety.

  The present disclosure relates to golf club heads having cast components, and related methods for making such golf club heads.

  Due to the increasing popularity and competitiveness of golf, a considerable amount of effort and resources are currently being spent on improving golf clubs. Much of the recent improvement activity has involved the combination of the use of new and increasingly sophisticated materials in concert with advanced club head engineering. For example, what are the latest "wood-type" golf clubs (such as "drivers", "fairway woods", "rescue", and "utility or hybrid clubs") that have sophisticated shafts and non-wooden club heads? It looks a lot like the "wood" drivers, low-loft long irons, and higher numbered fairway woods that were used years ago. These modern wood-type clubs are commonly referred to as "metal wood" or simply "wood."

  The current ability to produce strong, lightweight metal and other metal metal wood club heads allows the club head to be hollow. The use of high strength and high fracture toughness materials also allows the club head walls to be thinner, compared to previous club heads without the swing speed penalty associated with increased weight. It allows for a reduction in total weight and an increase in club head size. Larger club heads tend to have larger face plate areas and can also be made with higher club head inertia, which makes the club head more "forgiving" than smaller club heads. .. Characteristics such as the size of the optimum impact location (also known as the “sweet spot”) are dependent on many variables, including the shape, profile, size, and thickness of the faceplate, and the location of the center of gravity (CG) of the club head. It is determined.

  Exemplary metalwood golf clubs typically include a shaft having a lower end to which a club head is mounted. Most modern versions of these club heads are made, at least in part, of lightweight but strong metals such as titanium alloys. The club head may include a body to which a face plate (herein used interchangeably with the terms "face", "face insert", "striking plate" or "strike plate") is attached. In some cases, the body and face place are cast together as a unitary structure, eliminating the need to later attach the face plate to the body. The face plate defines a front surface or strike face that actually contacts the golf ball.

  Considering the total mass of a metal wood club head as the club head mass budget, at least a portion of the mass budget must be devoted to providing sufficient strength and structural support to the club head. This is called the "structural" mass. The mass remaining within the budget is referred to as the "discretionary" or "performance" mass and can be distributed within the metal wood club head, for example, to address performance issues. Thus, the ability to reduce the structural mass of a metalwood club head without compromising strength and structural support offers the potential to increase discretionary mass and thereby improve club performance.

  One opportunity to reduce the total mass of the club head is to reduce the faceplate mass by reducing the faceplate thickness, but because the face absorbs the initial impact of the ball, its physical and mechanical The opportunity to do this is somewhat limited given the very stringent requirements of the traits. Club manufacturers use titanium and titanium alloys in the manufacture of face plates and in the manufacture of entire club heads due to their light weight and high strength. In the case of club heads that allow for relatively complex three-dimensional structures, casting processes are typically used to manufacture them. Many such face plates are made by the investment casting process in which a suitable metal melt is cast into a preheated ceramic investment mold formed by the lost wax process. Investment casting is also used to prepare the faceplate either as a one-piece structure cast with the rest of the club head body or as a separately formed face plate that is usually attached to the front of the club head body by welding. Has been done. Although widely used, investment casting of such complex shaped parts of reactive materials is characterized by relatively high cost and low yield. Low casting yields may include some surface or surface-related void-type defects, and / or insufficient filling of certain mold cavity regions, especially thin mold cavity regions, and associated defects such as internal voids and shrinkage. Due to the factors of.

  To further combine the investment casting defects of the faceplate, club head manufacturers should introduce curvature into the face of the club to help compensate for orientation problems caused by shots other than at the center of gravity. There are also many. Therefore, rather than a flat face plate, manufacturers prefer faces with both a heel-to-toe convex curve (called a "bulge") and a crown-to-sole convex curve (called a "roll"). May want to form. In addition, manufacturers can also introduce variable face thickness profiles across the faceplate. Varying the faceplate thickness can increase the size of the club head COR area, commonly referred to as the golf club head's sweet spot, which is consistently high when hitting a golf ball with the golf club head. Allows for a larger area of the faceplate that provides ball speed and shot tolerance. Also, varying the thickness of the faceplate can be advantageous to reduce the weight of the face area for repositioning to another area of the club head.

  To compensate for these deficiencies in investment casting of more complex faceplate structures, manufacturers are looking at alternative methods of forming faceplates, which include rolling titanium sheet to faceplate shape. Laser cutting, then forging to provide any desired bulges and rolls, followed by machining steps on the lathe to introduce any desired face thickness profile. The drawback of these steps is that not only is the machining process on the lathe to form the variable thickness profile wasteful, requiring three separate forming steps, but also the profile as a result of the circular motion of the lathe. Includes the fact of limiting to circular areas.

  Therefore, it would be highly desirable to have a club head faceplate that has sufficient physical properties to allow a reduction in thickness and provide more discretionary weight available in the club head. It would also be desirable if the faceplate could exhibit any desired bulge and roll curvature in addition to any variable thickness profile having any shape of circle, ellipse, asymmetry, or other shape. .. It is also possible to use a simplified process for the manufacture of such face plates, which results in a face plate with the required thickness and physical strength properties, which also It would also be desirable if faceplates with any desired bulges and rolls and variable thickness profiles were obtained, requiring minimal processing steps and minimizing any waste generated in the process. .. It would also be desirable if the club head body and face could be co-cast from the same material as a single integral body rather than two parts that would have to be attached together later. It would also be desirable if the cast faceplate did not require chemical etching to remove or reduce the thickness of the alpha case to provide sufficient durability to the faceplate.

  Some golf club head bodies disclosed herein can be cast from 9-1-1 titanium and the faceplate is cast as an integral part of the body with the crown, sole, skirt, and hosel. The 9-1-1 titanium material allows the faceplate and other parts of the body to have less oxygen uptake from the mold and reduce the thickness of the alpha case, resulting in increased ductility and durability. To do. This eliminates the need to reduce the thickness of the alpha case after casting with hydrofluoric acid or other hazardous chemical etchants.

  The casting method includes preheating the mold to a temperature below room temperature and / or coating the inner surface of the mold to further reduce the amount of oxygen transferred from the mold to the 9-1-1 titanium during casting. Can be included.

  In some embodiments, a wood-type golf club head body includes a crown, a sole, a skirt, a faceplate, and a hosel, the body defining a hollow interior region, the body substantially entirely 9-1-1. Cast from titanium, the body is cast as a single, unitary casting, and the faceplate is integrally formed with the crown, sole, skirt, and hosel. The body may contain traces of fluorine atoms as alloying impurities found in titanium alloys, but since the face is not etched with hydrofluoric acid after casting, the fluorine content present in the body can be very low. .. In some embodiments, the faceplate may be substantially free of fluorine atoms, such as less than 1000 ppm, less than 500 ppm, less than 200 ppm, and / or less than 100 ppm. In some embodiments, the body can have an alpha case thickness of 0.150 mm or less, 0.100 mm or less, and / or 0.070 mm or less.

  Some exemplary methods include providing a mold for casting, and then using the mold to cast a golf club head body that is composed substantially entirely of 9-1-1 titanium, the cast body comprising: Including a crown, sole, skirt, faceplate, and hosel, the cast body defines a hollow interior region, the body is cast as a single, unitary casting, and the faceplate is crown, sole, skirt, and hosel during casting. Is formed integrally with. Some of these methods do not include etching the faceplate after casting. In some methods, preparing the mold comprises preheating the mold so that the temperature of the mold is 800 ° C. or less, 700 ° C. or less, 600 ° C. or less, and / or 500 ° C. or less when casting is performed. Including.

  Also disclosed herein are embodiments of golf club heads that include a cast metal cup that forms the front portion of the club head, including the hosel, the face portion, the front portion of the crown, and the front portion of the sole. A metal back ring is formed separately from the casting cup and coupled to the heel and toe of the casting cup to form a club head body, the metal club head body having a hollow interior region, a crown opening, and The sole opening may be defined. The composite crown insert can then be bonded to the crown opening. A sole insert made of composite, metal, or other material can be bonded to the sole opening. In some embodiments, there are no sole openings or sole inserts. The casting cup and back ring can be cast from a titanium alloy and welded together to form the club head body. In some embodiments, the ring and cup are made of two different titanium alloys, or different metallic materials such as titanium alloy and steel. The cast cup can include a face portion having a complex shape to provide the desired performance characteristics. The face portion can have a twisted front surface and / or the back surface of the face can have a shape that provides an asymmetric variable thickness profile across the face. The rear surface of the face portion of the casting cup may be machined and / or otherwise modified prior to mounting the rear ring to provide more space for the tool to access the entire rear surface of the face.

  A method of forming a wax cup from a wax cup frame and a separately formed wax face using the wax welding method is also disclosed. Such wax cups can then be used to make molds for casting the metal cups that form the front of the golf club head. The two-part wax welding process can provide manufacturing, prototyping, and testing advantages.

  Also disclosed is a cast faceplate such as comprising a titanium alloy having a novel shape.

  The foregoing and other objects, features, and advantages of the disclosed technology will become more apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

It is a side view of a golf club head. 2 is a front view of the golf club head of FIG. 1. FIG. 2 is a bottom perspective view of the golf club head of FIG. 1. FIG. It is a front view of the golf club head of FIG. 1 which shows the origin coordinate system of a golf club head. 2 is a side view of the golf club head of FIG. 1 showing a barycentric coordinate system. FIG. 2 is a top view of the golf club head of FIG. 1. FIG. FIG. 8 is a rear view of an exemplary faceplate having a variable thickness. 8 is a cross-sectional side view of the face plate of FIG. 7 taken along line 8-8 of FIG. 7. 9 is a cross-sectional side view of the face plate of FIG. 7 taken along line 9-9 of FIG. 7. 1 is a front view of a golf club head of the present invention showing a bulge and roll measurement system. It is a figure of a golf club head which hits a golf ball on the heel side of the golf club head. FIG. 6A is a top view of an exemplary initial pattern of a wood-type club head showing the main gate, assistant gates, and flow channels. FIG. 5 is a schematic view of a casting cluster including a plurality of mold cavities. FIG. 6 is a schematic view of another casting cluster including multiple mold cavities. FIG. 6 is a workflow diagram illustrating a method for casting a golf club head. 3 is a table of casting data for titanium alloys obtained on 6 different casters. 17 is a table that follows the table in FIG. 16. FIG. 3 is a plot of process loss vs. mass of injected material (molten metal) for a titanium alloy, where the mass of injected material shows the casting furnace size for various casters. 3 is a flow chart of one embodiment of a method for constructing a casting cluster. FIG. 6 is a bottom perspective view of yet another exemplary golf club head disclosed herein. 21 is an exploded bottom perspective view of the golf club head of FIG. 20. FIG. FIG. 21 is an exploded side perspective view of the golf club head of FIG. 20. 21 is a top view of the main body of the golf club head of FIG. 20. FIG. 23 is a cross-sectional view of the body taken along line 23-23 of FIG. 21 is a bottom view of the golf club head of FIG. 20. FIG. FIG. 25 is a cross-sectional view taken along line 25-25 of FIG. 24. 21 is a heel side view of the golf club head of FIG. 20. FIG. FIG. 21 is a toe side view of the golf club head of FIG. 20. FIG. 23 is a sectional top-down view of the lower portion of the body of FIG. 22. FIG. 23 is a sectional side view of a toe portion of the main body of FIG. 22. FIG. 23 is a bottom view of the front portion of the sole of the main body of FIG. 22. FIG. 30 is an enlarged detailed cross-sectional view of the left and right weight tracks taken generally along the line 30-30 of FIG. 29. 31 is another enlarged detail cross-sectional view of the left and right weight tracks taken generally along the line 31-31 of FIG. 29. FIG. FIG. 23 is a bottom view of a portion of the sole of the body of FIG. 22 including front and rear weight tracks. 33 is an enlarged detailed cross-sectional view of the front and rear weight tracks taken generally along line 33-33 of FIG. 32. FIG. 34 is another enlarged detail cross-sectional view of the front and rear weight tracks taken generally along line 34-34 of FIG. 32. FIG. FIG. 21 is a top view of the golf club head of FIG. 20, showing the sole portion positioned within the body, with the crown portion removed. 21 is a top view of the sole portion of the golf club head of FIG. 20. FIG. FIG. 21 is a top view of the golf club head of FIG. 20 with the crown in place. 21 is a top view of the golf club head of FIG. 20 with both the crown and sole portions removed. FIG. 21 is a front side view of the sole portion of the golf club head of FIG. 20. FIG. 21 is a bottom view of the sole portion of the golf club head of FIG. 20. FIG. 21 is a side view of the crown portion of the golf club head of FIG. 20. FIG. 21 is a top view of the crown portion of the golf club head of FIG. 20. FIG. FIG. 6 is a perspective view of another exemplary golf club head. FIG. 38 is a different perspective view of the club head of FIG. 37 with a head-shaft coupling assembly. FIG. 38 is a view showing a state where the main body of the club head of FIG. 37 is formed from two parts attached together. FIG. 40 shows the body of FIG. 39 in the assembled state. FIG. 41 shows how the crown insert and sole insert are assembled with the body of FIG. 40. It is a figure which shows the front surface of the cup face part of a main body. It is a figure which shows the rear part of the cup face part of a main body. It is a front view of a main body. It is a heel side elevation view of a main body. It is a top view of a main body. It is a bottom view of a main body. FIG. 6 is a cross-sectional view of a head-shaft coupling assembly. FIG. 6 is a diagram showing a two-part wax body in which the wax face is formed separately from the rest of the wax body. It is a figure which shows the wax face welded to the remaining part of the wax main body. It is a figure which shows the variable thickness profile of the back side of the face. FIG. 6 is a diagram showing another variable thickness profile on the rear side of the face. FIG. 53 is a perspective view of the face of FIG. 52. FIG. 8 is a diagram showing another variable thickness profile offset to the heel side. FIG. 3A illustrates a front side of an exemplary cast faceplate. FIG. 56 is a diagram showing the rear side of the cast face plate of FIG. 55.

  Embodiments of golf club heads for metal wood type golf clubs, including drivers, fairway woods, rescue clubs, utility clubs, hybrid clubs, etc., are described below.

  The features of the invention disclosed herein include all novel and non-obvious features disclosed herein, alone and in combination with any other feature. As used herein, the phrase “and / or” means “and”, “or”, and both “and” and “or”. As used herein, the singular forms "a", "an", and "the" unless the context clearly dictates otherwise. Refers to one or more. As used herein, the term "includes" means "comprises."

  The following also refers to the accompanying drawings, which form a part of this specification. Although the drawings show specific embodiments, other embodiments may be made and structural changes may be made without departing from the intended scope of the disclosure. Directions and references (eg, top, bottom, top, bottom, left, right, back, front, heel, toe, etc.) may be used to facilitate discussion of the drawings, but not limited thereto. It is not intended to be. For example, specific terms such as "top," "bottom," "top," "bottom," "horizontal," "vertical," "left," "right," etc. may be used. These terms are used, where appropriate, to provide some clarity of explanation when dealing with relative relationships, particularly with respect to the illustrated embodiments. However, such terms do not imply absolute relationships, positions, and / or orientations. For example, for an object, the "upper" surface can become the "lower" surface simply by rotating the object. Still, the object is still the same. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the property rights sought is defined by the appended claims and their equivalents.

  Inter alia, conditional languages such as “capable”, “capable”, “capable”, “may”, etc. generally refer to unless otherwise specified or otherwise understood within the context of use. It is intended to convey that certain embodiments include certain features, elements, and / or steps, but not other embodiments. Accordingly, such conditional languages generally require that features, elements and / or steps be somehow required by one or more particular embodiments, or that one or more particular embodiments require user input or prompting. Meaning that these features, elements, and / or steps, with or without, necessarily include logic for deciding whether or not to be included in any particular embodiment. Not intended to do.

  It should be emphasized that the embodiments described herein are merely examples of possible implementations and are merely a description for a clear understanding of the principles of the disclosure. Any process description or block in a flow diagram should be understood to represent a module, segment, or portion of code that contains one or more executable instructions for implementing a particular logical function or step in a process. Out of the order shown or discussed, including substantially simultaneous or reverse order, depending on the function involved, as would be reasonably understood by one of ordinary skill in the art of this disclosure. Alternative implementations are included that are not included or not implemented at all. Many variations and modifications may be made to the above-described embodiment (s) without departing substantially from the spirit and principles of the present disclosure. Furthermore, the scope of the present disclosure is intended to cover any and all combinations and subcombinations of all the elements, features and aspects described above. All such modifications and variations are intended to be included within the scope of this disclosure, and all possible claims for individual aspects or combinations of elements or steps are supported by this disclosure. To do.

  For reference purposes, within this disclosure, reference to "driver type golf club head" means any metal wood type golf club head primarily intended for use with the tee. In general, driver type golf club heads have lofts of 15 degrees or less, more typically 12 degrees or less. Reference to "a fairway wood-type golf club head" is intended to be used to hit the ball from the ground while also being usable to hit the ball from the tee. Means head. Generally, fairway wood type golf club heads have lofts of 15 degrees or more, more typically 16 degrees or more. Generally, fairway wood type golf club heads have a leading edge to trailing edge length of 73-97 mm. Various definitions distinguish fairway wood-type golf club heads from hybrid-type golf club heads, and hybrid-type golf club heads tend to resemble fairway wood-type golf club heads, but with a leading edge. Shorter length from to trailing edge. Generally, the hybrid type golf club head has a length from the leading edge to the trailing edge of 38 to 73 mm. Hybrid type golf club heads can also be distinguished from fairway wood type golf club heads by weight, lie angle, volume, and / or shaft length. Driver-type golf club heads of the present disclosure may be 15 degrees or less in various embodiments, or 10.5 degrees or less in various embodiments. In various embodiments, fairway wood type golf club heads of the present disclosure can be 13-26 degrees.

  As shown in FIGS. 1-6, a wood-type (eg, driver or fairway wood) golf club head, such as golf club head 2, may include a hollow body 10. The body 10 may include a crown 12, a sole 14, a skirt 16, and a face plate 18 (also referred to as a face or face portion) that defines an interior cavity while defining a striking surface 22. The face plate 18 may be formed separately from the body, attached to an opening in the front of the body, or integrally formed as an integral part of the body 10. The body 10 can include a hosel 20 defining a hosel bore 24 adapted to receive a golf club shaft (see FIG. 6). The body 10 further includes a heel portion 26, a toe portion 28, a front portion 30, and a rear portion 32.

  4 to 6 show ideal impact position 23 / origin 60, origin x-axis 70, origin y-axis 75, origin z-axis 65, center of gravity 50 of club head, CGx-axis 90, CGy-axis 95, and CGz-axis. 85 is shown. As shown, these axes are horizontal or vertical and the club head is in its normal address position. The origin axis passes through the origin 60 and the CG axis passes through the CG 50.

  The body may further include an opening in the crown and / or sole that is overlaid or covered with an insert formed of a lighter weight material such as a composite material. For example, the crown of the body can include a composite crown insert that covers most of the area of the crown and has a lower density than the metal from which the body is made, thereby saving crown weight. Similarly, the sole can include one or more openings in the body covered by the sole insert. The sole insert can be made of composite material, metallic material, or other material. In embodiments where the body includes an opening in the crown or sole, particularly if the faceplate is formed as an integral part of the body during casting (and there is no face opening in the body to provide access during manufacture). , Such openings may provide access to the internal cavity of the club head during manufacture. The club head disclosed herein in connection with FIGS. 20-36 includes a crown and sole opening that is covered or covered with an insert formed of a lighter weight material (eg, composite material). Provide an example. For more information on body openings and associated inserts, see US Patent Publication No. 2018/0185719, published July 5, 2018, and US Provisional Application No. 62/06, filed June 5, 2017. 515,401, both of which are incorporated herein by reference in their entirety.

  In some embodiments, the club head can include adjustable weights, such as one or more weights that are movable along a weight track formed on the sole and / or the periphery of the club head. Other exemplary weights can be adjusted by rotating the weight in a threaded weight port. Various ribs, struts, mass pads, and other structures can be included in the body for providing reinforcement, adjusting mass distribution and MOI properties, adjusting acoustic properties, and / or for other reasons.

Wood-type club heads, such as club head 2, have a volume generally measured in cubic centimeters (cm ³ ), which is equivalent to the volume displacement of the club head, assuming that any opening is enclosed in a generally flat plane. (See American Golf Association "Procedure for Measuring the Club Head Head Size of Wood Clubs" Revision 1.0, November 21, 2003). In the case of driver, golf club heads, such as about 300cm ³ ~ about 500cm ^3, can have a volume of about 250cm ³ ~ about 600cm ^3, it is possible to have a total mass of about 145g~ about 260g. For fairway woods, golf club heads can have a volume of about 120 cm ³ to about 300 cm ³ and can have a total mass of about 115 g to about 260 g. For utility clubs or hybrid clubs, the golf club head can have a volume of about 80 cm ³ to about 140 cm ³ and can have a total mass of about 105 g to about 280 g.

  The sole 14 is defined as the lower portion of the club head 2 extending upward from the lowest point of the club head when the club head is ideally positioned, i.e. at the proper addressing position for the golf ball in the horizontal plane. To be done. In some implementations, the sole 14 extends about 50% to 60% of the distance from the lowest point of the club head to the crown 12, and in some cases about 15 mm for drivers and about 10 mm for fairway woods. It can be 12 mm.

  Materials that can be used to construct the body 10 including the faceplate 18 include composite materials (eg, carbon fiber reinforced polymer materials), titanium or titanium alloys, steel or steel alloys, magnesium alloys, copper alloys, nickel alloys. , And / or any other metal or metal alloy suitable for golf club head construction. Other materials such as paints, polymeric materials, ceramic materials can also be included in the body. In some embodiments, the body including the faceplate is titanium or a titanium alloy (9-1-1 titanium, 6-4 titanium, 3-2.5, 6-4, SP700, 15-3-3-3. 10-2-3, or other alpha / near alpha, alpha-beta, beta / near beta titanium alloys, including but not limited to, or aluminum and aluminum alloys (3000 series alloys, 5000 series alloys, 6061- (Including but not limited to 6000 series alloys such as T6, 7000 series alloys such as 7075), 3.5-2.5% or less Al, 3.0-2.0% or less V, 0.02. % Of N, 0.013% or less of H, 0.12 or less of Fe having a chemical composition such as Ti grade 9 (Ti-3Al-2.5V).

Aspects of Investment Casting Injection molding is used to form the sacrificial "early" pattern of the desired casting (eg, made of cast "wax"). Suitable injection dies can be made of aluminum, other suitable metals or metal alloys, or other materials by, for example, a computer controlled machining process using a casting master. CNC (Computer Numerical Control) machining can be used to create the complexity of the mold cavity in the mold. The cavity size compensates for the linear and volumetric shrinkage of the casting wax that occurs during casting of the initial pattern, and during the actual metal casting that is performed later using the investment casting "shell" formed from the initial pattern. Established to compensate for similar contraction phenomena that are expected to occur.

  Usually, groups of initial patterns are assembled together and attached to a central wax sprue to form a cast "cluster". Each initial pattern within the cluster forms a respective mold cavity within the casting shell that is subsequently formed around the cluster. The central wax sprue defines the location and configuration of runner channels and gates for routing the molten metal introduced into the sprue to the mold cavity within the casting shell. The runner channel promotes a smooth laminar flow of molten metal into and into the casting shell, and one or more filters (e.g., e.g., to prevent ingress of dross into the shell cavity that may be trapped in the mold). Ceramic).

  Cast shells are constructed by immersing the cast clusters in a liquid ceramic slurry followed by a bed of refractory particles. This dipping sequence is repeated as needed to build a sufficient wall thickness of ceramic material around the casting clusters, thereby forming an investment casting shell. An exemplary dipping sequence comprises 6 dippings of casting clusters in a liquid ceramic slurry and 5 dippings in a bed of refractory particles, resulting in an investment casting shell containing alternating layers of ceramic slurry and refractory material. The first two layers of refractory material preferably include fine (300 mesh) zirconium oxide particles, and the third to fifth refractory material layers include coarser (200 mesh to 35 mesh) aluminum oxide particles. be able to. Each layer is dried under controlled temperature (25 ± 5 ° C.) and relative humidity (50 ± 5%) before applying the next layer.

The investment casting shell is placed in a closed steam autoclave where the pressure increases rapidly to 7-10 kg / cm ² . Under such conditions, the wax in the shell is melted using the injected steam. Next, the shell is baked in an oven whose temperature is raised to 1000 to 1300 ° C. to remove residual wax and enhance the strength of the shell. The shell is now ready for use in investment casting.

  After designing the club head and creating the initial pattern, manufacturing operations move to the metal casting machine. To make an investment casting shell, a metal casting machine first constructs a cluster containing multiple initial patterns for individual club heads. The configuration of the cluster also includes the configuration of the metal supply system (gate and runner for later supply of molten metal). After completing these operations, the casting machine is ready to manufacture the casting shell.

  An important aspect of forming a cluster is determining where to place the gate. The mold cavities of each club head typically have one main gate from which molten metal flows into the mold cavities. Additional auxiliary (“assistant”) gates can be connected to the main gate by flow channels. During investment casting using such shells, molten metal flows into each mold cavity via its respective main gate, flow channel, and auxiliary gate. Such flow requires that the mold for forming the initial pattern of the club head also define the main gate and any assistant gates. After molding the initial pattern of club head wax, the initial pattern is removed from the mold and the position of the flow channel is defined by "gluing" a piece of wax (using the same wax) between the gates. Referring to FIG. 12, an initial pattern 150 for a metal wood club head is shown. The main gate 152 and three assistant gates 154 are shown. The flow channel 156 interconnects the assistant gate 154 and the main gate 152.

  Next, multiple initial patterns for each club head are assembled into a cluster, which includes attaching individual main gates to the "ligament." The ligament includes sprues and runners in the cluster. A "receptor", typically made of graphite or the like, is placed in the center of the cluster, which is later used to receive the molten metal and direct the metal to the runner. The receiver desirably has a "funnel" configuration to aid in the flow of molten metal. Additional braces (eg, graphite) can be added to strengthen the cluster structure.

  Usually the entire wax cluster is large enough (especially if the furnace chamber used to form the shell is large) and the wax branches are first "glued" to the individual branches of the cluster before the branches are assembled together into the cluster. The individual branches may be separately ceramic coated before being applied. Then, after assembling the branches together, the cluster is transferred to a shell casting chamber.

  Two exemplary clusters are shown in Figures 13 and 14, respectively. In FIG. 13, the depicted cluster 160 includes graphite receivers 162, graphite cross spokes 164, runners 166, and mold cavities 168. Each mold cavity 168 is for a respective club head. Molten metal in crucible 170 is poured into cluster 160 using pouring cup 172, which directs the molten metal to receiver 162, branch 166, and then to mold cavity 168. In FIG. 14, the depicted cluster 180 includes a receptor 182 coupled to a shell runner 184. In this configuration, there are two types of mold cavities, a "straight feed" cavity 186 and a "side feed" cavity 188. Molten metal in crucible 170 is poured into cluster 180 using pouring cup 172, which directs the molten metal to receiver 182, shell runner 184, and then mold cavities 186,188.

  The toughened wax clusters are then coated with multiple layers of slurry and ceramic powder with drying between coatings. After forming all layers, the resulting investment casting shell is autoclaved to melt the wax inside (ceramic and graphite parts do not melt). After removing the wax from the shell, the shell is sintered (fired), greatly improving its mechanical strength. If the shell is used in a relatively small metal casting furnace (eg, it can hold clusters of only one branch), the shell can be used for investment casting. If the shell is used in a relatively large metal foundry, the shell can be combined with other shell branches to form large multi-branched clusters.

Modern investment casting of metal alloys is usually carried out while spinning the casting shell in a centrifugal manner, exploiting the force generated by the ω ² r acceleration of the shell undergoing such movement, where: ω is the angular velocity of the shell and r is the radius of the angular motion. This rotation is performed using a turntable located in the casting chamber under sub-atmospheric pressure. The force generated by the ω ² r acceleration of the shell promotes the flow of molten metal into the mold cavity without leaving voids. Investment casting shells (including component clusters and runners) are typically assembled outside the casting chamber and heated to a preset temperature before being placed as an integral unit on the turntable within the chamber. After mounting the shell on the turntable, the casting chamber is sealed and evacuated to a preset subatmospheric pressure (“vacuum”) level. When the chamber is evacuated, the molten alloy is prepared for casting and the turntable begins to rotate. When the molten metal is ready to be poured into the shell, the casting chamber is at the proper vacuum level, the casting shell is at the proper temperature and the turntable is rotating at the desired angular velocity. Thus, the molten metal is poured into the receiver of the cast shell and flows throughout the shell filling the mold cavity of the shell.

  As the molten metal flows into the shell cavity and contacts the cavity surface, the high temperature environment (from both the molten metal and the preheated shell) promotes diffusion of elements such as oxygen within the shell material. Titanium is always cast under sub-atmospheric pressure (vacuum), and although oxygen is not available in the ambient environment, it does not exist in the shell (because the shell is made up of multiple layers of "oxide"). Can still be found. When oxygen is introduced into the molten titanium, an alpha case, which is an oxygen rich layer, is formed on the surface of the cast titanium body. Usually, the thickness of the alpha case is about 1 to 4% of the thickness of the object.

  Because the Alpha case is "enriched" with oxygen, it is brittle (oxygen is one of the most effective elements that enhances the strength of titanium alloys, but increased strength significantly reduces ductility), Cracks may easily occur under the load. To reduce the tendency to form alpha cases, the diffusion rate of oxygen must be reduced, and to reduce the diffusion rate, the temperature must be reduced. However, it is impossible to lower the temperature of molten titanium. Therefore, reducing the temperature of the preheated shell is one way to reduce the diffusion rate of oxygen and reduces the formation of alpha cases.

  Usually, before moving to the casting furnace, the casting shell is heated (called preheating) to help the molten titanium flow. The higher the shell preheat temperature, the easier the titanium flow. This is essential for thin wall titanium casting and the preheat temperature can be as high as 1100-1200 ° C. On the other hand, such high temperatures tend to produce a thick alpha case layer (towards the upper end of the wall thickness range of 1-4%). Therefore, when the formation of the alpha case is concerned, the preheating temperature of the casting shell can be lowered. Typically, the preheat temperature of the casting shell is less than 1000 ° C, preferably less than 900 ° C for non-flow critical titanium castings where alpha case formation is not desired.

Cluster Casting Method As can be seen with reference to FIG. 15, a method of manufacturing a golf club head includes providing a cluster as disclosed elsewhere in this disclosure, as shown with reference to step 361. In various embodiments, the step of preparing the cluster may include a preheating step as disclosed elsewhere herein. One aspect of the present disclosure is that cluster preheating may be lower than that required for conventional investment casting techniques. For example, in conventional investment casting techniques, preheating is on the order of 1000 ° C to 1400 ° C, and in centrifugal casting of the present disclosure, the temperature of preheating is less than 1000 ° C in some embodiments, and 800 ° C in some embodiments. Less than, or in some embodiments less than or equal to about 500 ° C. In some embodiments, preheating is not required and casting can occur with the shell at room temperature. Once the cluster is prepared, it may be angularly accelerated according to step 362. The metal may be heated to the molten state at the same time as the cluster preparation and / or cluster acceleration, or may be an intermediate step. However, according to step 363, the metal can be heated to the molten state. Molten metal is introduced into the cluster according to step 364. The cluster may be angularly accelerated before, after, or at the same time as the introduction of the molten metal into the cluster, as indicated by the dashed line from step 362 to step 364. The molten metal is cooled according to step 365. The cluster casting is removed from the cluster shell at step 366 and post-processing occurs at step 367 and beyond.

  In some embodiments, step 363 includes heating the metal to a molten state. In various embodiments, the heating temperature may be higher or lower depending on the application. In some embodiments, step 362 includes angularly accelerating the cluster to an angular velocity, eg, about 360 revolutions per minute. In various embodiments, the angular velocity can range from 250 to 450 revolutions per minute. In various embodiments, low angular velocities as low as 150 rpm and high angular velocities as high as 600 rpm may be suitable.

  Due to the low casting temperature, the step of cooling the molten metal in the mold cluster involves a reduction in waiting time compared to conventional investment casting processes. As a result, the yield is improved and the cycle time is improved. Various conventional investment casting methods that rely on gravity have been capable of casting only up to 6-8 parts. When centrifugal casting is used, 18-25 or more parts can be cast in one cycle, which increases the production capacity of one casting cycle. Moreover, the yield per gram of injection is also increased. Conventional investment casting processes use a constant mass of metal to cast a fixed number of golf club heads. The spin casting technique of the present disclosure allows more golf club heads to be manufactured using the same mass of metal. Improvements and honing of the techniques in this disclosure can further reduce this metal mass / per head. Cycle times may be reduced depending on the particular methodology. Moreover, the method described herein leads to a reduction in the tooling and capital costs required for the same production demand. Therefore, the methods described herein reduce costs and improve production quality.

  Moreover, casting according to the methods described herein leads to material savings and achieves greater throughput, which results in greater acceleration, which forces the casting into more material. This is because it can be easily washed. Finally, alloys typically produced using other methods can be more easily cast into similar shapes.

Gating and Configuring Clusters To configure gates and cluster (s), several factors need to be considered. These considerations include (but are not necessarily limited to): (a) dimensional limitations of the casting chamber of the metal casting furnace, (b) handling requirements during the slurry dipping step, particularly to form investment casting shells, (c). Achieving an optimum flow pattern of molten metal in the investment casting shell, (d) providing the cluster (s) of the investment casting shell with at least the minimum strength required to withstand rotational movement during metal casting (E) to achieve a minimum resistance balance for the flow of molten metal into the mold cavity (by providing the runner with a sufficiently large cross section) to minimize metal waste. (E.g. by providing the runner with a small cross section), as well as (f) achieving mechanical balance of the clusters around the central axis of the casting shell. Item (e) may be important because after casting, the metal remaining in the runner may not form a product, but rather "contaminate" (some of which is usually recycled). These structural elements combine with metal casting parameters such as shell preheat temperature and time, vacuum level in the metal casting chamber, and angular velocity of the turntable to produce the actual casting results. As the walls of the club head are made thinner and thinner, careful selection and balance of these parameters is essential to obtaining satisfactory investment casting results.

The details of investment casting made in metal casters tend to be unique. However, experiments with various titanium casters have revealed some consistency and some general trends in the past. For example, a specific club head (volume 460 cm ³ , crown thickness 0.6 mm, and sole thickness 0.8 mm) is used in each of six titanium casting machines (the capacity of each metal casting furnace is 10 kg to 80 kg). It was manufactured and the data tabulated in FIGS. 16 and 17 were created. The parameters listed in FIGS. 16 and 17 include:

"Maximum R" is the maximum radius of the cluster,
"Minimum R" is the minimum radius of the cluster,
"Wet perimeter" is the total perimeter of the runner,
"R (flow radius)" is the cross-sectional area of the runner / wet perimeter,
"Rapid turn" is a turn of 90 degrees or more in the runner system,
"Process loss rate" is the ratio of process loss to injected material,
"Maximum velocity" is the velocity at the maximum radius,
"Minimum velocity" is the velocity at the minimum radius,
"Maximum acceleration" is the acceleration at the maximum radius,
"Minimum acceleration" is the acceleration at the minimum radius,
Note that "maximum force" is the force at maximum radius (this is an approximation of the amount of force applied to the molten metal at the gate. Due to each particular cluster design, the true force is almost Always lower than the calculated value, more complex clusters show a greater reduction in force.)
Note that the "minimum force" is the force at the minimum radius (this is an approximation of the amount of force exerted on the molten metal at the gate. Due to each particular cluster design, the true force is almost Always lower than the calculated value, more complex clusters show a greater reduction in force.)
“Maximum pressure” is the pressure of the molten metal in the runner at the maximum radius (= maximum force / runner cross-sectional area),
"Minimum pressure" is the pressure of the molten metal in the runner at the minimum radius (= minimum force / runner cross section),
"Maximum kinetic energy" is the kinetic energy of the molten metal at the maximum radius,
“Density” is the density of the molten metal (titanium alloy) at a melting point of 1650 ° C.,
“Viscosity” is the viscosity of molten titanium at 1650 ° C.,
"Max Re number" is the Reynolds number of the pipe flow at the maximum radius,
The "minimum Re number" is consistently defined as the maximum Re number, but is defined by the minimum radius.

Minimum Force Requirement FIGS. 16 and 17 show that at least a minimum force (and thus at least a minimum pressure) must be applied to the molten metal entering the casting shell of each cluster in order to achieve good casting yield. Provides a table of data. The force exerted on the molten metal is partly generated by the actual mass of molten metal entering the mold cavity in the cluster and the centrifugal force generated by the rotary turntable of the casting furnace. A lower minimum force is desirable because lower forces generally reduce the amount of molten metal required per casting per club head. However, other factors tend to show this increase in force, including thinner walls of the item being cast, more complex clusters (and thus more complex flow patterns of molten metal), shell preheating. Lower temperatures (leading to greater loss of thermal energy from the molten metal as it flows into the investment casting shell) and substandard shell qualities such as rough mold cavity walls. The data in FIGS. 16 and 17 show that the minimum force required to cast a titanium alloy club head having a wall thickness of at least a portion of 0.6 mm is about 160 Nt. The casting machine 1 achieved this minimum force.

  From the minimum force requirement, a lower threshold for the amount of molten metal required for injection into the shell can be derived. Except for unavoidable pouring losses, the best metal usage (as achieved with caster 1) was 386 g (0..g) for club heads (including gates and some runners) each having a mass of about 200 g. 386 kg). This corresponds to a material utilization of 200/386 = 52%. The accelerations (maximums) applied to the investment casting shell by casting machines 2-6 were all greater than the accelerations applied by casting machine 1, but each of casting machines 2-6 was achieved by casting machine 1. More molten metal was needed to obtain casting yields comparable to.

  Some process losses (scattering, cooling metal adhering to the side walls of the crucible, shutoff of liquid titanium alloy, cleaning loss recovery, etc.) are unavoidable. Process loss imposes an upper limit on the efficiency that can be achieved in smaller casting furnaces, that is, the percentage of process loss increases rapidly with decreasing furnace size, as shown in FIG.

  On the other hand, smaller casting furnaces advantageously have simpler operating and maintenance requirements. Other advantages of small furnaces are: (a) they tend to process small, simple clusters of mold cavities, (b) small clusters have a separate respective runner feeding each mold cavity. There is a tendency, which tendency provides a better interface gate ratio for the inflow of molten metal into the mold cavity, (c) preheats the furnace easier and faster before casting, and (d) the furnace has a potential Provides higher achievable shell preheat temperatures, and (e) smaller clusters tend to have shorter runners, which tends to have lower Reynolds numbers, thus reducing the likelihood of destructive turbulence. Large casting furnaces tend not to have these advantages, but smaller casting furnaces tend to have more unavoidable process losses of molten metal per mold cavity than larger furnaces.

  In view of the above, cost-effective casting systems (furnace, cluster, yield, net material cost) require proper cluster and gate design considerations in the construction of investment casting shells used in such furnaces. As long as it is embedded, it seems to include medium-sized systems. This can be seen by comparing the casters 1, 4, and 5. The overall material usage (without considering process losses) by these three casters is very close (664-667 g / cavity). The amount of material used by the casting machine 1 (when considering the process loss) is 386 g, but the amount of material used by the casting machines 4 and 5 is 510 g. Thus, while casters 4 and 5 can still be improved, caster 1 appears to be reaching its limit in this respect.

Flow Field Considerations At least the minimum threshold force exerted on the molten metal entering the investment casting shell is typically either one of by changing the mass of the molten metal entering the shell or increasing the velocity. Can be achieved by decreasing and increasing the other. There is a practical limit to how much the mass of "pouring material" (molten metal) can be reduced. As the mass of the injected material decreases, correspondingly more acceleration is required to generate sufficient force to effectively move the molten metal into the investment casting shell. However, increasing the acceleration increases the likelihood of turbulence of the molten metal entering the shell. Turbulence disturbs the flow pattern of the molten metal and is undesirable. Disturbed flow patterns may require more force to "push" metal through the main gate into the mold cavity.

  The Reynolds number can be easily modified by changing the shape and / or dimensions of the runner (s). For example, changing R (fluid radius) directly affects the Reynolds number. The smaller the R (fluid radius), the smaller the minimum force (the two are substantially interrelated). Thus, an advantageous consideration is to first reduce the Reynolds number to maintain a stable flow field of the molten metal and then adjust the amount of injected material to meet the minimum force requirement.

Another factor One of the additional factors is to preheat the investment casting shell before introducing the molten metal. Because of the highest shell preheat temperature of caster 1, caster 1 achieved a 94% yield with the lowest Reynolds number, the lowest amount of injected material (and thus the lowest force). Another factor is the complexity of the cluster (s). It is very difficult to evaluate complex clusters, and the high Reynolds number usually exhibited by such clusters is the only variable controlled to reduce the destructive turbulence of the molten metal in such clusters. Absent. For example, the number of "sudden" turns of the cluster runners and mold cavities (90 ° turns or more) is also a factor. 16 and 17, the investment casting shell used by caster 1 has one sharp turn (and another less steep turn), while the shell used by caster 6 has three turns. Having a sharp turn. The casting machine 6 may need to rotate the shell at a higher angular velocity just to overcome the flow resistance created by these sharp turns. However, this does not reduce the turbulent flow patterns caused by sharp turns. Therefore, investment casting shells that include simpler cluster (s) (fewer swirls to allow a more “natural” flow path for molten metal) are desired.

  Another factor is the alignment of runners and gates. The interface gate ratio for caster 1 is closest to 100% (indicating optimum gating) compared to the substantially inferior data from other casters. The “worst” was the casting machine 3, and its investment casting shell had a Reynolds number as low as that of the casting machine 1. However, the casting machine 3 had a low interface gate ratio (about 23%), resulting in 78%. The yield was only achieved. The low interfacial gate ratio exhibited by the shell of the caster 3 is due to the low yield of the caster 3 being due to insufficient pouring material to fill the gate, or the occurrence of "two-phase flow and voids". Made it difficult to determine if there is. In any case, the overall cross-sectional area of the runners and gates should be kept as nearly equal (and constant) as possible to achieve a constant liquid metal flow rate throughout the shell at any time during injection. it can. In thin-walled titanium alloy castings, this principle applies especially to the interface between the runner and the main gate, where the interface gate ratio must be 1 (1.0) or higher.

  Yet another factor is the cross-sectional shape of the runner. Comparing caster 4 and castor 5, and caster 2 and caster 5, it appeared that triangular cross-section runners produced lower Reynolds numbers than circular or rectangular runners. Although using a triangular cross-section runner can cause interface gate ratio problems (since metal flows from such a runner to a straight or circular cross-section gate), using a triangular cross-section runner The significant reduction in Reynolds number achieved is worth pursuing as a difference in the injection material used in casting machines 2 and 5 showing (39 kg vs. 32 kg).

  A flow chart for constructing a cluster of investment casting shells is shown in FIG. In the first step 301, an overall consideration of the intended cluster such as size, handling, balance etc. is made. Next, cluster complexity is reduced (step 302) by minimizing sharp turns and unnecessary (and certainly frequent) changes in the runner cross section. The interface gate ratio is maintained as close to 1 as possible (step 303). Also, the Reynolds number is minimized as much as practicable (step 304). Fine tune the turntable angular velocity (RPM) and raise the shell preheat temperature to obtain the highest possible product yield (step 305). Usually, an iteration (306) of steps 304, 305 is needed to achieve a satisfactory yield. In step 308, after a satisfactory yield has been achieved (307), the mass of the injected material (molten metal) is gradually reduced to reduce product yield and while maintaining other casting parameters. Reduces the force required to drive the flow of molten metal throughout the cluster.

  For more information on investment casting methods and equipment for casting thin-walled club heads using titanium alloys and other materials, see US Pat. No. 7,513,296 issued Apr. 7, 2009, and It can be found in US Patent Application Publication No. 2016/0175666, published June 23, 2016, both of which are incorporated herein by reference in their entirety. These incorporated references disclose methods and systems for casting club head bodies that do not include a face plate (the face plate is later attached to the body), but with the face formed separately. The same or similar method and system having the same or similar benefits and advantages for casting the club head body disclosed herein, which is the face of an integrally cast portion of the body that is not subsequently attached to the body Can be used.

  Detailed information on the coating of molds for casting titanium alloys, and the method for making molds with a face coat of calcium oxide for use in casting titanium alloys, was issued June 16, 1998. Can be found in US Pat. No. 5,766,329, which is incorporated herein by reference in its entirety.

Compared to titanium golf club faces formed for machining or forging club headsheets that include cast titanium alloy bodies / faces , cast faces offer the advantage of low cost and complete freedom of design. is there. However, the faces of golf clubs cast from conventional titanium alloys such as 6-4 Ti need to be chemically etched to remove the alpha case on one or both sides for the face to be durable. Such etching requires the application of hydrofluoric (HF) acid, a chemical etchant that is difficult to handle, highly harmful to humans and other materials, environmental pollutants, and expensive. is there.

  Includes aluminum (eg, 8.5-9.5% Al), vanadium (eg, 0.9-1.3% V), and molybdenum (eg, 0.8-1.1% Mo). Faces cast from titanium alloys, optionally together with other trace alloying elements and impurities, collectively referred to herein as "9-1-1 Ti", can have a less significant alpha case, HF acid etching is unnecessary or at least less necessary than faces made from conventional 6-4 Ti and other titanium alloys.

  In addition, 9-1-1 Ti can have minimum mechanical properties of yield strength of 820 MPa, tensile strength of 958 MPa, and elongation of 10.2%. These minimum properties are significantly superior to typical cast titanium alloys such as 6-4 Ti, which can have a minimum mechanical properties of 812 MPa yield strength, 936 MPa tensile strength, and elongation of about 6%. There is a possibility that

  A cast (eg, co-cast with a single casting object) golf club head that includes a face as an integral part of the body has the face formed separately and later attached to the front opening of the club head body. It can provide superior structural properties compared to club heads (eg, welded or bolted). However, the advantages of having a Ti face cast in one piece are mitigated by the need to remove the alpha case on the surface of the cast Ti face.

  The club head disclosed herein including a 9-1-1 Ti face and body unit cast together can eliminate or at least significantly reduce the disadvantage of having to eliminate the alpha case. You can For cast 9-1-1 Ti faces, using conventional mold preheat temperatures of 1000 ° C. or higher, the thickness of the alpha case is, in some embodiments, about 0.15 mm or less, about 0.20 mm or less, Or about 0.30 mm or less, for example 0.10 mm to 0.30 mm, but for cast 6-4 Ti faces, the thickness of the alpha case is, in some examples, greater than 0.15 mm, 0.20 mm. Can be greater than, or greater than 0.30 mm, such as about 0.25 mm to about 0.30 mm.

  In some cases, the reduction in the alpha case thickness of the 9-1-1 Ti faceplate (eg, 0.15 mm or less) provides sufficient durability for the faceplate, and is harsh such as HF acid. It may not be thin enough to avoid the need to etch away parts of the alpha case with a chemical etchant. In such cases, the preheat temperature of the mold can be lowered (below 800 ° C, below 700 ° C, below 600 ° C, and / or below 500 ° C) before pouring the molten titanium alloy into the mold. This can further reduce the amount of oxygen transferred from the mold to the cast titanium alloy, resulting in thinner alpha cases (eg, less than 0.15 mm, less than 0.10 mm, and / or less than 0.07 mm). This provides the cast body / face unit with better ductility and durability, which is especially important for face plates.

  The thin alpha case in the cast 9-1-1 Ti face improves durability and makes the face sufficiently durable to eliminate the need to remove some of the alpha case from the face by chemical etching. Therefore, especially when using a mold with a low preheat temperature, hydrofluoric acid etching can be eliminated from the manufacturing process by casting the body and face together using 9-1-1 Ti. This may simplify the manufacturing process, reduce costs, reduce safety and operational hazards, and eliminate the potential for environmental contamination by HF acid. Furthermore, since HF acid is not introduced into the metal, the body / face, or even the entire club head, will have little or substantially no fluorine atoms that can be defined as less than 1000 ppm, less than 500 ppm, less than 200 ppm, and / or less than 100 ppm. The fluorine atoms present, which may not be included in, are due to impurities in the metallic material used to cast the body.

Variable Face Thickness and Face Bulge and Roll Characteristics Certain embodiments include, for example, U.S. Patent Application No. 12 / 006,060 and U.S. Patent Nos. 6,997,820; 6,800,038; No. 6,824,475, No. 7,731,603, and No. 8,801,541, a variable thickness face profile can be mounted on the face plate, each of which is described in US Pat. Is incorporated herein by reference in its entirety. Varying the faceplate thickness increases the size of the club head COR area, commonly referred to as the golf club head sweet spot, and hitting a golf ball with the golf club head consistently increases the larger area of the faceplate. Golf ball speed and shot tolerance can be provided. Also, varying the thickness of the faceplate can be advantageous to reduce the weight of the face area for repositioning to another area of the club head. For example, as shown in FIG. 9, the face plate 18 has a thickness t defined between an outer surface 22 and an inner surface 40 that faces the internal cavity of the golf club head. The face plate 18 may include a central portion 42 positioned adjacent the ideal impact location 23 on the outer surface 22. The central portion 42 can have a thickness similar to, slightly larger or smaller than the thickness of the periphery of the faceplate. The face plate 18 can also include a diverging portion 44 extending radially outward from the central portion 42, which can be oval. The inner surface 40 may be symmetric about one or more axes and / or asymmetric about one or more axes. The thickness t of the diverging portion 44 increases radially outward from the central portion 42. The face plate 18 includes a converging portion 46 extending from the diverging portion 44 via a transition portion 48. The thickness t of the converging portion 46 decreases substantially at the position radially outward from the transition portion 48. In some cases, transition 48 is the apex between diverging portion 44 and converging portion 46. In other implementations, the transition 48 extends radially outward from the divergence 44 and has a substantially constant thickness t (see FIGS. 7-9).

  In some embodiments, the cross-sectional profile of the faceplate 18 along any axis that extends perpendicular to the faceplate at the ideal impact location 23 is substantially similar to FIGS. 7-9. In other embodiments, the cross-sectional profile can change, eg, asymmetric. For example, in certain implementations, the cross-sectional profile of the faceplate 18 along the z-axis of the head origin may include a central portion, a transition portion, a divergent portion, and a convergent portion as described above (see FIGS. 7-9). reference). However, the cross-sectional profile of the face plate 18 along the x-axis of the head origin may include a second divergent portion extending radially from the converging portion 46 and coupled to the converging portion via a transition. it can. In an alternative embodiment, the cross-sectional profile of the faceplate 18 along the head origin z-axis extends radially from the converging portion and converges as described above with respect to the change of the head origin along the x axis. And a second divergent portion coupled to the.

  In some embodiments of golf club heads having a faceplate with protrusions, the maximum faceplate thickness is greater than about 4.8 mm and the minimum faceplate thickness is less than about 2.3 mm. In a particular embodiment, the maximum faceplate thickness is about 5 mm to about 5.4 mm and the minimum faceplate thickness is about 1.8 mm to about 2.2 mm. In a more particular embodiment, the maximum faceplate thickness is about 5.2 mm and the minimum faceplate thickness is about 2 mm. Face thickness must have at least 25% thickness variation across the face (the thickest part compared to the thinnest part) in order to reduce weight and achieve higher ball speeds on off-center hits. I have to.

  In some embodiments of golf club heads having a faceplate with protrusions and a thin sole structure or a thin skirt structure, the maximum faceplate thickness is greater than about 3.0 mm and the minimum faceplate thickness is about 3.0 mm. Is less than. In certain embodiments, the maximum faceplate thickness is from about 3.0 mm to about 4.0 mm, about 4.0 mm to about 5.0 mm, about 5.0 mm to about 6.0 mm, or greater than about 6.0 mm. And the minimum faceplate thickness is about 2.5 mm to about 3.0 mm, about 2.0 mm to about 2.5 mm, about 1.5 mm to about 2.0 mm, or less than about 1.5 mm.

  10 and 11 show a golf club head 4 having a shaft 3. The club head 4 includes a central face 5a, a heel 5b, a toe 5c, a crown 5d, and a sole 5e. The club head 4 further includes a club face 6 that includes a curve from the heel 5b to the toe 5c, commonly referred to as a bulge 8. The club face 6 also includes a curve from the crown 5d to the sole 5e, which is generally called a roll 9. In at least one embodiment, the combination of curvatures may provide the club face 6 with a substantially toroidal shape, or a shape similar to the cross section of a toroid. The club face 6 includes an X axis X extending horizontally from the heel 5b to the toe 5c through the central face 5a, a Z axis Z extending vertically from the crown 5d to the sole 5e through the central face 5a, and a central face. And further includes a Y-axis Y extending horizontally through the page of FIG. The X axis X, the Y axis Y, and the Z axis Z are orthogonal to each other.

  As shown in FIG. 11, the club head 4 further has a center of gravity (CG) 5f located inside the club head. The club head 4 has a CG X axis, a CG Y axis, and a CG Z axis, which axes are mutually orthogonal to each other and pass through the CG 5f so as to define a CG coordinate system. The CG X-axis and CG Y-axis lie in a horizontal plane parallel to the flat ground. The CG Z-axis lies in a vertical plane perpendicular to the flat ground. In one embodiment, the CG Y-axis may coincide with the Y-axis Y, but in most embodiments these axes do not coincide.

  FIG. 11 is an exaggerated depiction of the club head 4 hitting a golf ball B with the club head heel 5b. This imparts clockwise spin to the golf ball B, causing the golf ball to turn right during flight. As described above, when the golf ball B is hit with the heel 5b of the club head 4, the golf ball separates from the club head 4 at an angle Θ with respect to the CG Y axis of the club head 4. The angle Θ is merely an indication of the general angle at which the ball leaves the club head and is not intended to depict or imply the actual angle to the centerline or the point at which that angle is measured. It will be understood. Angle Θ further indicates that the ball struck at the heel of the club first travels the flight path to the left of the centerline.

  The method used to obtain the values in this disclosure is the optical comparator method. Referring back to FIG. 10, the club face 6 includes a series of score lines 11 across the width of the club face generally along the X-axis X of the club head 4. In the optical comparator method, the club head 4 is mounted downward and substantially horizontally on the V block mounted on the optical comparator. The club head 4 is oriented so that the score line 11 is substantially parallel to the X axis of the optical comparator. More precise orientation steps may also be used. The measurement is then taken at the geometric center point 5a on the club face. Then, along the X-axis X of the club head on both sides of the geometric center point 5a, 20 millimeters away from the geometric center point 5a of the club face 6 and on the X-axis X of the club head on both sides of the center point. Further measurements are taken 30 millimeters away from the geometric center of the club face. An arc is fitted to these five measuring points, for example by using the radius function of the machine. This arc corresponds to a circumference with a given radius. This measurement of radius is meant by the bulge radius.

  To measure the roll, the club head 4 is rotated 90 degrees so that the Z-axis Z of the club head is substantially parallel to the X-axis of the machine. The measurement is taken at the geometric center point 5a of the club face. Then, along the Z-axis Z of the club face 6 at a distance of 15 millimeters from the geometric center point 5a, and on both sides of the center point 5a, and at a distance of 20 millimeters from the geometric center point, and on both sides of the center point. Further measurements are taken along the Z axis of the club face. An arc is fitted to these five measuring points. This arc corresponds to a circumference with a given radius. This measurement of radius is meant by roll radius.

The curvature is defined as 1 / R, where R is the radius of the circle corresponding to the measuring arc of the bulge or roll. As an example, a bulge with a curvature of 0.020 cm ⁻¹ corresponds to a bulge measured by a bulge measuring arc, which is part of a circle with a radius of 50 cm. A roll with a curvature of 0.050 cm ⁻¹ corresponds to a roll measured by a roll measuring arc that is part of a circle with a radius of 20 cm.

In some embodiments, the faceplate of the disclosed club head can have the following characteristics:
i) the roll curvature is about 0.033 cm ^-1 ~ about 0.066 cm ^-1, the bulge curvature ^{0 cm -1} greater, less than about 0.027 cm ^-1,
ii) The reciprocal of the bulge curvature is at least 7.62 cm greater than the reciprocal of the roll curvature, and / or iii) the ratio Ro of the bulge curvature divided by the roll curvature is greater than about 0.28 and less than about 0.75.

  The use of vacuum die casting to manufacture the club heads described herein improves quality and reduces scrap. In addition, defective products due to high porosity are substantially eliminated, as are defective products after secondary processing. Excellent surface quality is obtained while at the same time increasing the density and strength of the product, allowing for larger, thinner and more complex castings. From a processing perspective, the required casting pressure is low, extending tool life and mold life. It also reduces or eliminates metal or alloy waste from flash.

  By utilizing the vacuum die casting method, the titanium body and faceplate of the disclosed club head are surprisingly much smaller than those commonly observed with similar titanium objects made by investment casting. It was found to have a particle size of about 100 μm, whereas the particle size of investment cast titanium faceplates is about 750 μm (micrometers). More specifically, the titanium body / faceplate disclosed herein is less than about 400 μm, preferably less than about 300 μm, more preferably less than about 200 μm, even more preferably less than about 150 μm, and most preferably less than about 120 μm. Can have a particle size of.

  The titanium body / faceplate disclosed herein may also exhibit a much lower porosity than is commonly observed with similar separately formed titanium faceplates made by investment casting. .. More specifically, the titanium faceplates disclosed herein can have a porosity of less than 1%, preferably less than 0.5%, more preferably less than 0.1%.

  The titanium body / faceplate disclosed herein also has a much higher yield strength, as measured by ASTM E8, than is generally observed with similar titanium faceplates made by investment casting. Can be shown.

  The titanium faceplates disclosed herein can also exhibit fracture toughness similar to that typically observed with similar titanium faceplates made by investment casting, from forged and roll annealed products. Higher than similar face plates made.

  The titanium faceplates disclosed herein are also measured by the elongation reported in the tensile test, which is defined as the maximum elongation of the gauge length divided by the original gauge length of about 10% to about 15%. Such ductility can be exhibited.

  The titanium faceplates disclosed herein can also exhibit a Young's modulus of 100 GPa ± 10%, preferably ± 5%, and more preferably ± 2% as measured by ASTM E-111.

  The titanium faceplates disclosed herein can also exhibit a maximum tensile strength of 970 MPa ± 10%, preferably ± 5%, more preferably ± 2% as measured by ASTM E8.

  A metal with a titanium faceplate that is 10% thinner than a similar faceplate made by conventional investment casting while maintaining the strength properties that are as good or better by combining the various properties described above. It becomes possible to manufacture wood titanium club heads.

  In addition to the strength characteristics of the golf club heads of the present invention, in certain embodiments, the shape and dimensions of the golf club heads are described in US Patent Application Publication No. 2013/0123040 filed December 18, 2012 by Willett et al. Can be formed to produce an aerodynamic shape according to, and the entire contents of which are incorporated herein by reference. Aerodynamics of golf club heads are described in U.S. Pat. Nos. 8,777,773, 8,088,021, 8,540,586, 8,858,359 and 8,597. No. 137, No. 8,771,101, No. 8,083,609, No. 8,550,936, No. 8,602,909, and No. 8,734,269. Are also detailed, the teachings of which are incorporated herein by reference in their entirety.

  In addition to the strength properties of the rear body, and the aerodynamic properties of the club head, another set of properties for the club head that must be controlled is the acoustic or sound property that the golf club head emits when hitting a golf ball. is there. At club head / golf ball impact, the striking face of the club is deformed to excite club head, sole, or club head vibration modes associated with the striking face. Most golf club geometries are complex with surfaces having varying curvatures, thicknesses, and materials, and accurate calculation of club head modes can be difficult. Club head modes can be calculated using computer-aided simulation tools. In the club head of the present invention, the acoustic signal generated at ball / club impact is evaluated as described in co-pending US patent application Ser. No. 13 / 842,011 filed Mar. 15, 2013. Can be done, the entire contents of which are incorporated herein by reference.

  In a particular embodiment of the invention, a golf club head has a removable head-shaft coupling assembly as described in more detail in US Pat. No. 8,303,431 issued Nov. 6, 2012. May be attached to the shaft via, the entire contents of which are incorporated herein by reference. Further, in certain embodiments, the golf club head not only interchangeably connects the shaft to the head, but also utilizes a removable head-shaft coupling assembly to adjust the loft and / or lie angle of the club. The ability to provide a golf club head and / or golf club may also be incorporated. Such an adjustable lie / loft coupling assembly is disclosed in US Pat. No. 8,025,587 issued Sep. 27, 2011 and US Pat. No. 8,235, Aug. 7, 2012. 831, U.S. Pat. No. 8,337,319 issued December 25, 2012, and co-pending U.S. Patent Application Publication No. 2011/0312437, June 2012, filed June 22, 2011. US Patent Application Publication No. 2012/0258818 filed on 20th, US Patent Application Publication No. 2012/0122601 filed on December 29, 2011, US Patent Application Publication filed on March 22, 2011 No. 2012/0071264, and co-pending US patent application Ser. No. 13 / 686,677, filed Nov. 27, 2012, which is more fully described in the entire contents of these patents, publications and applications. Are incorporated herein by reference in their entirety.

  In certain embodiments, a golf club head features an adjustable mechanism on the sole portion to "separate" the relationship between face angle and hosel / shaft loft, including a golf club's square loft and Allows separate adjustment of face angle. For example, some embodiments of golf club heads can include an adjustable sole portion that can be adjusted with respect to the club head body to raise or lower the trailing end of the club head relative to the ground. Further details regarding the adjustable sole portion may be found in U.S. Pat. No. 8,337,319 issued Dec. 25, 2012 and U.S. Patent Application Publication No. 2011/0152000 filed Dec. 23, 2009. No. 2011/0312437 filed June 22, 2011, No. 2012/0122601 filed December 29, 2011, and co-pending US patents filed November 27, 2012. No. 13 / 686,677, the entire contents of each of which is incorporated herein by reference.

  In some embodiments, manufacturers and / or users can adjust the movable weights to adjust the position of the center of gravity of the club and use the desired performance characteristics in the golf club head. This function is provided by the following US Pat. Nos. 6,773,360, 7,166,040, 7,452,285, 7,628,707, and 7,186. No. 190, No. 7,591,738, No. 7,963,861, No. 7,621,823, No. 7,448,963, No. 7,568,985, No. No. 7,578,753, No. 7,717,804, No. 7,717,805, No. 7,530,904, No. 7,540,811, No. 7,407, No. 447, No. 7,632,194, No. 7,846,041, No. 7,419,441, No. 7,713,142, No. 7,744,484. 7, 223, 180 and 7,410, 425, the entire contents of each of which are incorporated herein by reference in their entireties.

  According to some embodiments of the golf club heads described herein, the golf club head also includes slidably repositionable weights positioned on the sole and / or skirt of the club head. be able to. Among other advantages, slidably repositionable weights allow the end user of the golf club to adjust the position of the CG of the club head over a range of positions with respect to the position of the repositionable weights. Further details regarding the slidably repositionable weight feature may be found in US Pat. Nos. 7,775,905, 8,444,505, filed May 20, 2013, US patent application Ser. / 898,313 and U.S. patent application Ser. No. 14 / 047,880, filed October 7, 2013, the entire contents of each of which are incorporated herein by reference. Similarly, paragraphs [430]-[470] and Figures 93-Figure of US Patent Application Publication No. 2014/0080622 corresponding to US patent application Ser. No. 13 / 956,046, filed July 31, 2013. 101, as well as co-pending US patent application No. 62 / 020,972 filed July 3, 2014 and 62/065/552 filed October 17, 2014. The contents of each of which are incorporated herein by reference.

  According to some embodiments of the golf club heads described herein, the golf club head also includes a coefficient of restitution feature that defines a gap in the body of the club located proximate to the face, such as at the sole. But it is okay. Such characteristics of the coefficient of restitution are characterized in US patent application No. 12 / 791,025 filed on June 1, 2010, and No. 13 / 338,197, 2013 filed on December 27, 2011. No. 13 / 839,727 filed on Mar. 15, 2014 (U.S. Patent Application Publication No. 2014/0274457), No. 14 / 457,883 filed on Aug. 12, 2014, and 2014 No. 14 / 573,701, filed Dec. 17, 2014, the entire contents of each of which is incorporated herein by reference in its entirety.

Additional Exemplary Club Heads FIGS. 20-36D show another exemplary wood-type golf club head 200 that may include any combination of the features disclosed herein. For example, club head body 202 and face 270 can be cast as a unitary structure from a titanium alloy, as described herein. The head 200 includes a raised sole structure (see benefits described in US Patent Application Publication No. 2018/0185719) and includes two weight tracks 214, 216 having slidably adjustable weight assemblies 210, 212. Including. The head 200 further includes both a crown insert 206 and a sole insert 208 (see exploded views in FIGS. 21 and 22), which inserts have the desired orientation pattern (see US Patent Application Publication No. 2018/0185719). The head 200 may be constructed from a variety of lightweight materials having multiple layers of fiber reinforcement arranged in a body 202, an adjustable head-shaft coupling assembly 204, and a top mount body. A crown insert 206, a sole insert 208 mounted inside the body above the bottom of the body, a front weight assembly 210 slidably mounted on a front weight track 214, and a rear weight track 216. And a rear weight assembly 212 slidably mounted. The head 200 includes a front seating pad or ground surface 226 between the front track 214 and the face 270 and a rear seating pad or ground surface 224 at the rear of the heel side body of the rear track 216 for normal addressing. When in position, the rest of the sole is above ground level.

  Head 200 has a raised sole defined by the combination of body 202 and sole insert 208. For example, as shown in FIGS. 22 and 27, the lower portion of body 202 includes toe side opening 240, heel side opening 242, and rear track opening 244, all covered by sole insert 208. .. The rear weight track 216 is positioned below the sole insert 208.

  The head 200 also includes a toe side cantilevered ledge 232 extending circumferentially from the rear weight track 216 or the rear seating pad 224 around the toe region adjacent to the face, the ledge 232 extending from the front seating pad 226. It is joined to the toe portion 230 of the main body extending in the toe direction. One or more optional ribs 236 may join the toe portion 230 to a raised sole adjacent the front end of the toe opening 240 of the body. Such three triangular ribs are shown in Figures 20 and 26A.

  The head 200 also includes a heel cantilevered ledge 234 that extends rearward from near the hosel region to the rear seating pad 224 or the rear end of the rear weight track 216. In some embodiments, the two cantilevered ledges 232 and 234 can contact and / or form a continuous ledge extending around the back of the head. The rear seating pad 224 can optionally include a recessed rear portion 222 (as shown in FIG. 26).

  The lower portion of the body 202, which forms part of the sole, provides various features, varying thicknesses, to provide enhanced stiffness if desired and light weight if less stiffness is desired. , Ribs and the like. The body may include a thicker region 238 near the intersection of the two weight tracks 214, 216, for example. The body may also include a thin ledge or seat 260 around the openings 240, 242, the ledge 260 configured to receive and mate with the sole insert 208. The lower surface of the body can also include various internal ribs such as ribs 262, 263, 265, and 267 shown in FIGS. 27 and 28 to enhance rigidity and acoustics.

  The top of the body may include various features, thickness variations, ribs, etc. to provide enhanced stiffness if desired and light weight if less stiffness is desired. it can. For example, the body includes a thin seat area 250 around the top opening to receive the crown insert 206. As shown in FIG. 21A, the seats 250 and 260 for the crown and sole inserts may share a common edge or be proximate to each other around the outer circumference of the body.

  35A-35D show top views of head 200 in various states with crown and sole inserts in place and / or removed. 36A-36D show the crown and sole inserts in more detail. As shown in FIGS. 36A and 36B, the sole insert 208 can have an irregular shape with a concave upper surface and a convex lower surface. The sole insert 208 can also include a notch 209 at the rear heel end to accommodate a fit around the rear seating pad 224 area where increased ground strength stiffness is required. In various embodiments, the sole insert may cover at least about 50% of the surface area of the sole, at least about 60% of the surface area of the sole, at least about 70% of the surface area of the sole, or at least about 80% of the surface area of the sole. it can. In another embodiment, the sole insert covers about 50% to 80% of the surface area of the sole. The sole insert has sufficient strength and rigidity to withstand the high dynamic loads imposed on the club head, while freeing up discretionary mass that can be strategically assigned elsewhere in the club head. Contributes to a club head structure that remains relatively lightweight.

  The sole insert 208 has a shape and size selected to cover at least the openings 240, 242, 244 in the bottom of the body and can be secured to the frame by gluing or other secure fastening technique. In some embodiments, the ledge 260 may include indentations to receive protrusions or bumps that align with the underside of the sole insert to further secure and align the sole insert on the frame.

  Like the sole, the crown also has an opening 246 that reduces the mass of the body 202 and, more significantly, the mass of the crown, the increased mass increasing the CG of the head (desirably). This is the area of the head that has the greatest impact. Along the perimeter of the opening 246, the frame includes a recessed ledge 250 for seating and supporting the crown insert 206. Crown insert 206 (see FIGS. 36C and 36D) has a geometry and size that fits into crown opening 246 and is secured to the body by gluing or other secure fastening technique over opening 246. It Ledge 260 may include recesses along its ledge to receive protrusions or bumps that align with the underside of the crown insert to further secure and align the crown insert on the body. The crown insert can also include a forward protrusion 207 that extends into the front crown 252 of the body.

  In various embodiments, the body ledges (eg, ledges 250 and 260) that receive the crown and sole inserts may be made from the same metallic material (eg, titanium alloy) as the body, and thus the golf club head. Can add significant mass to. In some embodiments, to control the mass contribution of the ledge to the golf club head, the width of the ledge can be adjusted to achieve the desired mass contribution. In some embodiments, of the sole and crown inserts that can be made from lighter materials (eg, carbon fiber or graphite composites and / or polymeric materials) if the ledge adds excessive mass to the golf club head. Weight loss may be compromised. In some embodiments, the width of the ledge can range from about 3 mm to about 8 mm, preferably about 4 mm to about 7 mm, more preferably about 4.5 mm to about 5.5 mm. In some embodiments, the width of the ledge can be at least 4 times the thickness of the respective insert. In some embodiments, the thickness of the ledge can range from about 0.4 mm to about 1 mm, preferably about 0.5 mm to about 0.8 mm, more preferably about 0.6 mm to about 0.7 mm. .. In some embodiments, the thickness of the ledge ranges from about 0.5 mm to about 1.75 mm, preferably about 0.7 mm to about 1.2 mm, more preferably about 0.8 mm to about 1.1 mm. possible. The ledges may extend or run along the entire interface boundary between the respective insert and body, but in an alternative embodiment, the ledge extends only partially along the interface boundary. Good.

  The perimeter of crown opening 246 is proximate to and closely track the perimeter of the toe, back, and heel sides of head 200. In contrast, the face side of the crown opening 246 may be further spaced from the face 270 area of the head. In this way, the head can have additional frame mass and reinforcement in the crown region 252 directly behind the face 270. This region, as well as other regions adjacent the face along the toe, heel, and sole, support the face and are subject to relatively high impact loads and stresses from the impact of the ball on the face. As described elsewhere herein, the frame may be made of a wide range of materials including high strength titanium, titanium alloys, and / or other metals. The opening 246 can have a notch in the front that mates and mates with the crown insert protrusion 207 to help align and seat the crown insert in the body.

  A front weight track 214 and a rear weight track 216 are disposed on the sole of the club head for mounting two-part slidable weight assemblies 210, 212, respectively, which may be fastened to the weight track by fastening means such as screws. Define a track. The weight assembly can take forms other than that shown in FIG. 21A, can be attached in other ways, and can take the form of a single-part design or a multi-part design. The weight track allows the weight assembly to be loosened for slidable adjustment along the track and then tightened in place to adjust the effective CG and MOI characteristics of the club head. .. For example, the CG of the club head may be moved forward or backward through the rear weight assembly 212 or in the heel or toe direction through the front weight assembly 210 to modify the performance characteristics of the club head, It can affect the flight of the golf ball, especially the spin characteristics of the golf ball. In other embodiments, the front weight track 214 may instead be a front channel without moving weights.

  The sole of the body 202 preferably extends generally parallel to and near the face of the club head and is generally perpendicular to a rear weight track 216 extending rearward from near the center of the front track toward the rear of the head. It is integrally formed with the front weight track 214 extending to the.

  In the illustrated embodiment, each weight track includes only one weight assembly. In other embodiments, more than one weight assembly may be attached to one or both weight tracks to provide the club head with another mass distribution capability.

  Adjusting the CG in the heel or toe direction via the front weight track 214 modifies the performance characteristics of the club head to influence the flight of the ball, especially the tendency of the ball to draw or fade, and / or Or it can counter the tendency of the ball to slice or hook. Adjusting the CG forwards or backwards via the rear weight track 216 modifies the performance characteristics of the club head to influence the flight of the ball, especially the tendency of the ball to move upwards, or fly with backspin. Can resist falling inside. The use of two weight assemblies in the weight track allows for alternative coordination and interaction between the two weights. For example, with respect to front track 214, two independent adjustable weight assemblies are positioned completely on the toe side, completely on the heel side, and spaced a maximum distance apart, with one weight completely on the toe side, The other can be fully positioned on the heel side, co-positioned in the center of the weight track, or positioned with other weight placement patterns. As shown, with a single weight assembly in the track, the weight adjustment options are more limited, but the effective CG of the head is along the continuum, eg, along the heel or toe direction, or in the front. The neutral position, with the weights centered on the partial weight track, is still adjustable.

  As shown in FIGS. 29-34, each weight track 214, 216 preferably has a recess that is generally rectangular in shape to provide a recessed track for the weight to adjustably slide along the track. When you do, sit down and guide you. Each track preferably includes one or more peripheral rails or ledges to define an elongated channel having a width dimension that is less than the width of a weight located within the channel. For example, as shown in FIGS. 29 and 30, front track 214 includes opposed peripheral rails 288 and 284, and as shown in FIGS. 33 and 34, rear track 216 includes opposed peripheral rails 290 and 292. .. In this way, the weight slides within the weight track and the rail prevents the weight from coming off the track. At the same time, the channel between the ledges allows the threads of the weight assembly to thread through the center of the outer weight element, through the channel, and then with the inner weight element. The ledges provide a track or rail on which the joined weight assemblies slide freely, while at the same time effectively prevent the weight assemblies from accidentally slipping off the tracks, even if the weight assemblies become loose. At the front track 214, the inner weight members of the assembly 210 overlie the rails 284 and 288 in the inner recesses 280 and 286, while the outer weight members include the front rail 284 and the overhanging lip 228 of the front seating pad 226. It partially sits in the recess 282 between (FIGS. 30, 31). At the rear track 216, the inner weight member of the assembly 212 overlies the rails 290 and 292 in the inner recesses 296 and 298, while the outer weight member engages the heel side rail 290 and the overhanging lip 225 of the rear seating pad 224. It can be partially seated in the recess 294 in between.

  The weight assemblies can be adjusted by loosening the screws and moving the weights to the desired position along the track, then the screws can be tightened to lock the assemblies in place. The weight assembly may be replaced and replaced with another weight assembly having a different mass to provide additional mass adjustment options. When a second or third weight is added to the weight track, many additional weight positions and distribution options further enhance the effective CG position of the head in heel-toe and anterior-posterior directions, and combinations thereof. Available for fine tuning. It also provides a wide range of adjustments to the club head MOI characteristics.

  Either or both of the weight assemblies 210, 212 can include a three-part assembly that includes an inner weight member, an outer weight member, and a fastener that joins the two weight members together. The assembly is clamped to the front, rear, or side ledges of the weight track by tightening the fasteners so that the inner member contacts the inside of the ledge and the outer weight member contacts the outside of the ledge. And has sufficient clamping force to hold the assembly stationary with respect to the body for the entire golf round. The weight members and assemblies are designed to accommodate the use of () in the available portion of the weight track, as opposed to inserting the inner weight in the enlarged opening at one end of the weight track where the weight assembly is not configured to be locked in place. Inserting an inner weight member into the inner channel across the ledge (s) can be shaped and / or configured to be inserted into the weight track. This eliminates such wide, non-functional openings at the ends of the tracks, allowing shorter tracks or longer functional ledge widths that can secure the weight assembly. Can have. The inner weight member is inserted at a non-perpendicular angle to the ledge, eg at an angled insertion, in order to allow the inner weight member to be inserted over the ledge (for example) in the middle of the track. be able to. The weight member can be inserted at an angle and gradually rotated into the inner channel to be inserted over the clamp ledge. In some embodiments, the inner weight member is rounded, oval, to better allow the weight member to be inserted across the ledge and into the channel at the available portion of the track. It can have an oval, arcuate, curved, or other specially shaped structure.

  The golf club heads of the present disclosure combine slidably adjusted weights and / or threaded adjustments in combination with the weight savings achieved through the use of titanium alloy materials and the incorporation of lightweight crown and / or sole inserts. The ability to adjust the relative position and mass of the possible weights, further coupled with the discretionary mass provided by the raised sole configuration, allows for wide variation in many properties of the club head, and these variations are All affect the final club head performance, including the club head CG location, club head MOI value, club head acoustic properties, club head aesthetic and subjective feel properties, and / or other properties. Exert.

  In particular embodiments, the front and rear weight tracks have a particular track width. Track width can be measured, for example, as a horizontal distance between a first track wall and a second track wall that are substantially parallel to each other on opposite sides of an inner portion of the track that receives an inner weight member of the weight assembly. 29-31, the width of the front track 214 can be the horizontal distance between the opposing walls of the inner recesses 280 and 286. With reference to FIGS. 32-34, the width of the rear track 216 may be the horizontal distance between the opposing walls of the inner recesses 296 and 298. For both the front and rear tracks, the track width may be about 5 mm to about 20 mm, such as about 10 mm to about 18 mm, or about 12 mm to about 16 mm. According to some embodiments, the depth of the track (ie, the vertical distance between the top inner wall of the track and an imaginary plane that includes the area of the sole adjacent the outermost edge of the track) is about 6 mm or more. It may be about 20 mm, for example about 8 mm to about 18 mm, or for example about 10 mm to about 16 mm. For the front track 214, the depth of the track may be the vertical distance from the inner surface of the flared lip 228 to the upper surface of the inner recess 280 (FIG. 30). For the rear track 216, the depth of the track may be the vertical distance from the inner surface of the flared lip 225 to the upper surface of the inner recess 296 (FIG. 34).

  Furthermore, both front and rear tracks have a certain track length. Track length may be measured as the horizontal distance between opposite longitudinal end walls of the track. For both the front and rear tracks, their track length may be about 30 mm to about 120 mm, such as about 50 mm to about 100 mm, or for example about 60 mm to about 90 mm. Additionally or alternatively, the front track length may be expressed as a percentage of the striking face length. For example, the front track may be about 30% to about 100% of the length of the striking face, such as about 50% to about 90% of the length of the striking face, or even about 60% to about 80% mm. Good.

  The above-described track depth, width, and length characteristics are similarly applicable to the front channel 36 of the club head 10.

  In FIGS. 30 and 34, the front and rear seating pad lips 228, 225 extend or overhang each respective weight track to limit the track opening and to provide the weight (s). It can be seen that it helps to keep it in the truck.

  Referring to FIG. 34, the sole area on the heel side rear seating pad 224 of the rear track 216 is significantly greater than the toe side sole area (ledge bottom 292) when the head is in the address position relative to the ground plane. Vertical distance is low. This is a head having a "recessed sole" or "raised sole" structure with one portion of the sole positioned lower (eg, on the heel side) relative to another portion of the sole (eg, on the toe side). Can be considered. In other words, a portion of the sole (eg, most of the sole excluding the rear seating pad 224) is raised with respect to another portion of the sole (eg, the rear seating pad). The same is true for the front track 214 whose front seating pad 226 and its lip 228 are significantly lower than the rear side of the front track (as shown in FIG. 30) in the normal address position.

  In one embodiment, the vertical distance between the level of the grounding surface of the seating pad and the adjacent surface of the raised sole portion is about 2-12 mm, preferably about 3-9 mm, more preferably about 4-7 mm, most preferably. May range from about 4.5 to 6.5 mm. In one example, the vertical distance is about 5.5 mm.

  FIGS. 37-48 show a cup-shaped unit integrally cast with the front portion of the club head body as a single unit and including the face portion, the hosel, and the front portion of the crown, sole, toe, and heel (herein referred to as “cup unit”). Another exemplary golf club head 400 having a face portion forming a cup 402). However, the rear portion of the body (referred to herein as ring 404) is formed separately and later attached to cup 402 to form the club head body. The combination of cup 402 and ring 404 is referred to herein as the body of club head 400. The crown insert 406 and sole insert 408 can then be attached to the body to form the club head 400. In some embodiments, there is no sole opening or sole insert and the back ring completely surrounds the sole. In some embodiments, the sole insert is made of metallic material, composite material, and / or other material.

  37 and 38 show an assembled club head 400 including a cup 402, a ring 404, a crown insert 406, and a sole insert 408. The head-shaft coupling assembly 410 can be coupled to the hosel 412. The cup 402 and ring 404 can comprise a metallic material such as a titanium alloy or steel, while the inserts 406 and 408 can comprise a less dense material such as a carbon fiber reinforced composite material. Any of the other materials disclosed herein can be used for club head 400. The cup and ring may be made of the same material (eg, the same titanium alloy), or the ring may be made of a different material than the cup (eg, a steel ring and titanium alloy cup, or two different titanium alloys). Good.

  39 and 40 illustrate how ring 404 is coupled to cup 402 at toe and heel joint 420 to form an annulus having an upper crown opening and a lower sole opening. The ring 404 may include a forwardly extending toe and heel engaging end 424 that mates with a toe and heel engaging end 422 that extends rearwardly of the cup 402 to form a joint 420. In the example shown, the ring has a male protrusion that mates with a female notch in the cup. However, these joints can be reversed at the male protrusion of the cup and the female notch of the ring. In other embodiments, any other suitable engagement shape can be used within joint 420 to couple the ring to the cup. The joint 420 can be formed by any suitable means such as welding, brazing, adhesives, mechanical fasteners, and the like.

  In some embodiments, the joint 420 can be located a sufficient distance from the strike face to avoid potential failure due to severe impact on the golf club when hitting the golf ball. For example, in some embodiments, the juncture 420 has at least 20 mm, at least 30 mm, at least 40 mm, at least 50 mm, at least 60 mm, and / or the center plane of the club head as measured along the y-axis (forward-backward direction). Alternatively, it can be separated by 20 mm to 70 mm rearward.

  FIG. 41 illustrates that inserts 406 and 408 can be joined to the body to cover the crown and sole openings and enclose the interior cavity of the club head. The crown insert 406 can be coupled to a body crown ledge 426 that extends around the crown opening, and the sole insert 408 can be coupled to a body sole ledge 428 that extends around the sole opening. .. Ledges 426 and 428 may be formed from a combination of both cup 402 and ring 404, the cup including the front portion of the ledge and the ring including the rear portion of the ledge. Ledge portions 426 and 428 may be offset inwardly from the outer perimeter surface such that there is space for receiving the insert with the outer surface of the insert flush or flush with the outer perimeter surface of the cup / ring body. .. The ring 404 can also include a protrusion 430 extending downwardly and forwardly from the rear of the ring and forming part of a sole ledge 428 that supports the sole insert 408 and helps increase rigidity.

  In some embodiments, the ring 404 can include a mass pad of increased thickness, such as at the protrusion 430 or elsewhere, to provide a rear load to the golf club and center of mass. Move backwards to increase MOI around z-axis and x-axis. Such rear loading can also be accomplished by additional weight members coupled to the rear ring, such as removable, replaceable, and / or adjustable weight members coupled to the rear of the ring. For example, the protrusions 430 or other portions of the ring 404 can include openings, such as threaded openings, tracks, or other weight member receiving features. FIG. 47 shows an example of two weight ports 431 and 433 capable of receiving such adjustable weight members. It is also possible to connect more than one weight member to the rear ring at the same time. The mass pad or weight member (s) can include a relatively dense material such as tungsten or steel.

  In some embodiments, the cup 402 can include a mass pad, such as the mass pad 432 shown, in the bottom sole region to lower the center or mass and / or move the center of mass forward. .. In some embodiments, the cup 402 includes one or more additional weight members coupled to the sole portion of the cup, such as in or near the mass pad 432 and / or behind the slot 418, eg, one coupled to the cup. One or more removable, replaceable, and / or adjustable weight members may be included. For example, the mass pad 432 or other portion of the cup 402 can include one or more openings, such as threaded openings, tracks, or other weight member receiving features. It is also possible to connect more than one weight member to the cup at the same time. The weight member (s) can include a relatively denser material than the cast cup material, such as tungsten or steel. In some embodiments, the cups and rings have aligned weight ports that allow the weight members to be exchanged between the rear ring position and the lower cup position, providing adjustable function options that alter the mass characteristics of the club head. Can have. In some such examples, the club head may be provided with a group of interchangeable weights, including a weight of 1 to 3 grams and a weight of 8 to 15 grams, the weights being the weight ports or cups of the rear ring. Can be coupled to the weight port of the sole part of the sole, allowing a higher MOI (heavier weight at the rear) or lower spin (heavier weight at the lower forward position), or other combinations and mass characteristics. it can.

  44-47 show the body formed by the joined cups 402 and 404 without the inserts 406 and 408 in more detail in some respects. FIG. 44 is a front view showing the integral face 434. FIG. 45 is a side view of the heel. FIG. 46 is a top view showing a front crown portion 436, a front toe portion 440, and a front heel portion 442 that are part of the cup 402, as well as a toe and heel joint 420, and a crown ledge 426 that receives a crown insert 406. Is. FIG. 47 is a bottom view of a front sole portion 438 that includes a sole slot 418 that extends into the interior cavity of the club head and a ledge 428 that receives the sole insert 408. Also shown in FIG. 47 is an exemplary rear weight port 431 located within ring protrusion 430 and an exemplary sole weight port located within cup 402 behind slot 418 in the region of mass pad 432. It is shown. In other embodiments, such weight ports may be located on the cup or other parts of the ring, such as at the end of the ring, and there may be more than two such weight ports. The weight port is threadable and can receive an adjustable weight member, allowing for adjustment of the club head center of mass and MOI characteristics.

  Cup 402 is shown in more detail in FIGS. 42 and 43. The rear surface of the face 434 is shown in FIG. As described elsewhere herein, the back of the face 434 can be formed to have a variety of intricate shapes and thickness profiles, before the ring 404 is attached to the cup 402. It is easily accessible from the rear for processing, etching, material removal, and / or other post-casting treatments. FIG. 43 also shows the mass pad 432 on the sole portion 438 of the cup. The mass pad 432 can include a thickened portion of the sole with increased mass, which significantly affects the overall mass properties of the club head. The mass pad 432 can have a central notch with greater mass on the central toe and heel sides to enhance mass and MOI properties. Further information regarding the mass pad 432, alternative mass pad shapes and embodiments, and associated properties can be found in US Patent Application Publication No. 2018/0126228, published May 10, 2018, which is incorporated herein by reference. It is incorporated herein by reference in its entirety.

  FIG. 48 allows the hosel 412 of the head 400 to be coupled to the shaft in multiple selectable orientations, such as loft angle, lie angle, and / or face angle of the assembled golf club at normal address positions. A head-shaft coupling assembly 410 is shown that allows for adjustment. Assembly 410 may include various components such as sleeve 450, ferrule 452, ... Hosel insert 454, fasteners 456, and washers 458 shown in FIG. Further information regarding the adjustable head-shaft coupling assembly can be found in US Pat. No. 9,033,821 issued May 19, 2015, which is incorporated herein by reference in its entirety. Be done.

  49 and 50 illustrate some of the methods for making a golf club head, and more specifically, some of the methods for making a mold for casting the front cup 402 of a club head 400. . FIG. 49 shows a wax cup 500 that is a combination of a wax cup frame 502 and a wax face 504. The wax cup frame 502 and the wax face 504 are formed separately, and then the wax face is placed within the slightly larger sized face opening in the wax cup frame 502. The two pieces of wax can then be wax welded around the annular joint 506 by adding hot liquid wax to the joint and cooling it to fuse the face to the frame. The additional hot wax fills the joint 506 and joins the wax cup frame 503 and the wax face 504 into a single integral wax cup 500. After the wax has cooled, excess wax can be removed from the front and back of weld joint 506. In some embodiments, the wax face 504 extends radially outward to help contact the front surface of the wax cup frame 502 and set the depth of the wax face 504 relative to the wax cup frame, resulting in Prongs 508 may be included to ensure that the front surface of the wax cup 500 to be filled is uniform and smooth across the joint 506. The wax prongs 508 can be removed after the wax welding process.

  FIG. 50 shows that wax cup frame 512 and wax face 514 are wax welded together via wax added around joint 516, and wax prongs 518 of the wax face are optionally used at the opening of the wax cup frame. 7 illustrates another example of a wax cup 510 formed by helping to set the depth of the wax face. In this example, the wax cup 510 includes additional protrusions 520 that create additional gates in the resulting mold to help the molten metal flow evenly toward the face of the mold. Wax cups 500 and 510 may also include gating features at other locations, such as the heel side near the hosel, the back side of the face, and / or other locations, as shown.

  Forming a wax cup from two separate pieces of wax (eg, as in FIGS. 49 and 50) can facilitate the production of more complex shapes for the wax cup, as well as several different shapes. The embodiments of can be simplified and facilitated to be formed in a faster and more cost effective manner. Starting with two separate wax pieces, the wax frame tooling and forming process is decoupled from the wax face tooling and forming process. With respect to wax cup 500, the same wax cup frame 502 (and the same tool) can be combined with any of a number of differently shaped wax faces 504 to create a corresponding number of different wax cups, which means that the wax This means that only the tool for the face needs to be changed to produce a different wax cup. For example, a manufacturer can make two identical wax frames 502, then combine one wax frame with a first wax face and a second wax frame with a first wax face. Can be combined with a second wax face having a different thickness profile from. These two different wax cups and the resulting mold and final product metal cup can be measured, compared, tested, and so on. See FIGS. 51-54 for various exemplary face thickness profiles and associated descriptions herein. Therefore, using a two-part wax cup forming process can provide advantages in rapid prototyping and other manufacturing and development efficiencies.

  Also, starting with two separate wax pieces is also more efficient in forming multiple wax pieces because each wax piece is smaller and can be produced in greater numbers per batch on the same tree. Increase.

  Once the wax cup (eg, 500 or 510) is made, the wax cup can be used to form a mold for casting a metal cup (eg, cup 402). The mold can include any suitable material for casting ceramic materials and / or metal cups. Once the mold is formed around the wax cup, the wax can be melted and expelled from the mold. Various subsequent steps may then be applied, including the addition of gating and / or surface treatments to the mold, to prepare the mold for casting. Further, several cup molds can be combined into one mold tree to cast several metal cups simultaneously. After the mold is prepared, molten metal can be introduced into the mold to cast the metal cup. The mold can then be opened and removed to access the cast metal cup. The cast metal cup can be formed of any suitable metal or metal alloy, including titanium alloys (any suitable metal material disclosed herein can be used in the cast cup).

  After casting the metal cup, a portion of the casting cup can be machined or modified to remove a portion of the casting cup as desired. As an example, the front surface of the face portion of the cup can be machined to add horizontal scorelines and / or create more accurate textures, curvatures, and twists. In another example, the posterior surface of the face portion of the cup can be machined to modify the thickness profile across the height and width of the face portion to produce the desired variable thickness profile across the face portion. A casting method, such as machining or chemically etching (for example, using hydrofluoric acid) the front surface and / or the rear surface of the face portion of the casting cup to make the face portion less brittle and increase the durability of the face portion ( It is also possible to remove some or all of the alpha case layer that was formed, for example (in the case of titanium alloys).

  Assuming that material is removed from the face of the cup after casting, the face of the cup will have an excess thickness such that the desired amount of material and the desired thickness profile remain after post-cast material removal. Can be cast in material.

  As shown in FIGS. 39 and 40, and as described above, cup 402 and ring 404 are separately formed (eg, cast) and then combined together at joint 420 (eg, welded, brazed). , Adhesive bonds, mechanical fasteners, etc.), which can form a metal club head body that acts as a rigid frame that receives other components to form the golf club head 400. . One advantage of this method of making the club head body from the separate cup 402 and ring 404 is the lack of a back ring that results in post-casting machining, chemical etching, and And / or better access to the rear surface of the face portion for other post-cast modifications. For example, in the absence of ring 404, there is more room for a cutting tool, milling machine, CNC machine, drill bit, or other tool to access the entire rear surface of the face of cup 402. After such post-cast modifications have been made to cup 402, ring 404 can be attached to the cup and the rest of the club head can be assembled.

  Another advantage of casting the cup and ring separately is that each cast piece is smaller than the combined body and can be manufactured in a larger number per batch on the same wood, so each ring and cup piece can be made larger. It is to enable efficiency in casting. Also, since the same ring piece can be used with a variety of differently shaped cup pieces, only the tool for the cup piece can be changed to accommodate changes in the club head body or different cup / face shapes. It is necessary to make several different variations of club heads that have.

  FIG. 51 shows an exemplary rear view of the face portion of a cast cup 600, similar to cup 402, from the rear with the hosel / heel to the left and the toe to the right. 52 and 53 show another exemplary face portion 700 having a variable thickness profile and FIG. 54 shows yet another exemplary face portion 800 having a variable thickness profile. As a result of the casting method and any post-cast modifications to the face, the face of the casting cup can have a wide variety of novel thickness profiles. By casting the face into the desired shape, rather than forming the faceplate from a flat rolled metal sheet in the conventional process, the face can be made in a wider variety of shapes, with different grain orientations and chemical It can have different material properties such as impurity content, which can provide advantages in golf performance and manufacturing.

  In a conventional process, the faceplate is formed from a flat metal sheet having a uniform thickness. Such metal sheets are usually rolled along one axis to reduce their thickness to a uniform thickness throughout the sheet. This rolling process can impart a grain direction to the sheet that creates different material properties in the rolling axis direction as compared to the direction perpendicular to the rolling direction. This variation in material properties can be undesirable and can be avoided by using the disclosed casting method to make the face portion instead.

  Moreover, since conventional faceplates begin as flat sheets of uniform thickness, the total thickness of the sheet must be at least as great as the maximum thickness of the faceplate of the desired end product, which is the starting sheet. Much of the material must be removed and wasted, increasing material costs. In contrast, with the disclosed casting method, the face portion is initially formed very close to its final shape and mass, removed and wasted very little material. This saves time and costs.

  Moreover, in conventional processes, the initial flat metal sheet must be bent in a special process to impart the desired bulge and roll curvature to the faceplate. Such a bending process is not necessary when using the disclosed casting method.

  The unique thickness profile shown in FIGS. 51-54 is made possible using the disclosed casting method, where a metal sheet of uniform thickness is mounted on a lathe or similar machine and spread across the rear of the faceplate. It was previously impossible to achieve using conventional processes that are rotated to produce a variable thickness profile. In such a turning process, the applied thickness profile must be symmetrical with respect to the central axis of rotation, which means that the thickness profile is uniform at any given radius from the center point, each uniform. Limited to concentric annular shaped compositions having a thickness. In contrast, the disclosed casting method is not used to impose such restrictions and more complex face shapes can be made.

  By using the casting method disclosed herein, many of the disclosed club heads can be manufactured faster and more efficiently. For example, 50 or more cups 402 can be cast simultaneously on a single casting tree, but a conventional face milling method using a lathe can be used to create a new face thickness profile at once on a faceplate. Creating one by one takes much longer and requires more resources.

  In FIG. 51, the back face surface of the casting cup 600 includes an asymmetric variable thickness profile, which shows only one example of the wide variety of variable thickness profiles made possible using the disclosed casting method. The face center 602 can have a center thickness, and the face thickness gradually increases outward from the center across the inner blend zone 603 to a maximum thickness ring 604, which can be circular. You can The thickness of the face can be gradually reduced radially outward from the maximum thickness ring 604 to across the variable blend zone 606 to a second ring 608, which can be non-circular such as elliptical. The face thickness is from the second ring 608 across the outer blend zone 609 to a constant thickness (eg, minimum face thickness) heel and toe zone 610 and / or the face is cast cup 600. Can be moved radially outward to a gradual decrease, up to a radial perimeter region 612 that defines the extent of the face transitioning to the rest of the.

  The second ring 608 itself can have a variable thickness profile such that the thickness of the second ring 608 changes as a function of the circumferential position about the center 602. Similarly, the variable blend zone 606 varies as a function of circumferential position about the center 602 to provide a thickness transition from the maximum thickness ring 604 to a variable and thinner second ring 608. Can have. For example, the variable blend zone 606 to the second ring 608 is labeled Top Zone A, Top Toe Zone B, Toe Zone C, Bottom Toe Zone D, Bottom Zone E, Bottom labeled AH in FIG. It can be divided into eight sectors, including a heel zone F, a heel zone G, and a top heel zone H. The eight zones can have different angular widths as shown, or each can have the same angular width (eg, one-eighth of 360 degrees). Each of the eight zones can have a unique thickness variation from a common maximum thickness adjacent to ring 604 to a different minimum thickness in second ring 608. For example, the second ring can be thicker in zones A and E, thinner in zones C and G, and have an intermediate thickness in zones B, D, F, and H. In this example, the thickness of zones B, D, F, and H moves radially (moves radially outward and becomes thinner) and circumferentially (zones A and E toward zones C and G). And become thinner).

  An example of a cast cup 600 can have the following thickness, 3.1 mm at center 602, 3.3 mm at ring 604, and a second ring 608 is 2.8 mm in area A to 2. mm in area C. It can vary up to 2 mm, up to 2.4 mm in zone E, up to 2.0 mm in zone G, and up to 1.8 mm in heel and toe zone 610.

  52 and 53 show another example cast face 700 rear face surface including an asymmetric variable thickness profile. The face center 702 can have a center thickness, with the face thickness gradually increasing radially outward from the center across the inner blend zone 703 to a maximum thickness ring 704, which can be circular. You can The face thickness moves radially outwardly from the maximum thickness ring 704 across the variable blend zone 705 to an outer zone 706 of wedge sectors AH with varying thicknesses. be able to. As best shown in FIG. 53, sectors A, C, E, and G can be relatively thick and sectors B, D, F, and H can be relatively thin. An outer blend zone 708, which surrounds the outer zone 706, transitions in thickness from the variable sector to a peripheral ring 710 having a relatively small but constant thickness. The outer zone 706 may also include a blend zone between each of the sectors A-H with a gradual transition in thickness from one sector to an adjacent sector.

  An example of face portion 700 has the following thicknesses: 3.9 mm at center 702, 4.05 mm at ring 704, 3.6 mm in area A, 3.2 mm in area B, 3.25 mm in area C, area. It can have 2.05 mm in D, 3.35 mm in zone E, 2.05 mm in zone F, 3.00 mm in zone G, 2.65 mm in zone H, and 1.9 mm at the perimeter ring 710.

  FIG. 54 shows the rear surface of another exemplary cast face portion 800 including an asymmetric variable thickness profile having a target thickness offset toward the heel side (left side). The face center 802 has a center thickness and gradually increases to the toe / top / bottom, across the inner blend zone 803 to an inner ring 804 having a greater thickness than the center. The thickness is then reduced radially across the second blend zone 805 to a second ring 806 having a thickness less than that of the inner ring 804. The thickness is then reduced radially across the third blend zone 807 to a third ring 808 having a thickness less than that of the second ring 806. The thickness is then reduced radially across the fourth blend zone 810 to a fourth ring 811 having a thickness less than that of the third ring 808. The toe end area 812 merges with the outer perimeter 814, which has a relatively thin thickness, across the outer blend area 813.

  On the heel side, the thickness is offset by a set amount (eg, 0.15 mm) so that it is slightly thicker than the corresponding area on the toe side. The thickened area 820 (dashed line) provides a transition where all thicknesses gradually increase towards a thicker offset area 822 on the heel side (dashed line). In the offset area 822, the ring 823 is thicker than the heel side ring 806 by a set amount (eg, 0.15 mm) and the ring 825 is thicker than the ring 808 by the same set amount. The blend zones 824 and 826 move radially outward and gradually decrease in thickness, being thicker than the corresponding blend zones 807 and 810 on the toe side, respectively. In the thickened area 820, the thickness of the inner ring 804 gradually increases toward the heel.

  An example of face portion 800 is the following thickness, 3.8 mm at center 802, 4.0 mm at inner ring 804, thickening up to 4.15 mm across thickened area 820, at second ring 806. 3.5 mm and 3.65 mm at ring 823, 2.4 mm at third ring 808 and 2.55 mm at ring 825, 2.0 mm at fourth ring 811, and 1 at perimeter ring 814. It can have 0.8 mm.

  The targeted offset thickness profile shown in FIG. 54 can help provide a desired characteristic time (CT) profile across the face. Thickening the heel side can help avoid having CT spikes on the heel side of the face, for example, which can help avoid having an incompatible CT profile over the face. You can Such an offset thickness profile can be similarly applied to the toe side of the face or both the toe and heel sides of the face to avoid CT spikes on both the heel and toe sides of the face. In other embodiments, the offset thickness profile may be applied toward the top of the face and / or the bottom of the face.

  Various other variable face thickness profiles are disclosed in U.S. Patent Application No. 12 / 006,060, as well as U.S. Patent Nos. 6,997,820, 6,800,038, 6,824,475. No. 7,731,603, No. 8,801,541, No. 9,943,743, and No. 9,975,018 using the disclosed methods. Can be manufactured, the entire contents of each of which is incorporated herein by reference in its entirety. For example, US Pat. No. 9,975,018 discloses an example of a striking face that includes localized hardening regions such as an inverted cone or "donut" shaped thickness profile offset from the face center. , Thereby changing the firing conditions of the golf ball hit by the club head, in whole or in part, to correct, overcome, or prevent the occurrence of right / left deviations. In particular, the localized hardened regions are located on the ball striking face such that a golf ball struck under typical conditions will not impart left and / or right side spin to the golf ball.

  All of the disclosed face thickness profiles can be enabled by the casting methods disclosed herein. Such an arrangement is not possible using the conventional turning process of removing material in a concentric pattern from the back of an originally flat faceplate.

  In some golf club head embodiments, the faceplates can be individually cast and then welded to the front opening of the clubhead frame. When the faceplate is welded to the front opening of the frame, it usually creates extra material around the weld, which extra material is used to smooth the transition between the faceplate and the frame. , Must be removed after the welding process. This process can be avoided by casting the entire cup, including the face and front frame, as a single casting unit, as disclosed herein.

  However, casting the faceplate separately may provide advantages over casting the entire cup as one piece. For example, post treatment of a cast face plate is much easier than post treatment of the face surface when the face plate is part of the cup. 55 and 56 show the front 902 and back 904 of an exemplary cast faceplate 900. In particular, it is much easier to access all parts of the back surface of the cast faceplate as compared to the back face surface of the casting cup. Since there are no obstructions such as soles, crowns, tows, heels, hosel, etc., there is an infinite space to access the cast faceplate with tools for the desired post-casting process. It also allows the cast faceplate to approximate the exact final shape of the faceplate, resulting in less material removal and less work required to modify the face after casting. For example, the faceplate can be cast with less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, and / or less than 0.2 mm excess material on each side of the face that is removed after casting. This equates to less waste being removed compared to machining a faceplate from a flat sheet of rolled metal. The front face of the cast face can be machined to remove some or all of the alpha case layer to achieve precise bulge, roll and twist curvatures and / or add scorelines. The back of the cast face can be machined to remove some or all of the alpha case layer to achieve a precise variable thickness profile across the face. As described elsewhere herein, the casting process produces a much more complex and asymmetric thickness profile, as opposed to the 360 degree concentric circular symmetry required by conventional facesheet turning processes. to enable.

  A cast (eg, co-cast with a single casting object) golf club head that includes a face as an integral part of the body has the face formed separately and later attached to the front opening of the club head body. It can provide superior structural properties compared to club heads (eg, welded or bolted). However, the advantages of having a Ti face cast in one piece are mitigated by the need to remove the alpha case on the surface of the cast Ti face.

  The club head disclosed herein including an integrally cast titanium alloy face and body unit (eg, a cast cup) may eliminate the disadvantage of having to remove the alpha case, or at least It can be greatly reduced. For cast 9-1-1 Ti faces, using a mold preheat temperature of 1000 ° C. or higher, the thickness of the alpha case is, in some embodiments, about 0.10 mm or less, 0.15 mm or less, about 0.20 mm. For cast 6-4 Ti faces, the alpha case thickness may be greater than 0.10 mm, less than 0.30 mm, or less than about 0.30 mm, for example 0.10 mm to 0.30 mm. It can be greater than 15 mm, greater than 0.20 mm, or greater than 0.30 mm, such as about 0.25 mm to about 0.30 mm. In some embodiments, the thickness of the alpha case is as low as 0.1 mm, up to 0.15 mm, while providing a sufficiently durable product with desirably high CT times across the face. You can In some embodiments, the alpha case of the back of the face at the geometric center of the face can have a thickness of less than 0.30 mm and / or less than 0.20 mm, which chemically reduces the surface after formation. Can be achieved without mechanical etching.

  Other titanium alloys that may be used to form any of the striking faces and / or club heads described herein may include titanium, aluminum, molybdenum, chromium, vanadium, and / or iron. it can. For example, in one exemplary embodiment, the alloy is 6.5 wt% to 10 wt% Al, 0.5 wt% to 3.25 wt% Mo, 1.0 wt% to 3.0 wt%. Cr, 0.25 wt% to 1.75 wt% V, and / or 0.25 wt% to 1 wt% Fe, and the balance Ti (one example being "1300 “Titanium alloy” is also included).

  In another exemplary embodiment, the alloy is 6.75 wt% to 9.75 wt% Al, 0.75 wt% to 3.25 wt% or 2.75 wt% Mo, 1.0 wt%. % To 3.0 wt% Cr, 0.25 wt% to 1.75 wt% V, and / or 0.25 wt% to 1 wt% Fe, with the balance Ti.

  In another exemplary embodiment, the alloy is 7 wt% to 9 wt% Al, 1.75 wt% to 3.25 wt% Mo, 1.25 wt% to 2.75 wt% Cr, It may contain 0.5 wt% to 1.5 wt% V, and / or 0.25 wt% to 0.75 wt% Fe, with the balance Ti.

  In another exemplary embodiment, the alloy is 7.5 wt% to 8.5 wt% Al, 2.0 wt% to 3.0 wt% Mo, 1.5 wt% to 2.5 wt%. % Cr, 0.75 wt% to 1.25 wt% V, and / or 0.375 wt% to 0.625 wt% Fe, with the balance Ti.

  In another exemplary embodiment, the alloy comprises 8 wt% Al, 2.5 wt% Mo, 2 wt% Cr, 1 wt% V, and / or 0.5 wt% Fe. And the balance comprises Ti. Such a titanium alloy can have the formula Ti-8Al-2.5Mo-2Cr-1V-0.5Fe. As used herein, references to "Ti-8Al-2.5Mo-2Cr-1V-0.5Fe" refer to titanium alloys containing the elements mentioned in any of the above proportions. Certain embodiments may also include traces of K, Mn, and / or Zr, and / or various impurities.

Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have minimum mechanical properties of 1150 MPa yield strength, 1180 MPa maximum tensile strength, and 8% elongation. These minimum properties may be significantly superior to other cast titanium alloys including 6-4 Ti and 9-1-1 Ti, which may have the minimum mechanical properties mentioned above. In some embodiments, Ti-8Al-2.5Mo-2Cr-1V-0.5Fe has a tensile strength of about 1180 MPa to about 1460 MPa, a yield strength of about 1150 MPa to about 1415 MPa, and about 8% to about 12%. It can have an elongation, a modulus of elasticity of about 110 GPa, a density of about 4.45 g / cm ³ , and a hardness of about 43 (43 HRC) on the Rockwell C scale. In a particular embodiment, the Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy can have a tensile strength of about 1320 MPa, a yield strength of about 1284 MPa, and an elongation of about 10%.

  In some embodiments, the striking face and / or the cup having the face portion can be cast from Ti-8Al-2.5Mo-2Cr-1V-0.5Fe. In some embodiments, the striking face and club head body may be integrally formed or cast from Ti-8Al-2.5Mo-2Cr-1V-0.5Fe, depending on the particular properties desired. ..

  The mechanical parameters of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe described above can provide surprisingly superior performance compared to other existing titanium alloys. For example, due to the relatively high tensile strength of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe, a cast hitting face containing this alloy has a unit thickness when hitting a golf ball as compared to other alloys. It can be shown that there is little deflection around. This is because the high tensile strength of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe results in less deflection of the striking face, reducing the tendency of the striking face to flatten on repeated use, thus speeding up the ball. It may be particularly beneficial for metal wood type clubs configured to strike at. This allows the striking face to retain its original bulge, roll, and "twist" dimensions over extended use, including those by advanced and / or professional golfers who tend to hit the ball at particularly high club speeds. be able to.

  In any of the embodiments disclosed herein, the upper toe portion of the striking surface is opened more than the lower toe portion of the striking surface and the lower heel portion of the striking surface is closed more than the upper heel portion of the striking surface. Thus, a face portion having a twisted striking surface can be included. For more information on golf club heads with twisted striking surfaces, see US Pat. No. 9,814,944, US Provisional Application No. 62 / 687,143, 2018, filed June 19, 2018. It can be found in US patent application Ser. No. 16 / 160,884, filed March 15, all of which are incorporated herein by reference in their entireties. Any of these twisted face techniques disclosed in these incorporated references can be implemented in the club heads disclosed herein in any combination with the techniques disclosed herein.

  The techniques disclosed herein may be implemented for any type of golf club head, not just the disclosed examples, including drivers, fairways, rescues, hybrids, utility clubs, irons, wedges, and putters. it can.

  For purposes of this description, certain aspects, advantages, and novel features of the disclosed embodiments are described herein. The disclosed methods, devices, and systems should not be construed as limiting in any way. Instead, the present disclosure is directed to all novel and non-obvious features and aspects of various disclosed embodiments, alone and in various combinations and subcombinations with each other. The methods, devices, and systems are not limited to any particular aspect or feature or combination thereof, and the disclosed embodiments are in the presence of any one or more of the particular advantages or problems solved. You don't need to be done.

  Although some operations of the disclosed embodiments are described in a particular sequential order for convenience of presentation, unless a specific ordering is required by the specific language described herein, unless otherwise required. It should be understood that the method of this description involves relocation. For example, the operations described sequentially may be rearranged in some cases, or may be performed simultaneously. Moreover, for the sake of simplicity, the attached figures may not show various ways in which the disclosed method may be used in combination with other methods.

  As used in this application and the claims, the singular forms "a", "an", and "the" clearly indicate otherwise. Including plural unless otherwise specified. Also, the term "includes" means "comprises." Furthermore, the terms "coupled" and "associated with" generally mean electrically, electromagnetically, and / or physically (eg, mechanically or chemically) coupled or linked, with the specific opposite term. Does not preclude the presence of intervening elements between related items or no associations.

  In some examples, a value, procedure, or device may be referred to as "lowest," "best," "minimum," etc. Such an explanation may make a choice among a number of choices, such choices need not be better or smaller than the other choices, and are preferred over the other choices. It will be appreciated that it is intended to indicate that it need not be.

  As used herein, certain terms such as “top”, “bottom”, “top”, “bottom”, “horizontal”, “vertical”, “left”, “right” can be used. These terms are used, where applicable, to provide some clarity of explanation when dealing with relative relationships. However, these terms do not imply an absolute relationship, position, and / or orientation. For example, for an object, the "upper" surface can become the "lower" surface simply by rotating the object. Still, the object is still the same.

  It should be appreciated that the illustrated embodiments are merely preferred examples and should not be construed as limiting the scope of the present disclosure, given the many possible embodiments to which the principles of the present disclosure may be applied. .. It will be apparent that various modifications may be made thereto without departing from the broader spirit and scope of the disclosure as described. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. Accordingly, the scope of the present disclosure is at least as broad as the following claims. We therefore claim all that comes within the scope of these claims.

2 golf club head 3 shaft 4 golf club head 5a central face, geometric center point 5b heel 5c toe 5d crown 5e sole 6 club face 8 bulge 9 roll 10 main body 11 scoreline 12 crown 14 sole 16 skirt 18 face plate 20 hosel 22 striking surface, outer surface 23 impact position 24 hosel bore 26 heel portion 28 toe portion 30 front portion 32 rear portion 40 inner surface 42 central portion 44 diverging portion 46 converging portion 48 transition portion 50 center of gravity (CG)
60 origin 65 origin z axis 70 origin x axis 75 origin y axis 85 CGz axis 90 CGx axis 95 CGy axis 150 initial pattern 152 main gate 154 assistant gate 156 flow channel 160 cluster 162 graphite receptor 164 graphite cross spoke 166 runner 168 mold cavity 170 Crucible 172 Injection Cup 180 Cluster 184 Shell Runner 182 Receptors 186, 188 Mold Cavity 200 Golf Club Head 202 Club Head Body 204 Head-Shaft Coupling Assembly 206 Crown Insert 207 Forward Protrusion 208 Sole Insert 209 Notch 210 Front Weight Assembly 212 Rear weight assembly 214 Front weight track 216 Rear weight track 224 Rear seating pad (ground plane)
225 Overhanging lip 226 Front seating pad (ground plane)
228 Overhanging lip 230 Toe section 232 Toe side cantilever ledge 234 Heel side cantilever ledge 236 Rib 238 Thick area 240 Toe side opening 242 Heel side opening 244 Rear track opening 250 Ledge 252 Crown area 260 Ledge 262 263, 265, 267 Rib 270 Face 280, 286 Inner recess 282, 294 Recess 284, 288 Peripheral rail 290, 292 Peripheral rail 296, 298 Inner recess 400 Club head 402 Cup 404 Ring 406 Crown insert 408 Sole insert 410 Head-shaft Coupling Assembly 412 Hosel 418 Sole Slot 420 Joint 426 Crown Ledge 428 Sole Ledge 430 Protrusion 431 Rear Weight Port 432 Mass Pad 433 Weight Port 434 Integrated Face 438 Sole Part 450 Sleeve 452 Ferrule 454 Hosel Insert 456 Fastener 458 Washer 500 Wax Cup 502 Wax Cup Frame 504 Wax Face 506 Annular Junction 508 Wax Prong 510 Wax Cup 520 Additional Protrusion 600 Cast Cup 602 Face Center 603 Inner Blend Area 604 Maximum Thickness Ring 606 Variable Blend Area 608 Second Ring 609 Outer Blend Area 610 Heel and toe area 612 Radial peripheral area 700 Cast face portion 702 Face center 703 Inner blend area 704 Maximum thickness ring 705 Variable blend area 706 Outer area 708 Outer blend area 710 Perimeter ring 800 Cast face portion 802 Face center 803 Inner blend Zone 804 Inner Ring 805 Second Blend Zone 806 Second Ring 808 Third Ring 810 Fourth Blend Zone 811 Fourth Ring 812 Toe End Zone 813 Outer Blend Zone 814 Outer Perimeter, Perimeter Ring 820 Thickening Zone 822 Offset Zones 823, 825 Rings 824, 826 Blend Zone 900 Cast Faceplate 902 Front 904 Rear B Golf Ball X X-axis Y Y-axis Z Z-axis

Claims (10)

A method of making a golf club head, the method comprising:
Made of a titanium alloy, the entire face portion of the golf club head, only the front portion of the crown of the golf club head, only the front portion of the sole of the golf club head, only the front portion of the toe of the golf club head, the Casting a cup including only the front portion of the heel of the golf club head and the hosel, such that a layer of the alpha case is formed on the rear surface of the face portion;
Machining the back surface of the face portion, thereby removing at least a portion of the layer of the alpha case from the back surface of the face portion;
A method comprising: Forming a ring separate from the step of casting the cup;
Attaching the ring to the cup such that the ring defines the outermost periphery of the rear portion of the golf club head.
The method of claim 1, wherein the step of machining the rear surface of the face portion occurs prior to the step of attaching the ring to the cup.   The method of claim 2, wherein the ring is formed of a metallic material different from the titanium alloy of the cup. Attaching a crown insert made of composite material to the front portion of the crown of the golf club head defined by the ring and the cup;
The method of claim 2, further comprising attaching a sole insert made of a composite material to the front portion of the sole of the golf club head defined by the ring and the cup.   The method of claim 1, wherein the at least a portion of the layer of alpha case is removed from the back surface of the face portion without chemically etching the back surface of the face portion. The step of casting the cup forming a layer of alpha case on the front surface of the face portion opposite the rear surface,
The method of claim 1, wherein the method further comprises machining the front surface of the face portion to remove at least a portion of the layer of the alpha case from the front surface of the face portion. A golf club head,
Having a single unitary body made of titanium alloy, the entire face portion of the golf club head, only the front portion of the crown of the golf club head, only the front portion of the sole of the golf club head, the golf club A cup comprising only a front portion of the toe of the club head, only a front portion of the heel of the golf club head, and a hosel, the rear surface of the face portion of the golf club head being defined by the cup, A cup, which is a machined surface,
A ring attached to the cup and defining an outermost periphery of a rear portion of the golf club head;
A crown insert made of a composite material and attached to the front portion of the crown of the golf club head defined by the ring and the cup;
A golf club head, comprising:   The golf club head of claim 7, wherein the ring is made of a metallic material different from the titanium alloy of the cup. The cup further comprises a ledge formed in the front portion of the crown of the golf club head defined by the cup,
8. The golf club head of claim 7, wherein the crown insert is received by the ledge such that the ledge is located inside the crown insert.   8. The golf club head of claim 7, further comprising a sole insert made of a composite material and attached to the front portion of the sole of the golf club head defined by the ring and the cup.

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