JP7433011B2 - golf club head - Google Patents

Description

CROSS REFERENCES TO RELATED APPLICATIONS This application is a continuation-in-part of U.S. Patent Application No. 16/059,801 filed on August 9, 2018, and is a continuation-in-part of U.S. Patent Application No. 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 parts and related methods for manufacturing such golf club heads.

Due to the increasing popularity and competitiveness of golf, a significant amount of effort and resources are currently being expended to improve 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 modern "wood-type" golf clubs (for example, "drivers," "fairway woods," "rescue," and "utility or hybrid clubs") that have polished shafts and non-wood club heads? It bears little resemblance to the "wood" drivers, low-lofted long irons, and higher-numbered fairway woods that were used years ago. These modern wood type clubs are commonly referred to as "metal woods" or simply "woods."

The current ability to make metal wood club heads of strong, lightweight metals and other materials has made it possible to make club heads hollow. Also, the use of high strength and high fracture toughness materials allows for thinner clubhead walls compared to previous clubheads without the swing speed penalty due to increased weight. , total weight is reduced and club head size can be increased. Larger clubheads tend to have larger faceplate areas and can also be made with higher clubhead inertia, which makes the clubhead more "forgiving" than smaller clubheads. . Characteristics such as the size of the optimal impact location (also known as the "sweet spot") are determined by many variables, including the shape, profile, size, and thickness of the faceplate, as well as the location of the clubhead's center of gravity (CG). It is determined.

An exemplary metal wood golf club typically includes a shaft having a lower end to which a club head is attached. 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 (used interchangeably herein with the terms "face," "face insert," "striking plate," or "strike plate") is subsequently attached. In some cases, the body and faceplace are cast together as a unitary structure, eliminating the need for later attachment of the faceplate to the body. The faceplate defines the front or strike face that actually contacts the golf ball.

When 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 dedicated to providing sufficient strength and structural support to the club head. This is called "structural" mass. The mass remaining within the budget is referred to as "discretionary" or "performance" mass and can be distributed within a metal wood club head, for example, to address performance issues. Therefore, the ability to reduce the structural mass of a metal wood 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 clubhead is to reduce the mass of the faceplate by reducing its thickness, but since the face absorbs the initial impact of the ball, its physical and mechanical Opportunities to do this are somewhat limited, given the very strict requirements on physical characteristics. Club manufacturers use titanium and titanium alloys in the manufacture of faceplates as well as the manufacture of entire club heads due to their light weight and high strength. Typically, club heads with relatively complex three-dimensional structures are manufactured using a casting process. Many such faceplates are made by investment casting in which a suitable metal melt is cast into a preheated ceramic investment mold formed by a lost wax process. Investment casting is also used to prepare the faceplate either as a unitary structure cast with the rest of the clubhead body or as a separately formed faceplate that is attached to the front of the clubhead body, usually by welding. has been done. Although widely used, investment casting of complex-shaped parts of such reactive materials is characterized by relatively high costs and low yields. Low casting yields can be caused by several defects, including surface or surface-related void-type defects, and/or insufficient filling of certain mold cavity areas, especially thin mold cavity areas, and associated internal voids, shrinkage, etc. Due to the following factors.

To further combine faceplate investment casting deficiencies, club head manufacturers are introducing curvature into the face of the club to help compensate for directional issues caused by shots outside the location of the center of gravity. There are also many. Therefore, rather than a flat faceplate, manufacturers prefer faces that have both a convex curvature from heel to toe (called a "bulge") and a convex curvature from crown to sole (called a "roll"). You may wish to form a Additionally, manufacturers may also introduce variable face thickness profiles across the faceplate. Varying the thickness of the faceplate can increase the size of the clubhead COR area, commonly referred to as the sweet spot of a golf club head, which results in a consistently high golf ball when hitting a golf ball with a golf club head. Allows for a larger area of the faceplate giving ball speed and shot forgiveness. Varying the thickness of the faceplate may also be advantageous in reducing the weight of the face area for relocation to another area of the club head.

To compensate for the deficiencies of investment casting of these more complex faceplate structures, manufacturers are turning to alternative methods of forming faceplates, including forming faceplates from rolled titanium sheets. after laser cutting, forging to impart any desired bulges and rolls, followed by a machining step on a lathe to introduce any desired face thickness profile. The disadvantage of these steps is that three separate forming steps are required, and the machining process on the lathe to form the variable thickness profile is not only wasteful, but also the profile cannot be changed as a result of the circular motion of the lathe. Including the fact that it restricts to a circular area.

Therefore, it would be highly desirable to have a club head faceplate with sufficient physical properties to allow for a reduction in thickness to provide more available discretionary weight 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 with any shape, circular, oval, asymmetric, or other shapes. . Also, a simplified process for the manufacture of such faceplates can be used, which results in a faceplate with the required thickness and physical strength properties, and this process also It would also be desirable if faceplates with any desired bulges and rolls and variable thickness profiles could be obtained, while requiring minimal processing steps and minimizing any waste produced in the process. . It would also be desirable if the club head body and face could be cast simultaneously from the same material as a single unitary body, rather than two parts that must later be attached together. 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 may be cast from 9-1-1 titanium, with the faceplate being cast as an integral part of the body along with the crown, sole, skirt, and hosel. 9-1-1 titanium material allows the faceplate and other parts of the body to absorb less oxygen from the mold, allowing for reduced alpha case thickness, resulting in increased ductility and durability do. This eliminates the need to reduce the alpha case thickness after casting using hydrofluoric acid or other hazardous chemical etchants.

The casting method involves preheating the mold to a temperature below ambient temperature and/or coating the inner surfaces of the mold to further reduce the amount of oxygen that migrates from the mold to the 9-1-1 titanium during casting. can include.

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, and the body generally having a 9-1-1 diameter. Cast from titanium, the body is cast as a single monolithic casting, and the faceplate is integrally formed with the crown, sole, skirt, and hosel. The body may contain trace amounts of fluorine atoms as an alloying impurity 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 example methods include preparing a mold for casting and then using the mold to cast a golf club head body comprised substantially entirely of 9-1-1 titanium, the casting comprising: The casting body defines a hollow interior region, the body is cast as a single monolithic casting, and the faceplate is attached to the 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 includes preheating the mold such that the mold is at a temperature of no more than 800°C, no more than 700°C, no more than 600°C, and/or no more than 500°C when casting is performed. include.

Also disclosed herein are embodiments of golf club heads that include a metal cast cup forming a forward portion of the club head, including a hosel, a face, a forward portion of the crown, and a forward portion of the sole. A metal rear ring is formed separately from the casting cup and joined to the heel and toe portions of the casting cup to form the clubhead body, and the metal clubhead body includes a hollow interior region, a crown opening, and A sole opening may be defined. A composite crown insert can then be coupled to the crown opening. A sole insert made of composite, metal, or other materials can be coupled to the sole opening. In some embodiments, there are no sole openings or sole inserts. The cast cup and rear ring can be cast from titanium alloy and welded together to form the club head body. In some embodiments, the ring and cup are made of different metal materials, such as two different titanium alloys, or a titanium alloy and steel. Cast cups can include faces with complex shapes to provide desirable performance characteristics. The face portion can have a twisted anterior surface and/or the rear surface of the face can have a shape that provides an asymmetric variable thickness profile across the face. The rear surface of the cast cup face can be machined and/or otherwise modified prior to installing the rear ring to increase the space for accessing the entire rear surface of the face with tools.

A method of forming a wax cup from a wax cup frame and a separately formed wax face using a wax welding process is also disclosed. Such a wax cup can then be used to create a mold for casting a metal cup that forms the front of a golf club head. Two part wax welding methods can offer manufacturing, prototyping, and testing advantages.

A cast faceplate is also disclosed that includes a titanium alloy with 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.

FIG. 2 is a side view of a golf club head. 2 is a front view of the golf club head of FIG. 1. FIG. FIG. 2 is a bottom perspective view of the golf club head of FIG. 1; FIG. 2 is a front view of the golf club head of FIG. 1 showing an origin coordinate system of the golf club head. FIG. 2 is a side view of the golf club head of FIG. 1 showing a center of gravity coordinate system. FIG. 2 is a top view of the golf club head of FIG. 1; FIG. 3 is a rear view of an exemplary faceplate with variable thickness. 8 is a cross-sectional side view of the faceplate of FIG. 7 taken along line 8-8 of FIG. 7; FIG. 8 is a cross-sectional side view of the faceplate of FIG. 7 taken along line 9-9 of FIG. 7; FIG. 1 is a front view of a golf club head of the present invention showing a bulge and roll measurement system; FIG. FIG. 2 is a diagram of a golf club head hitting a golf ball with the heel direction side of the golf club head. 1 is a top view of an exemplary initial pattern for a wood-type club head showing main gates, assistant gates, and flow channels; FIG. 1 is a schematic illustration of a casting cluster including multiple mold cavities; FIG. FIG. 2 is a schematic diagram of another casting cluster including multiple mold cavities. FIG. 1 is a workflow diagram illustrating a method for casting a golf club head. 1 is a table of titanium alloy casting data obtained for six different casting machines. This table is a continuation of the table in FIG. 16. 1 is a plot of process losses versus mass of injection material (molten metal) for a titanium alloy showing casting furnace size for casting machines with varying mass of injection material; 1 is a flowchart of one embodiment of a method for configuring a casting cluster. FIG. 2 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. 21 is an exploded side perspective view of the golf club head of FIG. 20. FIG. 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. 22. FIG. 21 is a bottom view of the golf club head of FIG. 20. FIG. 25 is a cross-sectional view taken along line 25-25 of FIG. 24. FIG. 21 is a heel side view of the golf club head of FIG. 20. FIG. 21 is a toe side view of the golf club head of FIG. 20. FIG. 23 is a cross-sectional top-down view of the lower portion of the body of FIG. 22; FIG. FIG. 23 is a cross-sectional side view of the toe portion of the main body of FIG. 22; 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 line 30-30 of FIG. 29; FIG. 30 is another enlarged detailed cross-sectional view of the left and right weight tracks taken generally along line 31-31 of FIG. 29; FIG. 23 is a bottom view of a portion of the sole of the body of FIG. 22 including the front and rear weight tracks; FIG. 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. 33 is another enlarged detailed cross-sectional view of the front and rear weight tracks taken generally along line 34-34 of FIG. 32; FIG. 21 is a top view of the golf club head of FIG. 20 with the crown removed showing the sole portion positioned within the body; FIG. 21 is a top view of the sole portion of the golf club head of FIG. 20. FIG. 21 is a top view of the golf club head of FIG. 20 with the crown in place; FIG. FIG. 21 is a top view of the golf club head of FIG. 20 with both the crown and sole removed. 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. 2 is a perspective view of another exemplary golf club head. 38 is a different perspective view of the club head of FIG. 37 with a head-shaft connection assembly; FIG. 38 illustrates how the body of the club head of FIG. 37 is formed from two pieces attached together; FIG. Figure 40 shows the body of Figure 39 in an assembled state; 41 shows how the crown insert and sole insert are assembled with the body of FIG. 40; FIG. FIG. 3 is a diagram showing the front surface of the cup face portion of the main body. It is a figure which shows the rear part of the cup face part of a main body. FIG. 3 is a front view of the main body. It is a heel side elevational view of a main body. FIG. 3 is a top view of the main body. FIG. 3 is a bottom view of the main body. FIG. 3 is a cross-sectional view of the head-shaft connection assembly. FIG. 3 shows a two-part wax body with the wax face formed separately from the rest of the wax body. FIG. 3 shows the wax face wax welded to the remainder of the wax body. FIG. 7 shows a variable thickness profile on the rear side of the face. FIG. 7 shows another variable thickness profile on the rear side of the face. FIG. 53 is a perspective view of the face of FIG. 52; FIG. 7 shows another variable thickness profile offset toward the heel. FIG. 3 is a front view of an exemplary cast faceplate. 56 is a view showing the rear side of the cast face plate of FIG. 55; FIG.

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 features. 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" refer to 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."

Reference is also made to the accompanying drawings, which form a part of this specification. Although the drawings depict particular embodiments, other embodiments may be formed and structural changes may be made without departing from the intended scope of the disclosure. Directions and references (e.g., top, bottom, top, bottom, left, right, rear, forward, heel direction, toe direction, etc.) may be used to facilitate discussion of the drawings, but are not limiting. It is not intended to be. For example, specific terms such as "above", "bottom", "top", "bottom", "horizontal", "vertical", "left", "right", etc. may be used. These terms are used, where applicable, to provide some clarity in the description when addressing 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, a "top" surface can become a "bottom" surface simply by rotating the object. However, the object is still the same object. Therefore, the following detailed description is not to be construed in a limiting sense, with the scope of claimed proprietary rights being defined by the appended claims and their equivalents.

In particular, conditional language such as "could," "could," "could," "might," etc. generally means, unless specified otherwise or understood otherwise within the context in which it is used. It is intended to convey that certain embodiments include certain features, elements, and/or steps while other embodiments do not. Thus, such conditional language generally indicates that a feature, element, and/or step is required in some way by one or more particular embodiments, or that one or more particular embodiments are required by user input or prompts. whether or not these features, elements, and/or steps are necessarily included or implemented in any particular embodiment. not intended to.

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

For reference, within this disclosure, reference to a "driver-type golf club head" means any metal wood-type golf club head intended primarily for use with a tee. Generally, driver-type golf club heads have a loft of 15 degrees or less, more typically 12 degrees or less. References to a "fairway wood type golf club head" refer to any wood type golf club that is intended to be used for hitting a ball from the ground, while also being usable for hitting a ball from a tee. means head. Generally, fairway wood type golf club heads have lofts of 15 degrees or more, more commonly 16 degrees or more. Generally, fairway wood type golf club heads have a leading edge to trailing edge length of 73 to 97 mm. Various definitions distinguish between fairway wood type golf club heads and hybrid type golf club heads, with hybrid type golf club heads tending to resemble fairway wood type golf club heads but with a leading edge The length from to the trailing edge is shorter. Generally, a 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. The driver-type golf club head 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, the fairway wood type golf club head of the present disclosure can be between 13 and 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. As shown in FIGS. Body 10 may include a crown 12 that defines an interior cavity while defining a striking surface 22, a sole 14, a skirt 16, and a face plate 18 (also referred to as a face or face portion). Faceplate 18 may be formed separately from the body and attached to an opening in the front of the body, or it may be integrally formed as an integral part of body 10. Body 10 may include a hosel 20 defining a hosel bore 24 adapted to receive a golf club shaft (see FIG. 6). 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, and origin z-axis 65, club head center of gravity 50, CGx-axis 90, CGy-axis 95, and CGz-axis 85 is shown. As shown, these axes are horizontal or vertical, with the club head 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 capped 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 weight of the crown. Similarly, the sole may include one or more openings within the body that are covered by the sole insert. The sole insert can be made of composite, metallic, or other materials. In embodiments where the body includes an opening in the crown or sole, particularly where the faceplate is formed as an integral part of the body during casting (and where there is no face opening into the body to provide access during manufacturing) , such openings can provide access to the interior cavity of the club head during manufacture. The club heads disclosed herein in connection with FIGS. 20-36 have crown and sole openings that are capped or covered with inserts formed of lighter weight materials (e.g., composite materials). Provide an example. Further information regarding the body opening and associated inserts may be found in U.S. Patent Publication No. 2018/0185719, published on July 5, 2018, and U.S. Provisional Patent Application No. 62/01, filed on June 5, 2017. No. 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 movable along a weight track formed in the sole and/or around the club head. Other exemplary weights may be adjusted by rotating the weight within a threaded weight port. Various ribs, struts, mass pads, and other structures may be included within the body to provide reinforcement, adjust mass distribution and MOI characteristics, adjust acoustic characteristics, and/or for other reasons.

A wood-type club head, such as club head 2, has a volume, generally measured in cubic centimeters (cm ³ ), equal to the volumetric displacement of the club head, assuming any openings are generally planar and sealed. (See United States Golf Association "Procedure for Measuring the Club Head Size of Wood Clubs" Revision 1.0, November 21, 2003). For drivers, the golf club head can have a volume of about 250 cm ³ to about 600 cm ³ , such as about 300 cm ³ to about 500 cm ³ , and can have a total mass of about 145 g to about 260 g. For fairway woods, the golf club head can have a volume of about 120 cm ³ to about 300 cm ³ and 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 a total mass of about 105 g to about 280 g.

The sole 14 is defined as the lower part of the club head 2 that extends upwardly from the lowest point of the club head when the club head is ideally positioned, i.e., in the proper address position relative to a golf ball in a horizontal plane. be done. In some implementations, the sole 14 extends from about 50% to 60% of the distance from the lowest point of the club head to the crown 12, in some cases from about 15 mm for a driver to about 10 mm for a fairway wood. It can be 12mm.

Materials that may be used to construct body 10, including faceplate 18, include composite materials (e.g., carbon fiber reinforced polymeric materials), titanium or titanium alloys, steel or alloys of steel, magnesium alloys, copper alloys, nickel alloys. , and/or any other metal or metal alloy suitable for golf club head construction. Other materials may also be included within the body, such as paints, polymeric materials, ceramic materials, etc. In some embodiments, the body including the faceplate is made of 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), or aluminum and aluminum alloys (3000 series alloys, 5000 series alloys, 6061- 6000 series alloys such as T6, 7000 series alloys such as 7075), 3.5 to 2.5% Al, 3.0 to 2.0% V, 0.02 % N, 0.013% H, and 0.12% Fe.

Aspects of Investment Casting Injection molding is used to form a sacrificial "initial" pattern (eg, made of casting "wax") of the desired casting. Suitable injection dies can be made of aluminum, other suitable metals or metal alloys, or other materials, for example, by a computer-controlled machining process using a casting master. CNC (computer numerical control) machining can be used to form the complexity of the mold cavity within the mold. The cavity dimensions compensate for the linear and volumetric shrinkage of the casting wax that occurs during the casting of the initial pattern, and during the actual metal casting performed later using the investment casting "shell" formed from the initial pattern. established to compensate for similar shrinkage phenomena expected to occur.

Typically, groups of initial patterns are assembled together and attached to a central wax sprue to form a casting "cluster." Each initial pattern within the cluster forms a respective mold cavity within the casting shell that is later formed around the cluster. The central wax sprue defines the location and configuration of runner channels and gates for routing molten metal introduced into the sprue to a mold cavity within the casting shell. The runner channel may include one or more filters (e.g., (made of ceramic).

The cast shell is constructed by dipping the cast cluster into a liquid ceramic slurry followed by a bed of refractory particles. This dipping sequence is repeated as necessary to build up a sufficient wall thickness of ceramic material around the casting cluster, thereby forming an investment casting shell. An exemplary dip sequence includes six dips of the cast cluster in a liquid ceramic slurry and five dips in a bed of refractory particles, resulting in an investment cast shell containing alternating layers of ceramic slurry and refractory material. The first two layers of refractory material desirably include fine (300 mesh) zirconium oxide particles and the third through fifth layers of refractory material 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 these conditions, the wax within the shell is melted using injected steam. The shell is then baked in an oven at an elevated temperature of 1000-1300°C to remove residual wax and increase 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 create 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 feed system (gates and runners for subsequent feed of molten metal). After completing these operations, the casting machine is ready to produce cast shells.

An important aspect of configuring a cluster is deciding where to place the gates. Each club head mold cavity typically has one main gate through which molten metal flows into the mold cavity. Additional auxiliary (“assistant”) gates can be connected to the main gate by flow channels. During investment casting using such a shell, molten metal flows into each mold cavity through a respective main gate, flow channel, and auxiliary gate. In this vein, the mold for forming the initial pattern of the club head must also define the main gate and any assistant gates. After the initial pattern of wax for the club head is molded, the initial pattern is removed from the mold and the locations of the flow channels are defined by "gluing" pieces 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. A main gate 152 and three assistant gates 154 are shown. Flow channel 156 interconnects assistant gate 154 and main gate 152.

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

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

Two exemplary clusters are shown in FIGS. 13 and 14, respectively. In FIG. 13, the depicted cluster 160 includes a graphite receptor 162, a graphite cross spoke 164, a runner 166, and a mold cavity 168. Each mold cavity 168 is for a respective club head. Molten metal in crucible 170 is poured into cluster 160 using pour cup 172, which directs the molten metal into receiver 162, branch 166, and then mold cavity 168. In FIG. 14, the depicted cluster 180 includes receptors 182 coupled to shell runners 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 pour cup 172, which directs the molten metal into receiver 182, shell runner 184, and then mold cavities 186, 188.

The reinforced wax cluster is 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 (the ceramic and graphite parts do not melt). After removing the wax from the shell, the shell is sintered (fired) to significantly improve its mechanical strength. If the shell is used in a relatively small metal casting furnace (e.g., can hold a cluster of only one branch), the shell can be used for investment casting. When the shell is used in a relatively large metal casting furnace, 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 rotating the casting shell in a centrifugal manner, harnessing and exploiting the forces 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 angular motion. This rotation is performed using a turntable located within the casting chamber under sub-atmospheric pressure. The force generated by the ω ² r acceleration of the shell facilitates the flow of molten metal into the mold cavity without leaving any voids. The investment casting shell (including the construction cluster and runners) is typically assembled outside the casting chamber and heated to a preset temperature before being placed as an integral unit on a turntable within the chamber. After attaching the shell to the turntable, the casting chamber is sealed and evacuated to a preset sub-atmospheric pressure ("vacuum") level. Once the chamber is evacuated, the molten alloy is prepared for casting and the turntable begins to rotate. When the molten metal is ready to pour into the shell, the casting chamber is at the appropriate vacuum level, the casting shell is at the appropriate temperature, and the turntable is rotating at the desired angular velocity. The molten metal is thus poured into the receiver of the casting shell, flows across the shell and fills the mold cavity of the shell.

As the molten metal flows into the shell cavity and contacts the cavity surfaces, the high temperature environment (both from the molten metal and the preheated shell) promotes the diffusion of elements such as oxygen within the shell material. Casting of titanium is always done under sub-atmospheric pressure (vacuum), and while no oxygen is available in the ambient environment (because the shell is made up of multiple layers of "oxide"), oxygen is present within the shell. can still be found. When oxygen is introduced into molten titanium, an alpha case, an oxygen-rich layer, is formed on the surface of the titanium object being cast. Typically, 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 for increasing the strength of titanium alloys, but increasing strength greatly reduces ductility); Cracks may easily occur under load. To reduce the tendency to form alpha cases, the oxygen diffusion rate needs to be lowered, and to reduce the diffusion rate, the temperature needs to be lowered. However, it is not possible to lower the temperature of molten titanium. Therefore, lowering the temperature of the preheated shell is one way to lower the oxygen diffusion rate, reducing alpha case formation.

Typically, before moving to the casting furnace, the casting shell is heated (called preheating) to aid in the flow of molten titanium. The higher the shell preheating temperature, the easier the titanium will flow. This is essential for thin-walled titanium castings, where preheating temperatures can be as high as 1100-1200°C. On the other hand, such high temperatures tend to produce thick alpha case layers (towards the upper end of the 1-4% wall thickness range). Therefore, if alpha case formation is a concern, the preheating temperature of the cast shell can be lowered. Typically, the casting shell preheating temperature is less than 1000°C, preferably less than 900°C, for non-flowing critical titanium castings where the formation of an alpha case is undesirable.

Cluster Casting As can be seen with reference to FIG. 15, a method of manufacturing a golf club head includes preparing clusters as disclosed elsewhere in this disclosure, as shown with reference to step 361. In various embodiments, preparing the clusters may include a preheating step as disclosed elsewhere herein. One aspect of the present disclosure is that preheating of the cluster may be lower than that required for conventional investment casting techniques. For example, in conventional investment casting techniques, the preheating is on the order of 1000°C to 1400°C, and in the centrifugal casting of the present disclosure, the preheating temperature is less than 1000°C in some embodiments, and 800°C in some embodiments. or in some embodiments about 500° C. or less. In some embodiments, no preheating is necessary and casting may 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 a molten state simultaneously with cluster preparation and/or cluster acceleration, or may be an intermediate step. However, in accordance with step 363, the metal may be heated to a molten state. According to step 364, molten metal is introduced into the cluster. As shown by the dashed line from step 362 to step 364, the cluster may be angularly accelerated before, after, or simultaneously with the introduction of molten metal into the cluster. According to step 365, the molten metal is allowed to cool. The cluster casting is removed from the cluster shell in step 366 and post-processing occurs from step 367 onwards.

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 may range from 250 to 450 revolutions per minute. In various embodiments, angular velocities as low as 150 rpm and as high as 600 rpm may be suitable.

Because of the lower casting temperatures, cooling the molten metal within the mold cluster involves reduced waiting times compared to traditional investment casting methods. As a result, yields are increased and cycle times are improved. Various conventional investment casting methods that rely on gravity have allowed the casting of only a maximum of six to eight parts. Using centrifugal casting increases the production capacity of a single casting cycle, as more than 18 to 25 parts can be cast in a single cycle. Additionally, the yield per gram injected is increased. In traditional investment casting, a fixed mass of metal is used to cast a fixed number of golf club heads. The spin casting technology of the present disclosure allows more golf club heads to be manufactured using the same mass of metal. Technological improvements and honing in this disclosure can further reduce this metal mass/head. Depending on the particular methodology, cycle times may also be reduced. Additionally, the methods described herein lead to reduced tooling and capital costs required for the same production demands. Thus, the methods described herein reduce costs and improve production quality.

Additionally, casting according to the method described herein results in material savings and achieves greater throughput, but this is due to the fact that the higher the accelerations and thereby the forces applied to the casting, the more the material is transferred to the head. This is because it can be easily washed away. Finally, alloys typically manufactured using other methods can be more easily cast into similar shapes.

Gating and Cluster Configuration Configuring gates and cluster(s) requires consideration of multiple factors. These factors to consider include (but are not necessarily limited to) (a) dimensional limitations of the casting chamber of the metal casting furnace; (b) handling requirements, particularly during the slurry dipping step to form the investment casting shell; (c) achieving an optimal flow pattern of molten metal within the investment casting shell; (d) providing the cluster(s) of the investment casting shell with at least the minimum strength necessary to withstand rotational motion during metal casting; (e) achieving a balance of minimum resistance to the flow of molten metal into the mold cavity (by providing the runner with a sufficiently large cross section) versus minimizing metal waste; (e.g. by providing the runner with a small cross-section), as well as (f) achieving mechanical balance of the cluster around the central axis of the cast shell. Item (e) can be important because after casting, the metal remaining in the runner may not form a product, but rather become "contaminated" (a portion of which is usually recycled). These structural elements are combined with metal casting parameters such as shell preheating temperature and time, vacuum level within the metal casting chamber, and turntable angular velocity to produce the actual casting result. As club head walls are made increasingly thinner, careful selection and balance of these parameters is essential to obtaining satisfactory investment casting results.

The details of investment casting performed on metal casting machines tend to be proprietary. However, past experiments with various titanium casting machines have revealed some consistencies and some general trends. For example, a particular club head (volume 460 cm ³ , crown thickness 0.6 mm, and sole thickness 0.8 mm) is placed in each of six titanium casting machines (each metal casting furnace has a capacity between 10 kg and 80 kg). The data were prepared and tabulated in FIGS. 16 and 17. The parameters listed in FIGS. 16 and 17 include:

"Max R" is the maximum radius of the cluster,
“Min 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/wetted perimeter of the runner,
A “sudden 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 smallest radius,
"Maximum acceleration" is the acceleration at the maximum radius,
"Minimum acceleration" is the acceleration at the smallest radius,
"Maximum force" refers to the force at the maximum radius (note that this is an approximation of the magnitude of the 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 indicate a greater reduction in force), and
"Minimum force" refers to the force at the smallest radius (note that this is an approximation of the magnitude of the 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 indicate a greater reduction in force), and
"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-sectional area),
"Maximum kinetic energy" is the kinetic energy of the molten metal at its maximum radius,
"Density" is the density of molten metal (titanium alloy) at a melting point of 1650 ° C.
"Viscosity" is the viscosity of molten titanium at 1650°C,
"Maximum 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 the minimum radius.

Minimum Force Requirements Figures 16 and 17 show that to achieve good casting yields, it is necessary to apply at least a minimum force (and therefore at least a minimum pressure) to the molten metal entering the casting shell of each cluster. Provide a table of data. The force exerted on the molten metal is generated in part by the actual mass of molten metal entering the mold cavity within the cluster and the centrifugal force generated by the rotating turntable of the casting furnace. A lower minimum force is generally desirable because lower forces can reduce the amount of molten metal per club head required for casting. However, other factors tend to indicate an increase in this force, including thinner walls of the item being cast, more complex clusters (and thus more complex flow patterns of the molten metal), shell preheating. These include lower temperatures (resulting in greater loss of thermal energy from the molten metal as it flows into the investment casting shell), and substandard shell quality such as rough mold cavity walls. The data in FIGS. 16 and 17 indicate that the minimum force required to cast a titanium alloy club head where at least a portion of the wall is 0.6 mm thick is approximately 160 Nt. Caster 1 achieved this minimum force.

From the minimum force requirement, a lower threshold for the amount of molten metal required to be injected into the shell can be derived. Excluding the unavoidable pouring losses, the best metal usage (as achieved in Caster 1) is 386g (0.5g) for club heads (including gate and some runners) each having a mass of about 200g. 386 kg). This corresponds to a material usage rate of 200/386=52 percent. The accelerations (maximum) applied to the investment casting shell by casters 2-6 were all greater than the accelerations applied by caster 1, but each of casters 2-6 was greater than that achieved by caster 1. More molten metal was required to obtain an equivalent casting yield.

Some process losses (splatters, cooled metal adhering to the crucible sidewalls, and liquid titanium alloy supply interruption, recovery of cleaning losses, etc.) are inevitable. Process losses impose an upper limit on the efficiency that can be achieved with smaller casting furnaces, i.e. the rate of process losses increases rapidly with decreasing furnace size, as shown in FIG.

On the other hand, smaller casting furnaces advantageously have simpler operation and maintenance requirements. Other advantages of small furnaces are: (a) they tend to process small, simple clusters of mold cavities, and (b) small clusters have separate respective runners feeding each mold cavity. (c) preheat the furnace more easily and quickly before casting; (d) the furnace has lower potential (e) small clusters tend to have shorter runners, which tend to have lower Reynolds numbers and therefore less potential for destructive turbulence. Large foundry furnaces tend not to have these advantages, while small foundry furnaces tend to have more unavoidable process losses of molten metal per mold cavity than larger furnaces.

Considering the above, a cost-effective casting system (furnace, cluster, yield, net material cost) will depend on proper cluster design and gate design considerations in the configuration of investment casting shells used in such furnaces. Seems to include medium-sized systems as long as they are included. This can be seen by comparing casters 1, 4, and 5. The overall material usage (not considering process losses) by these three casters is very close (664-667 g/cavity). The material usage by caster 1 (when considering process losses) is 386g, while the material usage by casters 4 and 5 is 510g. Casters 4 and 5 can therefore still be improved, but caster 1 appears to have reached its limit in this respect.

Flow Field Considerations At a minimum, the minimum threshold force that is applied to the molten metal entering the investment casting shell is typically determined by either changing the mass of molten metal entering the shell or increasing its velocity. This can be achieved by decreasing one and increasing the other. There are practical limits to the extent to which the mass of the "injection material" (molten metal) can be reduced. As the mass of the injection 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 creating turbulence of the molten metal entering the shell. Turbulence is undesirable because it disturbs the flow pattern of the molten metal. Disturbances in the flow pattern may require more force to "push" the metal through the main gate and 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 (flow radius) directly affects the Reynolds number. The smaller R (flow radius), the smaller the minimum force (the two are substantially interrelated). Therefore, advantageous considerations are first to reduce the Reynolds number to maintain a stable flow field of molten metal and then to meet the minimum force requirement by adjusting the amount of injection material.

Other Factors One additional factor is preheating the investment casting shell before introducing the molten metal. Because Caster 1 had the highest shell preheat temperature, Caster 1 achieved a 94% yield with the lowest Reynolds number and the lowest amount of injected material (and thus the lowest force). Another factor is the complexity of the cluster(s). Complex clusters are very difficult to evaluate, and the high Reynolds numbers typically exhibited by such clusters may not be the only variable controlled to reduce destructive turbulence of molten metal within such clusters. do not have. For example, the number of "sharp" turns (more than 90 degrees) of the cluster runners and mold cavities is also a factor. 16 and 17, the investment casting shell used by caster 1 has one sharp turn (and one less steep turn), whereas the shell used by caster 6 has three turns. It has sharp turns. Caster 6 may need to rotate the shell at a higher angular velocity just to overcome the flow resistance caused by these sharp turns. However, this does not alleviate the turbulent flow patterns caused by sharp turns. Therefore, investment casting shells containing simpler cluster(s) (with fewer sharp turns to allow for a more "natural" flow path of molten metal) are desired.

Another factor is runner and gate alignment. The interfacial gating ratio for caster 1 is closest to 100% (indicating optimal gating) compared to substantially poorer data from other casters. The "worst" was Caster 3, whose investment casting shell had a Reynolds number almost as low as Caster 1, but Caster 3 had a low interfacial gate ratio (approximately 23%), resulting in a 78% A yield of only 20% was achieved. The low interfacial gate ratio exhibited by the shell of caster 3 indicates that the low yield of caster 3 is due to insufficient injected material to fill the gate or the occurrence of "two-phase flow liquid and voids". It made it difficult to determine if there was. In any case, the overall cross-sectional area of the runner and gate should be kept as approximately equal (and constant) to each other as possible to achieve a constant flow rate of liquid metal across the shell at any point during injection. can. In thin-walled titanium alloy castings, this principle applies particularly to the interface between the runner and the main gate, where the interface gate ratio must be greater than or equal to one (1.0).

Yet another factor is the cross-sectional shape of the runner. Comparing Caster 4 and Caster 5 and Caster 2 and Caster 5, the triangular cross-section runners appeared to produce lower Reynolds numbers than the circular or rectangular runners. Although using runners with triangular cross section can lead to interfacial gate ratio problems (because metal flows from such runners to gates with straight or circular cross section), using runners with triangular cross section The significant reduction in Reynolds number achieved is worth pursuing as the difference in the injection material used in casters 2 and 5 shows (39 kg vs. 32 kg).

A flowchart for constructing a cluster of investment casting shells is shown in FIG. In the first step 301, overall considerations of the intended cluster are made, including dimensions, handling, and balance. Next, cluster complexity is reduced by minimizing sharp turns and unnecessary (although certainly frequent) changes in runner cross-section (step 302). The interface gate ratio is kept as close to unity as possible (step 303). Also, the Reynolds number is minimized to the extent practicable (step 304). Fine tune the turntable angular velocity (RPM) and increase the shell preheat temperature to obtain the highest possible product yield (step 305). Typically, repetition (306) of steps 304, 305 is necessary 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 without reducing the product yield and while maintaining other casting parameters. Reduces the force required to drive the flow of molten metal across the cluster.

Further information regarding investment casting methods and apparatus for casting thin-walled club heads using titanium alloys and other materials can be found in U.S. Patent No. 7,513,296, issued April 7, 2009, and 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 clubhead bodies that do not include a faceplate (the faceplate is later attached to the body), but where the face is formed separately. The same or similar methods and systems having the same or similar benefits and advantages for casting the club head bodies disclosed herein that are faces of monolithic parts of the body that are not attached to the body and are later attached to the body. can be used.

Detailed information on coating molds for casting titanium alloys and on methods for manufacturing molds with calcium oxide facecoats for use in casting titanium alloys was published on June 16, 1998. No. 5,766,329, incorporated herein by reference in its entirety.

Compared to titanium golf club faces formed for machining or forging of club head seats that include a cast titanium alloy body/face , cast faces offer the advantages of lower cost and complete design freedom. be. However, golf club faces cast from conventional titanium alloys such as 6-4 Ti must be chemically etched to remove the alpha case on one or both sides so that the face is 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, an environmental pollutant, and expensive. be.

Contains aluminum (e.g., 8.5-9.5% Al), vanadium (e.g., 0.9-1.3% V), and molybdenum (e.g., 0.8-1.1% Mo) Faces cast from titanium alloys, optionally with other trace alloying elements and impurities, collectively referred to herein as "9-1-1 Ti", can have a less significant alpha case; Compared to faces made from conventional 6-4 Ti and other titanium alloys, HF acid etching is not required, or at least less necessary.

Furthermore, 9-1-1 Ti can have the lowest 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 minimum mechanical properties of 812 MPa yield strength, 936 MPa tensile strength, and approximately 6% elongation. There is a possibility that there are.

A cast golf club head that includes a face as an integral part of the body (e.g., cast simultaneously with a single cast object), where the face is formed separately and later attached to the front opening of the club head body. It can provide superior structural properties compared to club heads (e.g., welded or bolted). However, the benefits of having an integrally cast Ti face are mitigated by the need to remove the alpha case on the surface of the cast Ti face.

The club head disclosed herein that includes an integrally cast 9-1-1 Ti face and body unit eliminates or at least significantly reduces the disadvantage of having to remove the alpha case. I can do it. For Casting 9-1-1 Ti faces, using conventional mold preheat temperatures of 1000° C. or higher, the alpha case thickness is, in some embodiments, about 0.15 mm or less, about 0.20 mm or less, or about 0.30 mm or less, such as 0.10 mm to 0.30 mm, but for cast 6-4 Ti faces, the alpha case thickness may be greater than 0.15 mm, 0.20 mm in some examples. or greater than 0.30 mm, such as from about 0.25 mm to about 0.30 mm.

In some cases, the reduced thickness of the alpha case of a 9-1-1 Ti faceplate (e.g., 0.15 mm or less) provides sufficient durability for the faceplate to withstand harsh conditions such as HF acid. It may not be thin enough to avoid the need to etch away part of the alpha case with a chemical etchant. In such cases, the preheating temperature of the mold can be reduced (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 a thinner alpha case (eg, less than 0.15 mm, less than 0.10 mm, and/or less than 0.07 mm). This provides better ductility and durability for the casting/face unit, which is particularly important for faceplates.

The thinness of the alpha case in the cast 9-1-1 Ti face improves durability, and the face is durable enough to eliminate the need to remove portions of the alpha case from the face by chemical etching. Therefore, monolithic casting of the body and face using 9-1-1 Ti can eliminate hydrofluoric acid etching from the manufacturing process, especially when using molds with low preheat temperatures. This can simplify the manufacturing process, reduce costs, reduce safety risks and operational hazards, and eliminate the possibility of environmental contamination with HF acid. Furthermore, because the HF acid is not introduced into the metal, the body/face, or even the entire club head, contains little or substantially no fluorine atoms, which 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 are due to impurities in the metal material used to cast the body.

Variable face thickness and face bulge and roll characteristics In certain embodiments, for example, U.S. Patent Application No. 12/006,060 and U.S. Pat. 6,824,475, 7,731,603, and 8,801,541, each of which , the entire contents of which are incorporated herein by reference. Varying the thickness of the faceplate increases the size of the COR area of the club head, commonly referred to as the sweet spot of the golf club head, so that when you hit a golf ball with the golf club head, the larger area of the face plate consistently increases Golf ball speed and shot latitude can be provided. Varying the thickness of the faceplate may also be advantageous in reducing the weight of the face area for relocation to another area of the club head. For example, as shown in FIG. 9, faceplate 18 has a thickness t defined between outer surface 22 and inner surface 40 facing the interior cavity of the golf club head. Faceplate 18 may include a central portion 42 positioned adjacent ideal impact location 23 on outer surface 22 . The central portion 42 can have a thickness similar to, slightly greater than, or less than the circumferential thickness of the faceplate. Faceplate 18 may also include a diverging portion 44 extending radially outwardly from central portion 42, which may be oval-shaped. Inner surface 40 may be symmetrical about one or more axes and/or asymmetrical about one or more axes. The thickness t of the diverging portion 44 increases in a radially outward direction from the central portion 42 . Faceplate 18 includes a converging section 46 extending from a diverging section 44 through a transition section 48 . The thickness t of the converging section 46 substantially decreases at a radially outward position from the transition section 48 . In some cases, transition section 48 is a vertex between diverging section 44 and converging section 46. In other implementations, transition section 48 extends radially outwardly from diverging section 44 and has a substantially constant thickness t (see FIGS. 7-9).

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

In some embodiments of golf club heads having faceplates 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 certain embodiments, 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 a 25% thickness variation across the face (thickest section compared to thinnest section) to reduce weight and achieve higher ball speed on off-center hits. Must be.

In some embodiments of golf club heads having faceplates with protrusions and thin sole or skirt structures, the maximum faceplate thickness is greater than about 3.0 mm and the minimum faceplate thickness is about 3.0 mm. less than In certain embodiments, the maximum faceplate thickness is 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. Yes, 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. FIG. The club head 4 includes a central face 5a, a heel 5b, a toe 5c, a crown 5d, and a sole 5e. Club head 4 further includes a club face 6 that includes a heel 5b to toe 5c curvature, commonly referred to as a bulge 8. Club face 6 also includes a curvature from crown 5d to sole 5e, commonly referred to as 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 has an 10 and extending horizontally into the page of FIG. The X axis X, the Y axis Y, and the Z axis Z are mutually 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 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 the CG Y-axis are in a horizontal plane parallel to the flat ground. The CG Z-axis is 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 that hits the golf ball B with the heel 5b of the club head. This imparts clockwise spin to the golf ball B, causing the golf ball to curve to the 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 leaves the club head 4 at an angle Θ with respect to the CG Y axis of the club head 4. Angle Θ merely indicates the general angle at which the ball leaves the clubhead and is not intended to depict or imply the actual angle relative to the centerline or the point from which that angle is measured. That will be understood. The angle Θ further indicates that a ball struck with the heel of the club will initially travel in its flight path to the left of the centerline.

The method used to obtain the values in this disclosure is an 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 generally horizontally on a V-block attached to an optical comparator. Club head 4 is oriented such that score line 11 is approximately parallel to the X-axis of the optical comparator. More precise orientation steps may also be used. A measurement is then taken at the geometric center point 5a on the club face. Next, 20 millimeters away from the geometric center point 5a of the club face 6 along the X-axis X of the club head on both sides of the geometric center point 5a, and along the X-axis A further measurement is taken along and 30 millimeters away from the geometric center point of the club face. Fit an arc to these five measurement points, for example by using a machine radius function. This arc corresponds to a circumference with a given radius. This measurement of radius is what is meant by bulge radius.

To measure roll, the club head 4 is rotated 90 degrees so that the club head Z-axis Z is approximately parallel to the machine's X-axis. The measurement is taken at the geometric center point 5a of the club face. Next, along the Z-axis Z of the club face 6 at a distance of 15 mm from the geometric center point 5a and on both sides of the center point 5a, and at a distance of 20 mm from the geometric center point and on both sides of the center point. Additional measurements are taken along the Z axis of the club face. Insert an arc into these five measurement points. This arc corresponds to a circumference with a given radius. This measurement of radius is what is meant by roll radius.

Curvature is defined as 1/R, where R is the radius of the circle corresponding to the measurement 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 measurement arc that 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 measurement 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 from about 0.033 cm ⁻¹ to about 0.066 cm ⁻¹ and the bulge curvature is greater than 0 cm ⁻¹ and 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 of the bulge curvature divided by the roll curvature, Ro, 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. Furthermore, rejects due to high porosity are virtually eliminated, as are rejects after secondary processing. Excellent surface quality is obtained while increasing the density and strength of the product, allowing for larger, thinner and more complex castings. From a processing point of view, lower casting pressures are required, increasing tool life and mold life. It also reduces or eliminates metal or alloy waste from flashing.

By utilizing a vacuum die-casting process, the titanium body and faceplate of the disclosed club head are surprisingly much smaller than those commonly observed in similar titanium objects made by investment casting. The particle size of the investment cast titanium face plate was found to be approximately 100 μm compared to approximately 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 bodies/faceplates disclosed herein can also exhibit much lower porosity than that typically 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%, and more preferably less than 0.1%.

The titanium body/faceplate disclosed herein also exhibits a much higher yield strength, as measured by ASTM E8, than that typically 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 commonly observed in similar titanium faceplates made by investment casting and from forged and rolled annealed products. Higher than similar faceplates made.

The titanium faceplates disclosed herein also have elongation as measured by the elongation reported in a tensile test, defined as the maximum elongation in gauge length divided by the original gauge length of about 10% to about 15%. It can exhibit similar ductility.

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

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

By combining the various properties mentioned above, the metal has a titanium faceplate that is 10% thinner than a similar faceplate made by traditional investment casting while maintaining strength properties that are as good or better. 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 as described in U.S. Patent Application Publication No. 2013/0123040 of Willett et al. , the entire contents of which are incorporated herein by reference. Golf club head aerodynamics is discussed in U.S. Pat. No. 8,777,773, U.S. Pat. No. 8,088,021, U.S. Pat. , No. 8,771,101, No. 8,083,609, No. 8,550,936, No. 8,602,909, and No. 8,734,269. is also detailed herein, the teachings of which are incorporated herein by reference in their entirety.

In addition to the strength characteristics of the rear body, and the aerodynamic characteristics of the club head, another set of characteristics of the club head that must be controlled is the acoustic characteristics, or sound, that the golf club head emits when it hits a golf ball. be. At club head/golf ball impact, the striking face of the club is deformed such that vibrational modes in the club head associated with the club crown, sole, or striking face are excited. Most golf club shapes are complex, consisting of surfaces with 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 by the ball/club impact is evaluated as described in co-pending U.S. patent application Ser. No. 13/842,011 filed March 15, 2013. , the entire contents of which are incorporated herein by reference.

In certain embodiments of the invention, the golf club head includes a removable head-shaft connection assembly as described in more detail in U.S. Pat. No. 8,303,431, issued November 6, 2012. , the entire contents of which are incorporated herein by reference. Additionally, in certain embodiments, the golf club head not only replaceably connects the shaft to the head, but also utilizes a removable head-shaft connection assembly to adjust the loft and/or lie angle of the club. Features may also be incorporated to provide the golf club head and/or golf club with the ability to. Such adjustable lie/loft connection assemblies are disclosed in U.S. Patent No. 8,025,587, issued September 27, 2011; No. 831, U.S. Pat. US Patent Application Publication No. 2012/0258818 filed on December 20, US Patent Application Publication No. 2012/0122601 filed on December 29, 2011, US Patent Application Publication No. 2012/0122601 filed on March 22, 2011 No. 2012/0071264 and copending U.S. Patent Application No. 13/686,677 filed November 27, 2012, and the entire contents of these patents, publications and applications is incorporated herein by reference in its entirety.

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

In some embodiments, the manufacturer and/or user can adjust the movable weight to adjust the location of the center of gravity of the club to achieve desired performance characteristics in the golf club head. This feature is similar to U.S. Pat. No. 6,773,360, U.S. Pat. No. 7,166,040, U.S. Pat. , 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, 447, 7,632,194, 7,846,041, 7,419,441, 7,713,142, 7,744,484, No. 7,223,180, and No. 7,410,425, the entire contents of each of which are incorporated herein by reference in their entirety.

According to some embodiments of the golf club head described herein, the golf club head also includes a slidably repositionable weight positioned in the sole and/or skirt of the club head. be able to. Among other benefits, the slidably relocatable weight allows the end user of the golf club to adjust the position of the CG of the club head over a range of positions relative to the position of the relocatable weight. Further details regarding slidably repositionable weight features may be found in U.S. Patent No. 7,775,905, filed May 20, 2013; No. 898,313, and U.S. Patent Application No. 14/047,880, filed October 7, 2013, the entire contents of each of which are incorporated herein by reference. , as well as paragraphs [430]-[470] and FIGS. No. 101, as well as co-pending U.S. Patent Application Nos. 62/020,972 and 62/065/552, filed on July 3, 2014 and October 17, 2014. , the contents of each of which are incorporated herein by reference.

According to some embodiments of the golf club head described herein, the golf club head also includes a coefficient of restitution feature that defines a gap in the body of the club, e.g., located proximate the face at the sole. But that's fine. Such characteristics of the coefficient of restitution are described in U.S. Patent Application No. 12/791,025 filed on June 1, 2010, U.S. Patent Application No. 13/338,197 filed on December 27, 2011, and 2013. No. 13/839,727 (U.S. Patent Application Publication No. 2014/0274457) filed on March 15, 2014; No. 14/457,883 filed on August 12, 2014; Ser. No. 14/573,701, filed Dec. 17, 2003, the entire contents of each of which are incorporated herein by reference in their entirety.

Additional Exemplary Club Heads FIGS. 20-36D illustrate another exemplary wood-type golf club head 200 that can 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 advantages discussed in U.S. Patent Application Publication No. 2018/0185719) and includes two weight tracks 214, 216 with slidably adjustable weight assemblies 210, 212. include. 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 are arranged in a desired orientation pattern (updated in U.S. Patent Application Publication No. 2018/0185719). The head 200 includes a body 202, an adjustable head-shaft connection assembly 204, and an adjustable head-shaft connection assembly 204 attached to the top of the body. a crown insert 206 attached to the body, a sole insert 208 attached to the inside of the body above the bottom of the body, a front weight assembly 210 slidably attached to the front weight track 214, and a rear weight track 216. and a slidably mounted rear weight assembly 212. The head 200 includes a front seating pad or surface 226 between the front track 214 and the face 270 and a rear seating pad or surface 224 at the rear of the body on the heel side of the rear track 216, and includes a rear seating pad or surface 224 at the rear of the body on the heel side of the rear track 216. When in position, the remainder of the sole is elevated above the ground.

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 a toe opening 240, a heel opening 242, and a rear track opening 244, all of which are covered by sole insert 208. . A rear weight track 216 is positioned below the sole insert 208.

The head 200 also includes a toe side cantilevered ledge 232 that extends circumferentially from the rear weight track 216 or rear seating pad 224 around the toe region adjacent the face; 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 toe portion 230 to a raised sole adjacent the front end of toe side opening 240 of the body. Three such triangular ribs are shown in FIGS. 20 and 26A.

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

The lower part of the body 202, which forms part of the sole, has various features, variations in thickness, to provide enhanced stiffness when desired and reduced weight when less stiffness is desired. , ribs, etc. The body can include a thicker region 238, for example, near the intersection of the two weight tracks 214, 216. The body may also include a thin ledge or seat 260 around the openings 240, 242, the ledge 260 being 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 increase stiffness and acoustics.

The upper part of the body can include various features, thickness variations, ribs, etc. to provide enhanced stiffness when desired and reduced weight when less stiffness is desired. 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 crown and sole insert seats 250 and 260 may share a common edge or be close to each other around the outer periphery of the body.

35A-35D show top views of the head 200 in various states with the crown and sole insert in place and/or removed. 36A-36D show the crown and sole insert 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 may also include a notch 209 at the rear heel end to accommodate a fit around the rear seating pad 224 area where ground forces require enhanced stiffness. In various embodiments, the sole insert can 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. 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 stiffness to withstand the large dynamic loads imposed on the clubhead, while freeing up discretionary mass that can be strategically allocated elsewhere within the clubhead. 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 bottom openings 240, 242, 244 of the body and may be secured to the frame by adhesive or other secure fastening techniques. In some embodiments, the ledge 260 may include a recess for receiving a projection or bump that aligns with the underside of the sole insert to further secure and align the sole insert on the frame.

Similar to the sole, the crown also has an opening 246 that reduces the mass of the body 202 and, more significantly, reduces the mass of the crown, where the increase in mass increases the CG of the head (desirably). This is the area of the head that has the greatest impact on Along the perimeter of opening 246, the frame includes a recessed ledge 250 for seating and supporting crown insert 206. The crown insert 206 (see FIGS. 36C and 36D) has a geometry and size that matches the crown opening 246 and is secured to the body by adhesive or other secure fastening techniques over the opening 246. Ru. The ledge 260 may include a recess along the length of the ledge for receiving a projection or bump that aligns with the underside of the crown insert to further secure and align the crown insert on the body. The crown insert may also include a forward projection 207 that extends into the forward crown portion 252 of the body.

In various embodiments, the ledges of the body that receive the crown insert and sole insert (e.g., ledges 250 and 260) may be made from the same metallic material (e.g., titanium alloy) as the body, and thus the golf club head. can add considerable mass to the 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 a desired mass contribution. In some embodiments, where the ledge adds excessive mass to the golf club head, sole inserts and crown inserts that can be made from lighter materials (e.g., carbon fiber or graphite composites and/or polymeric materials) This may negate the weight loss benefits. In some embodiments, the width of the ledge may range from about 3 mm to about 8 mm, preferably from about 4 mm to about 7 mm, and more preferably from about 4.5 mm to about 5.5 mm. In some embodiments, the width of the ledge can be at least four times as wide as the thickness of the respective insert. In some embodiments, the thickness of the ledge may range from about 0.4 mm to about 1 mm, preferably from about 0.5 mm to about 0.8 mm, more preferably from 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 from about 0.7 mm to about 1.2 mm, more preferably from about 0.8 mm to about 1.1 mm. could be. Although the ledge may extend or run along the entire interfacial boundary between the respective insert and the body, in alternative embodiments the ledge may extend or run only partially along the interfacial boundary. Good too.

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

A front weight track 214 and a rear weight track 216 are arranged in the sole of the club head for attaching two-piece slidable weight assemblies 210, 212, respectively, which can be fastened to the weight tracks by fastening means such as screws. Define the 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-piece or multi-piece design. The weight track allows the weight assembly to be loosened for sliding adjustment along the track and then tightened in place to adjust the effective CG and MOI characteristics of the club head. . For example, modifying the performance characteristics of the club head by moving the club head CG forward or backward through the rear weight assembly 212 or toward the heel or toe through the front weight assembly 210 It can affect the flight of a golf ball, particularly the spin characteristics of a 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 generally perpendicular to a rear weight track 216 that extends rearwardly toward the rear of the head from about the center of the front track. The front weight track 214 is integrally formed with a front weight track 214 that extends to the front weight track 214 .

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

Adjusting the CG toward the heel or toe via the front weight track 214 modifies the performance characteristics of the club head to affect ball flight, particularly the ball's tendency to draw or fade, and/or Or the ball's tendency to slice or hook can be countered. By adjusting the CG forward or backward via the rear weight track 216, the performance characteristics of the club head can be modified to affect the flight of the ball, particularly its tendency to travel upwards or with backspin. Can resist falling inside. Using two weight assemblies in a weight track allows alternative adjustments and interactions between the two weights. For example, with respect to the front track 214, two independent adjustable weight assemblies may be positioned a maximum distance apart, one weight fully toward the toe, one fully toward the heel, and one weight fully toward the toe. The other can be positioned completely on the heel side, positioned together in the center of the weight track, or in 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 can be adjusted along the continuum, e.g., along the heel or toe direction, or forward. The neutral position with the weight centered on the 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 doing so, seat it and guide it. Each track includes one or more peripheral rails or ledges to define an elongated channel, preferably having a width dimension less than the width of the weights disposed within the channel. For example, as shown in FIGS. 29 and 30, front track 214 includes opposing perimeter rails 288 and 284, and as shown in FIGS. 33 and 34, rear track 216 includes opposing perimeter rails 290 and 292. . In this way, the weights slide within the weight tracks and the rails prevent the weights from coming off the tracks. At the same time, the channel between the ledges allows the thread of the weight assembly to pass through the center of the outer weight element, through the channel, and then into threaded engagement with the inner weight element. The ledge provides a track or rail on which the joined weight assembly freely slides, while effectively preventing the weight assembly from accidentally sliding off the track even if the weight assembly becomes loose. In front track 214, the inner weight member of assembly 210 rests on rails 284 and 288 in inner recesses 280 and 286, while the outer weight member rests on front rail 284 and overhanging lip 228 of front seating pad 226. (FIG. 30, FIG. 31). In rear track 216, the inner weight member of assembly 212 rests on rails 290 and 292 in inner recesses 296 and 298, while the outer weight member rests between heel side rail 290 and overhanging lip 225 of rear seating pad 224. can be partially seated within a recess 294 between.

Weight assemblies can be adjusted by loosening the screws and moving the weights along the track to the desired position, and then tightening the screws to secure the assemblies in place. The weight assembly may also be interchanged and replaced with other weight assemblies having different masses to provide further mass adjustment options. If a secondary or tertiary weight is added to the weight track, many additional weight position and distribution options are available to further improve the effective CG position of the head in the heel-toe and fore/aft directions, and combinations thereof. Available for fine-tuning. This also provides wide adjustment of the MOI characteristics of the club head.

Either or both of the weight assemblies 210, 212 may include a three-piece assembly including 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 ledge 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 relative to the body for an entire round of golf. The weight members and assemblies are installed in the usable portion of the weight track (as opposed to inserting the inner weight at an enlarged opening at one end of the weight track where the weight assembly is not configured to be secured in place). The inner weight member can be shaped and/or configured to be inserted into the weight track by inserting the inner weight member into the inner channel over one or more ledges. This allows the elimination of such wide non-functional openings at the ends of the tracks, allowing the tracks to be made shorter, or a longer functional ledge width to which the weight assemblies can be fixed. can have. To enable the inner weight member to be inserted into the center track of the track (for example) over the ledge, the inner weight member is inserted at an angle that is not perpendicular to the ledge, e.g. at an angled insertion. be able to. The weight member can be inserted at an angle and gradually rotated into the inner channel and past the clamp ledge. In some embodiments, the inner weight member is rounded, oval, or rounded to better allow the weight member to be inserted over the ledge and into the channel in the usable portion of the track. It can have an oblong, arcuate, curved, or other specially shaped structure.

The golf club head of the present disclosure combines slidably adjustable weights and/or threadedly adjustable weights, coupled with weight savings achieved through the use of titanium alloy materials and the incorporation of lightweight crown inserts 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 a wide range of variation in numerous clubhead characteristics, and these variations All have an impact on final clubhead performance, including clubhead CG position, clubhead MOI value, clubhead acoustic characteristics, clubhead aesthetic appearance and subjective feel characteristics, and/or other characteristics. affect

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

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

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

In FIGS. 30 and 34, the lips 228, 225 of the front and rear seating pads extend or overhang their respective weight tracks, limiting the track opening and allowing the weight(s) to Can be found to help keep you in track.

Referring to FIG. 34, the sole area on the rear seating pad 224 on the heel side of the rear track 216 is significantly larger than the sole area on the toe side (bottom of the ledge 292) when the head is in the address position relative to the ground plane. Only the vertical distance is lower. This is a head with a "sunken sole" or "raised sole" structure in which one part of the sole is positioned low (e.g., on the heel side) relative to another part of the sole (e.g., on the toe side). You can think about it. In other words, a portion of the sole (eg, most of the sole except for the rear seating pad 224) is raised relative to another portion of the sole (eg, the rear seating pad). The same is true for the front truck 214, where in the normal address position, the front seating pad 226 and its lip 228 are significantly lower than the rear sides of the front truck (as shown in FIG. 30).

In one embodiment, the vertical distance between the level of the ground plane 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 approximately 5.5 mm.

37-48 are integrally cast as a single unit with the forward portion of the club head body and include a cup-shaped unit (herein referred to as 4 illustrates another exemplary golf club head 400 having a face portion (referred to herein as 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. Crown insert 406 and sole insert 408 can then be attached to the body to form club head 400. In some embodiments, there is no sole opening or sole insert, and the rear ring completely surrounds the sole. In some embodiments, the sole insert is comprised of metallic materials, composite materials, and/or other materials.

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. A head-shaft coupling assembly 410 can be coupled to a hosel 412. Cup 402 and ring 404 may include a metallic material such as titanium alloy or steel, while inserts 406 and 408 may include a less dense material such as carbon fiber reinforced composite material. Any of the other materials disclosed herein may be used for club head 400. The cup and ring may be made of the same material (e.g., the same titanium alloy), or the ring may be made of a different material than the cup (e.g., a steel ring and a titanium alloy cup, or two different titanium alloys). good.

39 and 40 show the ring 404 being coupled to the cup 402 at the toe-to-heel junction 420 to form an annular body having an upper crown opening and a lower sole opening. Ring 404 can include a forwardly extending toe and heel engagement end 424 that mates with a rearwardly extending toe and heel engagement end 422 of cup 402 to form joint 420 . In the illustrated example, the ring has a male protrusion that mates with a female notch in the cup. However, these joints can be reversed with the male protrusion of the cup and the female notch of the ring. In other embodiments, any other suitable engagement shape within joint 420 may be used to couple the ring to the cup. Joint 420 may be formed by any suitable means, such as welding, brazing, adhesives, mechanical fasteners, etc.

In some embodiments, joint 420 may be placed at a sufficient distance from the strike face to avoid potential failure due to severe impacts experienced by the golf club when striking a golf ball. For example, in some embodiments, the joint 420 is at least 20 mm, at least 30 mm, at least 40 mm, at least 50 mm, at least 60 mm, and/or Alternatively, it can be spaced 20 mm to 70 mm backward.

FIG. 41 shows how inserts 406 and 408 can be joined to the body to cover the crown opening and sole opening and surround the interior cavity of the club head. The crown insert 406 can be coupled to a crown ledge 426 of the body that extends around the crown opening, and the sole insert 408 can be coupled to a sole ledge 428 of the body that extends around the sole opening. . Ledges 426 and 428 can be formed from a combination of both cup 402 and ring 404, with the cup including the front portion of the ledge and the ring including the rear portion of the ledge. The ledges 426 and 428 can be offset inwardly from the surrounding outer surface such that there is space to receive the insert with the outer surface of the insert flush or coplanar with the surrounding outer surface of the cup/ring body. . The ring 404 may also include a protrusion 430 that extends downwardly and forwardly from the rear of the ring and forms part of a sole ledge 428 that helps support and stiffen the sole insert 408.

In some embodiments, the ring 404 can include a mass pad of increased thickness, such as at the protrusion 430 or elsewhere, to rearward load the golf club and center the center of mass. Move backwards to increase the MOI around the z and x axes. Such rearward loading may 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, protrusion 430 or other portions of 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 that can receive such adjustable weight members. It is also possible to couple more than one weight member to the rear ring at the same time. The mass pad or weight member(s) may include a relatively dense material such as tungsten or steel.

In some embodiments, the cup 402 can include a mass pad, such as mass pad 432 shown in the figures, 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 may include one or more additional weight members coupled to the sole of the cup, such as in or near the mass pad 432 and/or behind the slot 418, such as one coupled to the cup. One or more removable, replaceable, and/or adjustable weight members may be included. For example, mass pad 432 or other portions of cup 402 can include one or more openings, such as threaded openings, tracks, or other weight member receiving features. It is also possible to couple more than one weight member to the cup at the same time. The weight member(s) may include a relatively denser material than the cast cup material, such as tungsten or steel. In some embodiments, the cup and ring include matched weight ports that allow the weight member to be exchanged between the rear ring position and the lower cup position, providing adjustability options to change the mass characteristics of the club head. can have. In some such instances, the club head may be provided with groups of interchangeable weights, such as 1-3g weights and 8-15g weights, which may be connected to the rear ring's weight port or cup. can be coupled to a weight port in the sole of the shoe to allow for higher MOI (heavier weight in the rear) or lower spin (heavier weight in the lower forward position), or other combinations and mass characteristics. can.

44-47 show the body formed by joined cups 402 and 404 in more detail from several points of view, without inserts 406 and 408. FIG. 44 is a front view of the integral face 434. FIG. 45 is a side view of the heel. FIG. 46 is a top view showing the anterior crown portion 436, anterior toe portion 440, and anterior heel portion 442 that are part of the cup 402, as well as the toe-to-heel junction 420 and the crown ledge 426 that receives the crown insert 406. It is. FIG. 47 is a bottom view of the front sole portion 438 including a sole slot 418 extending 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 projection 430 and an exemplary sole weight port located within cup 402 rearward of slot 418 in the area of mass pad 432. It is shown. In other embodiments, such weight ports may be located in other parts of the cup or ring, such as at the rearmost portion 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 to allow adjustment of the center of mass and MOI characteristics of the club head.

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 rear portion of face 434 can be formed to have a variety of complex shapes and thickness profiles, and may be machined before ring 404 is attached to cup 402. Easy access from the rear for machining, etching, material removal, and/or other post-cast processing. FIG. 43 also shows a mass pad 432 on the sole portion 438 of the cup. Mass pad 432 may include a thickened portion of the sole with increased mass, which significantly affects the overall mass characteristics of the club head. The mass pad 432 can have a central notch with more mass on the toe and heel sides of the center to enhance mass and MOI characteristics. Further information regarding mass pad 432, alternative mass pad shapes and embodiments, and related characteristics can be found in U.S. Patent Application Publication No. 2018/0126228, published May 10, 2018, which 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 to adjust the loft angle, lie angle, and/or face angle of the assembled golf club in the normal address position. A head-shaft connection assembly 410 is shown that allows adjustment. Assembly 410 can include various parts, such as sleeve 450, ferrule 452, ... hosel insert 454, fasteners 456, and washers 458, shown in FIG. Further information regarding adjustable head-shaft coupling assemblies can be found in U.S. Patent No. 9,033,821, issued May 19, 2015, which is incorporated herein by reference in its entirety. It will be done.

49 and 50 illustrate a portion of a method for manufacturing a golf club head, specifically a mold for casting a 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 wax face 504 are formed separately and the wax face is then placed within a 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 allowing it to cool to fuse the face to the frame. Additional hot wax fills joint 506 and joins wax cup frame 503 and 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 the weld joint 506. In some embodiments, the wax face 504 extends radially outwardly and contacts the front surface of the wax cup frame 502 to help 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 is uniform and smooth across the joint 506. Wax prongs 508 can be removed after the wax welding process.

FIG. 50 shows wax welding the wax cup frame 512 and wax face 514 together through wax added around the joint 516 and optionally using the wax prongs 518 of the wax face at the opening of the wax cup frame. Another example of a wax cup 510 formed by helping to set the depth of the wax face is shown. In this example, wax cup 510 includes additional protrusions 520 that create additional gates in the resulting mold to help molten metal flow evenly toward the face of the mold. Wax cups 500 and 510 may also include gated portions in other locations, such as on the heel side near the hosel, on the backside of the face, and/or in other locations as shown.

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

Starting with two separate wax pieces is also more efficient in forming large numbers of wax pieces, as each wax piece is smaller and can be produced in higher numbers per batch on the same tree. enhance

Once a wax cup (eg, 500 or 510) is made, it 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 and/or metal cups. Once a mold is formed around the wax cup, the wax can be melted and drained from the mold. Various subsequent steps can then be applied to prepare the mold for casting, including adding gating and/or surface treatments to the mold. Furthermore, several cup molds can be combined into one mold tree to cast several metal cups at the same time. After the mold is prepared, molten metal can be introduced into the mold to cast the metal cup. The mold can then be opened or 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 the metal cup is cast, portions of the cast cup can be machined or modified to remove portions of the cast cup as desired. As an example, the front surface of the cup face can be machined to add horizontal score lines and/or create more precise textures, curvatures, and twists. In another example, the rear surface of the cup face can be machined to modify the thickness profile across the height and width of the face to produce a desired variable thickness profile across the face. Casting methods (such as machining or chemically etching (e.g., use of hydrofluoric acid) the front and/or back surfaces of the face of a cast cup to make the face less brittle and to make the face more durable) It is also possible to remove some or all of the alpha case layer that is sometimes formed (for example, in the case of titanium alloys).

In anticipation of post-casting removal of material from the face of the cup, the face of the cup is made of extra thickness such that the desired amount of material and desired thickness profile remains after material removal after casting. Can be cast in material.

As shown in FIGS. 39 and 40 and as described above, cup 402 and ring 404 are formed separately (e.g., cast) and then assembled together at joint 420 (e.g., welded, brazed, etc.). , adhesive bonds, mechanical fasteners, etc.) to form a metal club head body that functions as a rigid frame for receiving other components to form the golf club head 400. . One advantage of this method of making a club head body from separate cups 402 and rings 404 is that the lack of a rear ring section eliminates the need for post-cast machining, chemical etching, and and/or better access for other post-casting modifications to the rear surface of the face. For example, if ring 404 is not present, 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 are made to cup 402, ring 404 can be attached to the cup and the remainder of the club head 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 higher numbers per batch from the same wood, making it possible to produce a large number of each of the ring and cup pieces. It is to enable efficiency when casting. Additionally, the same ring piece can be used with a variety of different shaped cup pieces, so only the tooling for the cup piece can be changed to accommodate changes in the clubhead body or to accommodate different cup/face shapes. It is necessary to create several different variants of club heads with.

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

In conventional processes, the faceplate is formed from a flat sheet of metal having a uniform thickness. Such metal sheets are typically rolled along one axis to reduce their thickness to a constant, uniform thickness throughout the sheet. This rolling process can impart grain orientation to the sheet creating different material properties in the direction of the rolling axis compared to the direction perpendicular to the rolling direction. This variation in material properties may be undesirable and can be avoided by using the disclosed casting method to create the face instead.

Additionally, since traditional faceplates start out as flat sheets of uniform thickness, the overall thickness of the sheet must be at least the same as the maximum thickness of the desired final product faceplate, which means that the starting sheet Much of the material must be removed and wasted, increasing material costs. In contrast, in the disclosed casting method, the face is initially formed very close to the final shape and mass, and very little material is removed and wasted. This saves time and costs.

Additionally, in conventional processes, an initially 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 profiles shown in FIGS. 51-54 are made possible using the disclosed casting method, in which a metal sheet having a uniform thickness is mounted on a lathe or similar machine and placed across the rear of the faceplate. Rotated to produce a variable thickness profile, which was previously impossible to achieve using conventional processes. In such a turning process, the applied thickness profile must be symmetrical about the central axis of rotation, which makes the thickness profile, at any given radius from the center point, each uniform The composition is limited to concentric ring-shaped compositions having a thickness. In contrast, no such limitations are imposed using the disclosed casting method, and more complex face shapes can be created.

By using the casting methods disclosed herein, a large number of the disclosed club heads can be manufactured faster and more efficiently. For example, more than 50 cups 402 can be cast simultaneously on a single casting tree, but new face thickness profiles can be created on the face plate at once using traditional milling methods using a lathe. Making them one by one takes much longer and requires more resources.

In FIG. 51, the rear face surface of a cast cup 600 includes an asymmetric variable thickness profile, which is only one example of the wide variety of variable thickness profiles possible using the disclosed casting method. The center of the face 602 can have a center thickness, and the thickness of the face gradually increases moving radially outward from the center across the inner blend area 603 to a maximum thickness ring 604, which can be circular. I can do it. The thickness of the face may gradually decrease moving radially outward from the maximum thickness ring 604 across the variable blend zone 606 to the second ring 608, which may be non-circular, such as an ellipse. The thickness of the face extends from the second ring 608 across the outer blend area 609 to the heel and toe area 610 of a constant thickness (e.g., the minimum thickness of the face) and/or when the face is in the cast cup 600. may gradually decrease moving radially outward until a radial peripheral area 612 defining the extent of the face transitions into the remainder of the face.

The second ring 608 itself can have a variable thickness profile such that the thickness of the second ring 608 varies as a function of circumferential position about the center 602. Similarly, the variable blend zone 606 has a thickness profile that varies as a function of circumferential position about the center 602 and provides a thickness transition from the thickest ring 604 to a variable and thinner second ring 608. can have. For example, the variable blend zones 606 to the second ring 608 are labeled A-H in FIG. It can be divided into eight sectors, including heel area F, heel area G, and top heel area H. These 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 ring 604 to a different minimum thickness in second ring 608. For example, the second ring can have a thicker thickness in areas A and E, a thinner thickness in areas C and G, and an intermediate thickness in areas B, D, F, and H. In this example, the thickness of zones B, D, F, and H increases radially (thinner moving radially outward) and circumferentially (moving from zones A and E toward zones C and G). and thinning).

An example of a cast cup 600 may have the following thicknesses: 3.1 mm at center 602, 3.3 mm at ring 604, and second ring 608 from 2.8 mm in area A to 2.8 mm in area C. 2 mm, up to 2.4 mm in area E, up to 2.0 mm in area G, and up to 1.8 mm in heel and toe area 610.

52 and 53 illustrate a rear face surface of another exemplary cast face portion 700 that includes an asymmetric variable thickness profile. The center of the face 702 can have a center thickness, and the thickness of the face gradually increases moving radially outward from the center across the inner blend area 703 to a maximum thickness ring 704, which can be circular. I can do it. The thickness of the face gradually decreases moving radially outward from the maximum thickness ring 704 across the variable blend zone 705 to an outer zone 706 consisting of a plurality of wedge-shaped sectors A-H having 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. The outer blend zone 708 surrounding the outer zone 706 transitions in thickness from variable sectors to a peripheral ring 710 having a relatively small but constant thickness. The outer region 706 can also include blended regions between each of sectors AH that have a gradual transition in thickness from one sector to an adjacent sector.

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

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

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

An example face portion 800 has the following thicknesses: 3.8 mm at center 802 , 4.0 mm at inner ring 804 , thickening to 4.15 mm across thickened area 820 , at second ring 806 3.5 mm in ring 823 and 3.65 mm in ring 823, 2.4 mm in third ring 808 and 2.55 mm in ring 825, 2.0 mm in fourth ring 811, and 1 in peripheral ring 814. .8mm.

The targeted offset thickness profile shown in FIG. 54 can help provide a desirable characteristic time (CT) profile across the face. Thickening the heel side can, for example, help avoid having a CT spike on the heel side of the face, which can help avoid having a non-conforming CT profile across the face. I can do it. 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, an 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 described in U.S. patent application Ser. No. 12/006,060, as well as U.S. Pat. , No. 7,731,603; No. 8,801,541; No. 9,943,743; and No. 9,975,018. The entire contents of each of these are incorporated herein by reference in their entirety. For example, U.S. Patent No. 9,975,018 discloses an example of a striking face that includes localized hardening regions such as an inverted conical or "doughnut" shaped thickness profile offset from the center of the face. , whereby the launch conditions of the golf ball struck by the club head are altered, in whole or in part, to correct for, overcome, or prevent the occurrence of rightward/leftward deviation. In particular, the localized hardening region is located on the ball striking face such that a golf ball hit under typical conditions does not impart leftward and/or rightward side spin to the golf ball.

All of the face thickness profiles disclosed can be made possible by the casting methods disclosed herein. Such a configuration is not possible using conventional turning processes that remove material in a concentric pattern from the rear of an originally flat faceplate.

In some golf club head embodiments, the faceplate may be individually cast and then welded to the front opening of the club head frame. When the faceplate is welded to the front opening of the frame, extra material is typically produced around the weld, and this 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 offer advantages over casting the entire cup as one piece. For example, post-processing of a cast faceplate is much easier when the faceplate is part of a cup compared to post-processing of the face surface. 55 and 56 illustrate a front 902 and rear 904 of an exemplary cast faceplate 900. In particular, it is much easier to access all portions of the rear face of a cast face plate than the rear face surface of a cast cup. With no obstructing parts such as soles, crowns, toes, heels, or hosels, there is unlimited 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 having to be removed and less work needed 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 of excess material on each side of the face that is removed after casting. This equates to less waste being removed compared to machining the faceplate from a flat sheet of rolled metal. The front surface of the cast face can be machined to remove some or all of the alpha case layer, achieve precise bulge, roll and twist curvature, and/or add scorelines. The rear 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 asymmetrical thickness profile, as opposed to the 360 degree concentric symmetry required by the traditional facesheet turning process. enable.

A cast golf club head that includes a face as an integral part of the body (e.g., cast simultaneously with a single cast object), where the face is formed separately and later attached to the front opening of the club head body. It can provide superior structural properties compared to club heads (e.g., welded or bolted). However, the benefits of having an integrally cast Ti face are mitigated by the need to remove the alpha case on the surface of the cast Ti face.

The club heads disclosed herein that include integrally cast titanium alloy face and body units (e.g., cast cups) may eliminate or at least eliminate the drawbacks of having to remove the alpha case. can be significantly reduced. For casting 9-1-1 Ti faces, using a mold preheat temperature of 1000° C. or higher, the alpha case thickness may be less than or equal to about 0.10 mm, less than or equal to 0.15 mm, or less than about 0.20 mm in some embodiments. For cast 6-4 Ti faces, the thickness of the alpha case may be less than or equal to about 0.30 mm, such as from 0.10 mm to 0.30 mm, in some examples, greater than 0.10 mm, or less than about 0.30 mm, such as from 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 from about 0.25 mm to about 0.30 mm. In some embodiments, the alpha case thickness can be as low as 0.1 mm and up to 0.15 mm while providing a sufficiently durable product with a desirably high CT time across the face. I can do it. In some embodiments, the rear alpha case 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 is achieved by chemically treating the surface after formation. This can be achieved without additional 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. can. For example, in one exemplary embodiment, the alloy includes 6.5% to 10% Al, 0.5% to 3.25% Mo, 1.0% to 3.0% by weight. of Cr, 0.25 wt.% to 1.75 wt.% V, and/or 0.25 wt.% to 1 wt.% Fe, with the balance being Ti (one example is "1300 ” (sometimes called titanium alloys).

In another exemplary embodiment, the alloy comprises 6.75% to 9.75% Al by weight, 0.75% to 3.25% by weight or 2.75% Mo, 1.0% by weight % to 3.0 wt.% Cr, 0.25 wt.% to 1.75 wt.% V, and/or 0.25 wt.% to 1 wt.% Fe, with the remainder comprising Ti.

In another exemplary embodiment, the alloy comprises 7% to 9% Al, 1.75% to 3.25% Mo, 1.25% to 2.75% Cr, by weight. It may contain 0.5% to 1.5% by weight of V and/or 0.25% to 0.75% by weight of Fe, with the remainder containing Ti.

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

In another exemplary embodiment, the alloy includes 8% Al, 2.5% Mo, 2% Cr, 1% V, and/or 0.5% Fe by weight. The remainder contains Ti. Such a titanium alloy may 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 mentioned elements in any of the above proportions. Certain embodiments may also include trace amounts of K, Mn, and/or Zr, and/or various impurities.

Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have the lowest mechanical properties of yield strength of 1150 MPa, ultimate tensile strength of 1180 MPa, and elongation of 8%. 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 above-mentioned minimum mechanical properties. In some embodiments, the 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 a yield strength of about 8% to about 12%. elongation, a modulus of elasticity of about 110 GPa, a density of about 4.45 g/cm ³ , and a hardness of about 43 on the Rockwell C scale (43 HRC). In certain embodiments, 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 can be integrally formed or cast from Ti-8Al-2.5Mo-2Cr-1V-0.5Fe, depending on the specific properties desired. .

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

Any of the embodiments disclosed herein have an upper toe portion of the striking surface that is more open than a lower toe portion of the striking surface, and a lower heel portion of the striking surface that is more closed than an upper heel portion of the striking surface. The face portion may include a twisted striking surface so as to have a twisted impact surface. Further information regarding golf club heads with twisted striking surfaces can be found in U.S. Patent No. 9,814,944, U.S. Provisional Patent Application No. 62/687,143, filed June 19, 2018, October 2018. No. 16/160,884, filed May 15, 1999, all of which are incorporated by reference in their entirety. Any of these twisted face technologies disclosed in these incorporated references may be implemented in the club heads disclosed herein in any combination with the techniques disclosed herein.

The techniques disclosed herein can be implemented for all types of golf club heads, not just the disclosed examples, including drivers, fairway, rescue, hybrid, utility clubs, irons, wedges, and putters. can.

For this purpose, certain aspects, advantages, and novel features of embodiments of the present disclosure are described herein. The disclosed methods, apparatus, and systems are not to be construed as limiting in any way. Instead, this disclosure is directed to all novel and non-obvious features and aspects of the various disclosed embodiments, either alone or in various combinations and subcombinations with one another. The methods, apparatus, and systems are not limited to any particular aspects or features or combinations thereof, and the disclosed embodiments are not limited to any one or more particular advantages or problems solved. does not need to be done.

Although some operations of the disclosed embodiments are described in a particular sequential order for convenient presentation, unless a particular ordering is required by the particular language described herein, It is to be understood that the method of this description encompasses relocation. For example, operations described in succession may be rearranged or performed concurrently, as the case may be. Furthermore, for simplicity, the accompanying figures may not depict the various ways in which the disclosed method can 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 from the context. Including the plural unless otherwise specified. Also, the term "includes" means "comprises." Additionally, the terms "coupled" and "associated" generally mean electrically, electromagnetically, and/or physically (e.g., mechanically or chemically) coupled or linked, and the terms "coupled" and "associated" generally mean electrically, electromagnetically, and/or physically (e.g., mechanically or chemically) coupled or linked, and the terms "coupled" and "associated" generally refer to There is no conjunction or excludes the existence of intermediate elements between related items.

In some examples, a value, procedure, or device may be referred to as a "minimum," "best," "minimum," etc. Such an explanation allows a choice to be made among many alternatives, and such a choice need not be better or less than any other choice, and any such choice may be preferable to any other choice. It will be understood that the intent is to indicate that this does not have to be the case.

Certain terms may be used herein, such as "above," "bottom," "top," "bottom," "horizontal," "vertical," "left," "right," and the like. These terms are used, where appropriate, to provide some clarity when addressing relative relationships. However, these terms do not imply absolute relationships, positions, and/or orientations. For example, for an object, a "top" surface can become a "bottom" surface simply by rotating the object. However, the object is still the same object.

It should be appreciated that the illustrated embodiments are only preferred examples and should not be construed as limiting the scope of the disclosure, given the many possible embodiments to which the principles of the 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 this disclosure is at least as broad as the scope of 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 Body 11 Score line 12 Crown 14 Sole 16 Skirt 18 Face plate 20 Hosel 22 Impact 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 170 Crucible 172 Injection cup 180 Cluster 184 Shell runner 182 Receiver 186, 188 Mold cavity 200 Golf club head 202 Club head body 204 Head-shaft connection assembly 206 Crown insert 207 Forward projection 208 Sole insert 209 Notch 210 Forward weight assembly 212 Rear weight assembly 214 Front weight track 216 Rear weight track 224 Rear seating pad (touching surface)
225 Overhanging lip 226 Front seating pad (touching surface)
228 Overhanging Lip 230 Toe 232 Toe Cantilever Ledge 234 Heel Cantilever Ledge 236 Rib 238 Thick Area 240 Toe Opening 242 Heel 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 Connection 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 Integral face 438 Sole portion 450 Sleeve 452 Ferrule 454 Hosel insert 456 Fastener 458 Washer 500 Wax cup 502 Wax Cup Frame 504 Wax Face 506 Annular Joint 508 Wax Prongs 510 Wax Cup 520 Additional Protrusion 600 Cast Cup 602 Center of Face 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 702 Center of Face 703 Inner Blend Area 704 Maximum Thickness Ring 705 Variable Blend Area 706 Outer Area 708 Outer Blend Area 710 Peripheral Ring 800 Cast Face 802 Center of Face 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 periphery, peripheral ring 820 Thickening Area 822 Offset Areas 823, 825 Rings 824, 826 Blending Area 900 Cast Faceplate 902 Front 904 Rear B Golf Ball X X-axis Y Y-axis Z Z-axis

Claims (23)

A wood type golf club head,
A cast cup including a front portion, a heel portion, and a toe portion of the golf club head, the cup comprising:
the forward portion of the golf club head includes a hosel, a forward portion of a crown of the golf club head, and a forward portion of a sole of the golf club head;
a cast cup formed from a first metallic material having a first material density;
a rear ring formed separately from the cast cup and attached to the heel and toe portions of the cast cup to form the body of the golf club head;
the body of the golf club head defines a hollow interior region, a crown opening and a sole opening;
a rear ring formed of a second metal material having a second material density different from the first material density of the first metal material;
A face plate that defines a hitting surface of the golf club head,
A face plate made of 9-1-1 titanium and having an alpha case having a thickness of 0.3 mm or less, and/or
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% to 1% Fe, the remainder of the alpha-beta titanium alloy comprising Ti, and the face plate is 0.3 mm or less a faceplate having an alpha case thickness of , with a portion of the alpha case layer removed;
a crown insert adapted to be attached to and cover the crown opening and define at least a portion of the crown of the golf club head;
a wood-type golf club, comprising a sole insert adapted to be attached to and cover the sole opening and define at least a portion of the sole of the golf club head. head. The wood-type golf club head of claim 1, wherein the first metal material is a titanium alloy and the second metal material is an aluminum alloy. The wood-type golf club head of claim 2, wherein the crown insert and the sole insert are formed from a composite material. The wood-type golf club head of claim 1, wherein the cast cup defines a forward portion of the crown opening and the rear ring defines a rearward portion of the crown opening. 5. The wood-type golf club head of claim 4, wherein the cast cup defines a forward portion of the sole opening and the rear ring defines a rearward portion of the sole opening. the cast cup includes a recessed ledge at the crown opening and a recessed ledge at the sole opening;
a recessed ledge of the crown opening of the cast cup defines the forward portion of the crown opening; a recessed ledge of the sole opening of the cast cup defines the forward portion of the sole opening;
the rear ring includes a recessed ledge of the crown opening and a recessed ledge of the sole opening;
a recessed ledge of the crown opening of the rear ring defines the rear portion of the crown opening; a recessed ledge of the sole opening of the rear ring defines the rear portion of the sole opening;
the crown insert is attached to a recessed ledge of the crown opening of the casting cup and a recessed ledge of the crown opening of the rear ring;
6. The wood-type golf club head of claim 5, wherein the sole insert is attached to a recessed ledge of the sole opening of the cast cup and a recessed ledge of the sole opening of the rear ring. The wood-type golf club head of claim 1, wherein the second material density is lower than the first material density. The cast cup further includes a protrusion on each of the heel and toe portions of the cast cup, and the rear ring includes a notch on each of the heel and toe portions of the cast cup, the protrusion on the heel portion fits into the notch on the heel portion of the rear ring, and the protrusion on the toe portion of the cast cup fits into the notch on the toe portion of the rear ring;
Or
The cast cup further includes a notch in each of the heel and toe portions of the cast cup, and the rear ring includes a protrusion in each of the heel and toe portions of the cast cup. the notch in the heel portion fits with the projection on the heel portion of the rear ring, and the notch in the toe portion of the cast cup fits with the projection on the toe portion of the rear ring; The wood type golf club head according to claim 1. The wood-type golf club head of claim 1 further comprising a front weight attached to the cast cup at the front portion of the sole. 10. The wood-type golf club head of claim 9, further comprising a rear weight attached to the rear ring at a rear portion of the sole. The wood-type golf club head of claim 10, further comprising an adjustable head-shaft connection assembly coupled to the hosel. 12. The wood-type golf club head of claim 11, wherein the cast cup further includes a mass pad in the forward portion of the sole of the golf club head. The wood-type golf club head of claim 1, wherein the rear ring forms a skirt portion of the golf club head that defines an outermost perimeter around the rear of the golf club head. The wood-type golf club head of claim 1, wherein the rear ring is attached to the cast cup and a seam is defined between the rear ring and the cast cup. the front portion of the golf club head further includes a face opening;
The wood-type golf club head of claim 1, wherein the face plate is attached to and covers the face opening. 16. The wood-type golf club head of claim 15 , wherein the faceplate has a variable thickness profile, and the variable thickness profile of the faceplate is asymmetric. By twisting the striking surface of the face plate, 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 twisted. 16. The wood-type golf club head of claim 15 , wherein the wood-type golf club head is adapted to be closed over an upper heel portion of the golf club head. the second material density is lower than the first material density;
The wood-type golf club head of claim 1, wherein the crown insert and the sole insert are formed from a composite material. A wood type golf club head,
A cast cup including a front portion, a heel portion, and a toe portion of the golf club head, the cup comprising:
the forward portion of the golf club head includes a hosel, a forward portion of a crown of the golf club head, and a forward portion of a sole of the golf club head;
a cast cup formed from a first metallic material having a first material density;
a rear ring formed separately from the cast cup and attached to the heel and toe portions of the cast cup to form the body of the golf club head;
the body of the golf club head defines a hollow interior region, a crown opening and a sole opening;
a rear ring formed of a second metal material having a second material density different from the first material density of the first metal material;
A face plate that defines a hitting surface of the golf club head,
a face plate having an alpha case made of 9-1-1 titanium and having a thickness of 0.3 mm or less;
a crown insert adapted to be attached to and cover the crown opening and define at least a portion of the crown of the golf club head;
a sole insert adapted to be attached to and cover the sole opening and define at least a portion of the sole of the golf club head;
the cast cup defines a forward portion of the crown opening; the rear ring defines a rearward portion of the crown opening;
the cast cup defines a forward portion of the sole opening; the rear ring defines a rearward portion of the sole opening;
the cast cup includes a recessed ledge at the crown opening and a recessed ledge at the sole opening;
a recessed ledge of the crown opening of the cast cup defines the forward portion of the crown opening; a recessed ledge of the sole opening of the cast cup defines the forward portion of the sole opening;
the rear ring includes a recessed ledge of the crown opening and a recessed ledge of the sole opening;
a recessed ledge of the crown opening of the rear ring defines the rear portion of the crown opening; a recessed ledge of the sole opening of the rear ring defines the rear portion of the sole opening;
the crown insert is attached to a recessed ledge of the crown opening of the casting cup and a recessed ledge of the crown opening of the rear ring;
A wood-type golf club head, wherein the sole insert is attached to a recessed ledge of the sole opening of the cast cup and a recessed ledge of the sole opening of the rear ring. the front portion of the golf club head further includes a face opening;
20. The wood-type golf club head of claim 19 , wherein the face plate is attached to and covers the face opening. 21. The wood-type golf club head of claim 20 , wherein the faceplate is formed from a composite material and the second material density is lower than the first material density. The cast cup further includes a protrusion on each of the heel and toe portions of the cast cup, and the rear ring includes a notch on each of the heel and toe portions of the cast cup, the protrusion on the heel portion fits into the notch on the heel portion of the rear ring, and the protrusion on the toe portion of the cast cup fits into the notch on the toe portion of the rear ring;
Or
The cast cup further includes a notch in each of the heel and toe portions of the cast cup, and the rear ring includes a protrusion in each of the heel and toe portions of the cast cup. the notch in the heel portion fits with the projection on the heel portion of the rear ring, and the notch in the toe portion of the cast cup fits with the projection on the toe portion of the rear ring; The wood type golf club head according to claim 19 . A wood type golf club head,
A cast cup including a front portion, a heel portion, and a toe portion of the golf club head, the cup comprising:
the forward portion of the golf club head includes a hosel, a forward portion of a crown of the golf club head, and a forward portion of a sole of the golf club head;
a cast cup formed from a first metallic material having a first material density;
a rear ring formed separately from the cast cup and attached to the heel and toe portions of the cast cup to form the body of the golf club head;
the body of the golf club head defines a hollow interior region, a crown opening and a sole opening;
a rear ring formed of a second metal material having a second material density different from the first material density of the first metal material;
A face plate that defines a hitting surface of the golf club head,
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% to 1% Fe, the remainder of the alpha-beta titanium alloy comprising Ti, and the face plate is 0.3 mm or less a faceplate having an alpha case thickness of , with a portion of the alpha case layer removed;
a crown insert adapted to be attached to and cover the crown opening and define at least a portion of the crown of the golf club head;
a wood-type golf club, comprising a sole insert adapted to be attached to and cover the sole opening and define at least a portion of the sole of the golf club head. head.

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