WO2021051102A1

WO2021051102A1 - Golf club head with flex structure

Info

Publication number: WO2021051102A1
Application number: PCT/US2020/050769
Authority: WO
Inventors: Eric J. Morales; Jeremy S. Pope; Thomas J. NUTTALL
Original assignee: Karsten Manufacturing Corporation
Priority date: 2019-09-13
Filing date: 2020-09-14
Publication date: 2021-03-18
Also published as: GB2620032B; GB2603698A; GB202319025D0; KR20220061154A; JP2022547613A; GB2624315A; GB2603698B; GB202205331D0; EP4028137A1; GB202312919D0; GB2620032A; EP4028137A4

Abstract

Embodiments of a wood-type club head having a flex structure to control the characteristic time (CT) are described herein. The club head comprises a flex structure integrally formed with the club face and the sole. The flex structure comprises a curved shape including a nadir and an apex. The flex structure allows the club face to bend rearward, relieve stress within the club face, and reduce the CT variability within a localized club face region.

Description

GOLF CLUB HEAD WITH FLEX STRUCTURE

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This claims the benefit of U.S. Provisional Patent Application No. 62/900,318, filed on September 13, 2019, wherein the contents of all above-described disclosures are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

[0002] This disclosure relates generally to golf club heads with structures that control the characteristic time.

BACKGROUND

[0003] Golf club design takes into account several performance characteristics, such as ball speed and characteristic time (CT). Typically, golf club designs aim to control the amount of ball speed through the CT of the club face. However, current designs are limited in controlling the variability of CT across the club face, and sacrifice ball speed to achieve desirable CT values. Therefore, there is a need in the art for a club head that reduces the CT variability across the club face without sacrificing ball speed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 illustrates a front perspective view of a golf club head comprising a flex structure according to an embodiment.

[0005] FIG. 2 illustrates a front view of the golf club head of FIG. 1.

[0006] FIG. 3 illustrates a cross sectional view of the golf club head of FIG. 1 taken at line 3-

3 of FIG. 2.

[0007] FIG. 4 illustrates a cross sectional view of the golf club head of FIG. 1 taken at line 3- 3- of FIG. 2. [0008] FIG. 5 illustrates a partial cut-away rear perspective view of the golf club head of FIG. 1.

[0009] FIG. 6 illustrates a cross sectional view of the golf club head of FIG. 1 taken at line 3- 3 of FIG. 2.

[0010] FIG. 7 illustrates a partial cut-away rear perspective view of the golf club head of FIG. 1.

[0011] FIG. 8 illustrates a cross sectional view of a golf club head comprising a flex structure according to a second embodiment.

[0012] FIG. 9 illustrates an impact between a golf ball and a golf club head comprising a flex structure.

[0013] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numerals in different figures denote the same elements.

DETAILED DESCRIPTION

[0014] The present embodiments discussed below are directed to wood-type golf club heads (e.g. drivers, fairway woods, or hybrids) comprising a flex structure to reduce CT variability across the club face. The flex structure is integrally formed or connected to the club face and the club head sole. The flex structure comprises a double curved shape (e.g. s-shape) having at a nadir and an apex. The flex structure extends freely within the interior club head cavity to allow the club face to bend during golf ball impacts. The flex structure supports and relieves stress from the club face during golf ball impacts. The flex structure provides an alternative way to control the CT variability across the club face without having to increase the overall club face thickness. The flex structure reduces CT variability by increasing the frequency response of the club face within a localized location (i.e. the connection between the club face and the flex structure provides a localized increase in club face thickness). Locally increasing the club face thickness and the frequency response reduces CT variability while avoiding increasing the overall club face thickness. The wood-type club head having the flex structure provides CT variability control without sacrificing ball speed performance.

[0015] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0016] Referring to the drawings, wherein the like reference numerals are used to identify like of identical components in various views, FIGS. 1-7 schematically illustrate a first embodiment of the present design. Specifically, FIG. 1 illustrates a front perspective view of a driver-type club head 100. The club head 100 comprises a club face 104 and a body 108 that are secured together to define a substantially closed/interior volume. The club head comprises a crown 110, a sole 112 opposite the crown 110, a heel 116, a toe 120 opposite the heel 116, and a rear 122 opposite the club face 104.

[0017] The club face 104 further comprises a striking surface 124 intended to impact a golf ball, and a rear surface 128 opposite the striking surface 124. The striking surface 124 further defines a geometric center 132. In one approach, the geometric center 132 can be located equidistant between the crown 110 and the sole 112, and equidistant between the heel 116 and the toe 120. In another approach, the geometric center 132 of the striking surface 124 can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA). For example, the geometric center 132 of the striking surface 124 can be determined in accordance with Section 2.1 of the USGA’s Procedure for Measuring the Flexibility of a Golf Clubhead (USGA- TPX3004, Rev. 2.0, April 9, 2019) (available at h¾ps:/7www.usRa.org/e¾uipment-standards/t¾st-protocols-for-e_¾ui pment-9df6d04fhtml) (the “Flexibility Procedure”).

[0018] Referring to FIGS. 1-3, the geometric center 132 defines an origin for a coordinate system having an x-axis 700, a y-axis 800, and a z-axis 900. The club head 100 further defines a ground plane 1000 that is tangent to the sole 112 when the club head 100 is at an address position. The x-axis 700 extends through the geometric center 132 from near the heel end 116 to near the toe end 120 in a direction parallel to a ground plane 1000. The y-axis 800 extends through the geometric center 132 from near the crown 110 to near the sole 112, where the y-axis 800 is perpendicular to the x-axis 700 and to the ground plane 1000. The z-axis 900 extends through the geometric center 132 rearward the club face 104 in a direction parallel to the ground plane 1000. The z-axis 900 is perpendicular to the x-axis 700 and the y-axis 800.

[0019] Referring to FIG. 3, the club head 100 defines a loft plane 1100 that is tangent to the geometric center 132 of the striking surface 124 and extends towards the crown 110, the sole 112, the toe end 120, and the heel end 116. The loft plane 1100 is positioned at an acute angle with respect to the y-axis 800, wherein the acute angle can correspond to the loft angle of the club head 100. The club head 100 further defines a midplane 1200 that extends through the geometric center 132 in a direction perpendicular to the loft plane 1100. The midplane 1200 is positioned at an acute angle with respect to the z-axis 900. The midplane 1200 extends from near the toe end 120 to near the heel end 116, and extends rearward the club face 104 or the loft plane 1100. The midplane 1200 intersects the ground plane 1000 at a point away and rearward of the club face 104.

[0020] Referring back to FIG. 2, the club face 104 can further comprise a top portion 136 located near the crown 110, a bottom portion 140 located near the sole 112, a toe portion 142 located near the toe 120, a heel portion 144 located near the heel 116, and a central portion 148 located near the geometric center 132. Each club face portion 136, 140, 142, 144, 148 extends through a thickness of the club face 104 in a direction extending from the striking surface 124 to the rear surface 128. The club face 104 can comprise a variable thickness. In one embodiment, the club face 104 can comprise a maximum thickness in the central portion, and a decreasing or tapering thickness in a direction towards a periphery of the club face 104. The club face 104 can comprise a minimum thickness in at least one of the top portion, the bottom portion, the toe portion, and the heel portion. In some embodiments, the club face 104 can comprise a thickness ranging from 0.065 to 0.15 inch. In other embodiments, the thickness of the club face 104 can range from 0.065 to 0.10 inch, or 0.10 to 0.15 inch. In other embodiments, the thickness of the club face 104 can range from 0.065 to 0.11 inch, 0.07 to 0.12 inch, 0.075 to 0.13 inch, 0.08 to 0.14 inch, or 0.085 to 0.15 inch. For example, the thickness of the club face 104 can be 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.095, 0.10, 0.105, 0.11, 0.115, 0.12, 0.125, 0.13, 0.135, 0.14, 0.145, or 0.15 inch.

Flex Structure

[0021] As described above, the club head 100 comprises a flex structure 152. The flex structure 152 can be located within the closed interior cavity 156 of the club head 100. The flex structure 152 can be integrally formed or connected with the club face 104 and the sole 112, wherein the flex structure 152 can comprise a similar material as the club face 104 and/or the sole 112. The flex structure 152 extends away from the club face 104 to connect with the sole 112. The flex structure 152 couples or connects the club face 104 to the sole 112. The flex structure 152 allows the club face 104 to bend inward while relieving stress during golf ball impacts. As described in more detail below, the location and the shape of the flex structure 152 reduces the CT variability across the club face 104 without sacrificing ball speed performance and club face durability.

[0022] Referring to FIGS. 4-7, the flex structure 152 can define a first end 160 and a second end 162. The first end 160 of the flex structure 152 can be integral with the club head 104, and the second end 162 of the flex structure 152 can be integral with the sole 112. In one embodiment, as illustrated in FIGS. 4-7, the first end 160 can be integrally formed or connected to the central portion of the club face 104. In other embodiments, the first end 160 of the flex structure 152 can be integrally formed or connected to the top portion 136, the bottom portion 140, the toe portion 142, or the heel portion 144. [0023] Referring to FIGS. 5-7, the flex structure 152 can be parabolic, curved, S-shaped, double curved, doubled bended, or sinusoidal in shape between the first end 160 and the second end 162. In some embodiments, the flex structure 152 can comprise one or more interconnected parabolas. In some embodiments, the flex structure 152 can comprise one or more interconnected bends. The flex structure 152 comprises a cross-sectional shape. The cross- sectional shape of the flex structure 152 can be a rectangle, a triangle, an ellipse, a rectangle with rounded comers, a square with rounded comers, or any other suitable shape.

[0024] The curved nature of the flex structure 152 can define an apex 164 and a nadir 166. The apex 164 can define a highest or topmost portion of the flex structure 152, and the nadir 166 can define a lowest or bottommost portion of the flex structure 152. The flex structure 152 can comprise a concave curvature at the nadir 166 relative to the crown 110. The flex structure 152 can comprise a convex curvature at the apex 164 relative to the sole 112. The connection between the flex structure first end 160 and the club face 104, and the connection between the flex structure second end 162 and the sole 112 allows the flex structure 152 to freely extend within the interior cavity 156. This allows the apex 164 and the nadir 166 to be located above the sole 112, wherein the apex 162 and the nadir 164 do not contact any portion of the club face 104 or the sole 112.

[0025] As illustrated in FIGS. 4 and 5, the flex structure 152 extends in a direction towards the sole 112 away from the club face 104 to form the nadir 166. The flex structure 152 then extends from the nadir 166 in a direction towards the crown 110 to form the apex 164. The flex structure 152 then extends from the apex 164 in a direction towards the sole 112 to connect with the sole 112.

[0026] The apex 164 and the nadir 166 of the flex structure 152 can be referenced in relation to the structure of the club head 100 or in relation to the planes defined by the club head 100.

The nadir 166 can be located closer to the sole 112 than the apex 164, and the apex 164 can be located closer to the crown 110 than the nadir 166. In one configuration, the flex structure 152 can be located below the midplane 1200, wherein the apex 164 and the nadir 166 can be located below the midplane 1200. In another configuration, the apex 164 can be located above the midplane 1200 and the nadir 166 can be located below the midplane 1200. In another configuration, the nadir 166 can be located closer to the club face 104 than the apex 164. In another configuration, the apex 164 can be located closer to the club face 104 than the nadir 166.

[0027] The flex structure 152 can further define a radius of curvature. The flex structure 152 can define more than one radius curvature. As illustrated in FIG. 5, the flex structure 152 can define two radii, wherein the flex structure 152 can define a radius of curvature at the apex 164 and a radius of curvature at the nadir 166. In one example, the radius of curvature at the apex 164 and the nadir 166 can be equal. In another example, the radius of curvature at the apex 164 and the nadir 166 can be different. In another example, the radius of curvature at the apex 164 can be less than the radius of curvature at the nadir 166. In another example, the radius of curvature at the nadir 166 can be greater than the radius of curvature at the apex 164. The radius of curvature at the apex 164 and the nadir 166 can range from 0.25 to 1 inch. In other embodiments, the radius of curvature at the apex 164 and the nadir 166 can range from 0.25 to 0.5 inch, or 0.5 to 1 inch. In other embodiments still, the radius of curvature at the apex 164 and the nadir 166 can range from 0.25 to 0.5 inch, 0.5 to 0.75 inch, or 0.75 to 1 inch. For example, the radius of curvature at the apex 164 and the nadir 166 can be 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, or 1 inch.

[0028] The flex structure 152 further defines an upper surface 168 and a lower surface 172. The upper surface 168 of the flex structure 152 faces the crown 110 and the lower surface 172 of the flex structure 152 faces the sole 112. The flex structure 152 defines a thickness measured between the upper surface 168 and the lower surface 172. The thickness of the flex structure 152 can be defined as the distance between the upper surface 168 and the lower surface 172 measured in a direction perpendicular to either the upper surface 168 or the lower surface 172.

In some embodiments, the thickness of the flex structure 152 can be constant from the first end 160 to the second end 162.

[0029] In other embodiments, a portion of the flex structure 152 can comprise a tapered thickness. In one example, the thickness of the flex structure 152 can be greater at the first end 160 and decrease towards the nadir 166, and the thickness of the flex structure 152 can be greater at the second end 162 and decrease towards the apex 164. The tapered thickness of the flex structure 152 at the first end 160 and the second end 162 can increase the strength of connection between the flex structure 152, the club face 104, and the sole 112.

[0030] The thickness of the flex structure 152 can range from 0.05 inch to 0.15 inch. In some embodiments, the thickness of the flex structure 152 can range from 0.05 inch to 0.10 inch, or 0.10 to 0.15 inch. In some embodiments, the thickness of the flex structure 152 can range from 0.05 to 0.09 inch, 0.06 to 0.10 inch, 0.07 to 0.11 inch, 0.08 to 0.12 inch, 0.09 to 0.13 inch, 0.10 to 0.14 inch, or 0.11 to 0.15 inch. For example, the thickness of flex structure 152 can be 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, or 0.15 inch. In one example, the thickness of the flex structure 152 can be 0.06 inch.

[0031] The flex structure 152 defines a width. The width of the flex structure 152 is defined as a distance the flex structure 152 extend in the toe 120 to heel 116 direction. The width of the flex structure can range from 0.1 to 1 inch. In some embodiments, the width of the flex structure 152 can range from 0.1 to 0.5 inch, or 0.5 to 1 inch. In some embodiments, the width of the flex structure 152 can range 0.1 to 0.5 inch, 0.2 to 0.6 inch, 0.3 to 0.7 inch, 0.4 to 0.8 inch, 0.5 to 0.9 inch, or 0.6 to 1 inch. For example, the width of the flex structure 152 can be 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 inch. In one example, the width of the flex structure 152 can be 0.4 inch.

[0032] Referring to FIG. 6, the club head 100 further defines a XY plane 1300 extending in a direction of the x-axis 700 and the y-axis 800. The club head 100 further defines a vertical plane 1400. The vertical plane 1400 is parallel to the XY plane 1300 and is tangent to the second end 162 of the flex structure 152. The vertical plane 1400 is offset from the XY plane 1300, wherein the vertical plane is closer to the rear 122 of the club head 100 than the XY plane 1300. In reference to the planes defined by the club head 100, the flex structure 152 extends away from the club face 104 such that a flex structure distance 176 forms between the XY plane 1300 and the vertical plane 1400. The flex structure distance 176 extends between the XY plane 1300 and the vertical plane 1400 in a direction perpendicular to the XY plane 1300. The flex structure distance 176 can be the distance the flex structure 176 extends away from the club face 104, measured as a horizontal distance from the geometric center 132 to the second end 162 of the flex structure 152. The flex structure distance 176 can be measured along the z-axis 900 between the geometric center 132 and the second end 162 of the flex structure 152.

[0033] The flex structure distance 176 can be at least 0.7 inch. In other embodiments, the distance 176 can be at least 0.75, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or 1.5 inch. In other embodiments, the flex structure distance 176 can range from 0.8 to 2 inch. In other embodiments, the flex structure distance 176 can range from 0.8 to 1.4 inch, 0.9 to 1.5 inch, 1.0 to 1.6 inches, 1.1 to 1.7 inches, 1.2 to 1.8 inches, 1.3 to 1.9 inches, or 1.4 to 2.0 inches. For example, the flex structure distance 176 can be 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2.0 inches. During golf ball impacts, a portion of the sole 112 closest to the club face 104 experiences stress risers. To ensure the flex structure 152 does not add any additional stress risers to the forward portion of the sole 112, the flex structure 152 is spaced by the flex structure distance 176. The flex structure distance 176 improves the overall club head durability while still reducing the CT variability of the club face 104.

Club Head Assembly

[0034] Referring to FIG. 7, the club head 100 can further form an opening 178 within the crown 110. Specifically, the crown 110 forms the opening 178, wherein the opening 178 can be configured to receive a crown insert 180. The multi-component design of the club head 100 allows for the manufacturing of the flex structure 152 within the interior cavity 156. In one example, the club head 100 is formed with an additive manufacturing method. The opening 178 allows for support material used during the additive manufacturing process to be removed from the interior cavity 156. As described in more detail below, the club head 100 comprises a bond surface around a perimeter of the opening 178 to facilitate the securement of the crown insert 180.

[0035] The club head 100 can comprise a bond surface in the form of a recessed lip 182.

The recessed lip 182 is recessed from an outer surface of the crown 110 to accommodate the combined thickness of the overlapping crown insert 180, and any adhesives used to secure the crown insert 180 to the crown 110. The recessed lip 182 can extend around a perimeter of the opening 178. In one configuration, the recessed lip 182 can recessed from the outer surface of the crown 110 such that when the crown insert 180 is installed, the crown insert 110 may either be substantially flush with the outer surface of the crown 110, or else can be partially recessed relative to the outer surface of the crown 110.

[0036] The recessed lip 182 can comprise a plurality of bond features 184 to promote a uniform adhesive layer between the crown insert 180 and the recessed lip 182. The plurality of bond features can include one or more bumps, ridges, projections, ribs, apertures, or recesses that are spaced along the recessed lip 182. The plurality of bond features can be equally spaced from each other or localized within an area of the recessed lip 182 such as near the heel 116, toe 120, club face 104, or the rear 122.

[0037] The opening 178 can be configured to receive the crown insert 180. The crown insert 180 can be formed separately and be attached or secured to the opening 178 at the recessed lip 182. The crown insert 180 can be secured to the crown 110 using adhesives, epoxies, or adhesive tapes. The crown insert 180 overlaps with the recessed lip 182 to define a lap joint 186 therebetween. The crown insert 180 can be secured or adhered to the club head 100 across the lap joint 186. The lap joint 186 can extend around the perimeter of the opening 178. In some embodiments, the lap joint 186 can extend beyond the crown 110 to wrap around at least one of the toe 120 and heel 116.

Additional Embodiments

[0038] While FIGS. 1-7 illustrated a first embodiment of how the present technology may be employed, FIG. 8 illustrates a second embodiment. Specifically, FIG. 8 illustrates a club head 200. The club head 200 comprises a club face 204 and a body 208 that are secured together to define a substantially closed/interior volume 256. The club head 200 comprises a crown 210, a sole 212 opposite the crown 210, a heel, a toe opposite the heel, and a rear 222 opposite the club face 204. The club head 200 can be similar to the club head 100 as shown in FIGS. 1-7, but differ in the how the flex structure is secured to the club head.

[0039] The club head 200 comprises a flex structure 252. The flex structure 252 comprises a first end 260 and a second end 262. The flex structure 252 can be formed separately from the club head 100 and be secured within the interior cavity 256. The flex structure 252 can be removably connected or secured to the club face 204 and the sole 212. The flex structure 252 can be secured to the club face 204 and the sole 212, for example, through the use of adhesives, mechanical fasteners, or a combination thereof. In one configuration, the second end 262 of the flex structure 252 can be secured to the sole 212 with a mechanical fastener, and the first end 260 of the flex structure 252 can contact or rest against a rear surface of the club face 204. As illustrated in FIG. 8, a damping member 296 can be positioned between the first end 260 and the club face 204. The damping member 296 can be formed from a different material than the material of the flex structure 256 or the club head 200. The damping member 296 provides additional CT tuning capabilities to the club face 204. The damping member 296 in combination with the removable flex structure 252 can reduce the CT variability across the club face 204.

[0040] Further, the club head 100 or 200 can comprise a cascading sole (not shown) located on an inner surface of the sole between the club face and the second end of the flex structure.

The cascading sole can comprise multiple tiers of thickness. In one example, the cascading sole can comprise a first tier and a second tier. Each tier can comprise a constant thickness throughout the tier extending in a direction from the heel to the toe, and in a direction from the club face to the rear. The cascading sole allows the stress experienced by the club face near the sole to distribute to the first tier and the second tier. The first tier and the second tier of the cascading sole can prevent stress from collecting at the thinnest portion of the sole and can prevent permanent deformation of the club face.

[0041] In other embodiments, the cascading sole can comprise a first tier, a second tier, and a third tier (not shown). Each tier can comprise a constant thickness throughout the tier extending in a direction from the heel to the toe, and in a direction from the club face to the rear. The first tier can comprise a greater thickness than the second tier, and the second tier can comprise a greater thickness than the third tier. The thickness of the first, second, and third tier is measured in a direction perpendicular to the ground plane from an outer surface of the sole to the inner surface of the sole.

[0042] The first tier can comprise a first tier length, the second tier can comprise a second tier length, and the third tier can comprise a third tier length. In some embodiments, the first tier length can be greater than the second tier length, and the second tier length can be greater than the third tier length. In other embodiments, the first tier length, the second tier length, and the third tier length can be same. In some embodiments, the length of the first tier, second tier, and the third tier decreases in a direction extending from the club face to the rear. The cascading sole allows some of the stress experienced by the club face near the sole to distribute to the first tier, the second tier, and the third tier. The additional third tier allows the stress to move even further away from the club face, preventing permanent deformation of the club face.

Function and Benefits

[0043] The flex structure described in this disclosure (i.e. flex structure 152 and 252) provides a structure that strengthens the club face, relieves stress from the club face, and reduces CT variability across the club face. The flex structure allows the club face to bend rearward during golf ball impacts and achieves these advantages without sacrificing ball speed performance. The disclosed club head comprising the flex structure reduces CT variability across the club face to meet the United States Golf Association (USGA) standard of 257 microseconds or less.

[0044] During golf ball impacts, the curved shape of the flex structure (i.e. flex structure 152 and 252) allows the club face and the flex structure to bend under the impact force of a golf ball. FIG. 9 illustrates a final displacement of a club face and a flex structure after impacting a golf ball. As illustrated in FIG. 9, the flex structure bends rearward and downward. The flex structure bends greater at the nadir than at the apex because the nadir is closest to the source of the impact force. When subjected to impact forces, the total distance between the first end and the second end of the flex structure measured in a club face to rear direction is less than when the flex structure is at a resting state (i.e. no impact force is imparted onto the club head). The flex structure provides support to the club face without hindering club face bending.

[0045] The flex structure (i.e. flex structure 152 and 252) provides support to the club face while relieving stress during golf ball impacts. The flex structure allows for an overall thinner club face compared to club faces devoid of supporting structures. Club heads devoid of supporting structures need to comprise a greater club face thickness to provide enough structural support to withstand the impact forces from a golf ball. Increasing the club face thickness negatively affects CT and ball speed performance. A thickened club face decreases CT and the ball speed performance. To achieve a balance between club face thickness, CT, and ball speed performance, the disclosed flex structure couples the club face and the sole together thereby transmitting some of the impact forces away from the club face and into the sole. The flex structure causes the sole to flex slightly outward. By diverting the impact forces into the flex structure and the sole, the club face can be overall thinner to improve ball speed performance without exceeding the elastic limit of the club face’s material. The disclosed club head comprising the flex structure allows the club head to see greater ball speed compared to a club head devoid of a club face supporting structure. The disclosed club head comprising the flex structure can decrease the overall thickness of the club face by approximately 0.005 to 0.010 inch. The overall decrease of club face thickness can result in a 0.5 to 1.5 mph increase in ball speed compared to a club head having an increased club face thickness and devoid a club face supporting structure.

[0046] The flex structure (i.e. flex structure 152 and 252) reduces CT variability across the club face by increasing the frequency response of the club face within a localized location. The club head comprises resonant frequencies, wherein the response amplitude of the club head is at or close to a maximum. Imposing a resonant frequency onto the club head will cause the club head to oscillate at a higher amplitude compared to other non-resonant frequencies. Higher amplitude corresponds to greater displacement (i.e. greater movement). A finite element simulation was used to identify locations of greatest displacement on the club face. In one simulation, the location of greatest displacement can be located at the central portion of the club face at a frequency between 4100 to 4200 hertz. The flex structure can be secured to the central portion of the club face to increase the frequency response within the central portion by around 200 to 500 hertz. Increasing the frequency response by around 200 to 500 hertz can decrease the CT by about 5 to 20 microseconds. In some embodiments, the CT can decrease by about 5 to 15 microseconds, or 15 to 20 microseconds. In other embodiments, the CT can decrease by about 5 to 10 microseconds, 6 to 11 microseconds, 7 to 12 microseconds, 8 to 13 microseconds, 9 to 14 microseconds, 10 to 15 microseconds, 11 to 16 microseconds, 12 to 17 microseconds, 13 to 18 microseconds, 14 to 19 microseconds, or 15 to 20 microseconds. The flex structure locally increases the club face frequency response without having to increase the overall club face thickness. The flex structure can decrease the CT of the club face without sacrificing ball speed performance. Manufacturing

[0047] In many embodiments, a method for forming the club head 100 with the flex structure 152 includes forming the club head 100 with the club face 104, the rear 122, the crown 110, the sole 112, the toe 120, the heel 116, and the flex structure 152. The club head 100 with the flex structure 152 can be formed integrally as a single body. Forming the integral club head 100 can comprise casting, additive manufacturing, 3D printing, machining, or a combination thereof.

[0048] In embodiments where the club head 100 is formed with additive manufacturing, the club head 100 with the flex structure 152 can be integrally formed together as a single body, and the crown insert 180 can be formed separately from the club head 100. The crown insert 180 can be secured, adhered, or affixed to the club head 100 through the use of adhesives, adhesive tapes, mechanical fasteners, or a combination thereof.

[0049] In other embodiments, a method for forming the club head 200 with the flex structure 252 includes forming the club head 200 with the club face 204, the rear 222, the crown, the sole, the toe, and the heel, and forming the flex structure 252 separately. Forming the club head 200 or flex structure 252 can comprise casting, additive manufacturing, 3D printing, machining, or a combination thereof. The flex structure 252 can then be secured or affixed within the club head 200 through the use of adhesives, adhesive tapes, mechanical fasteners, or a combination thereof.

[0050] The club head 100 or 200 may be formed from a metal. Examples of metals may include, for example, but not limited to, steel, steel alloy, stainless steel, stainless steel alloy, C300, C350, Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 8620 alloy steel, S25C steel, 303 SS, 17-4 SS, carbon steel, maraging steel, 565 Steel, AlSItype 304 or AlSItype 630 stainless steel, titanium alloy, Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti 185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, or Ti-8-1-1 titanium alloy, amorphous metal alloy, or other similar metals.

[0051] The crown insert 180 can be formed from a non-metallic material. Examples of non- metallic material may include, for example, but not limited to, polymers, composites, thermoplastic, thermoplastic composites, or fiber reinforced polymers such as a reinforced carbon fiber polymer. [0052] The flex structure 152 may be formed from a similar material as the club head 100. The flex structure 152 may be formed from a metal. Examples of metals may include, for example, but not limited to, steel, steel alloy, stainless steel, stainless steel alloy, C300, C350, Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 8620 alloy steel, S25C steel, 303 SS, 17-4 SS, carbon steel, maraging steel, 565 Steel, AISI type 304 or AISI type 630 stainless steel, titanium alloy, Ti-6-4, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Til85, Ti 6-6-2, Ti-7s, Ti-9s, Ti- 92, or Ti-8-1-1 titanium alloy, amorphous metal alloy, or other similar metals.

[0053] The flex structure 252 may be formed form a metal described above for the flex structure 152, or a non-metallic material. Examples of non-metallic material may include, for example, but not limited to, polymers, composites, thermoplastic, thermoplastic composites, or fiber reinforced polymers such as a reinforced carbon fiber polymer.

[0054] Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims.

[0055] As the rules to golf may change from time to time (e.g., new regulations may be adopted or old rules may be eliminated or modified by golf standard organizations and/or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St. Andrews (R&A), etc.), golf equipment related to the apparatus, methods, and articles of manufacture described herein may be conforming or non-conforming to the rules of golf at any particular time. Accordingly, golf equipment related to the apparatus, methods, and articles of manufacture described herein may be advertised, offered for sale, and/or sold as conforming or non-conforming golf equipment. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

[0056] The terms "first," "second," "third," "fourth," and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "include," and "have," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0057] The terms "left," "right," "front," "back," "top," "bottom," "over," "under," and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0058] While the above example may be described in connection with a driver-type golf club, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of golf club such as a fairway wood-type golf club, hybrid-type golf club head, or ahollow wood-type club head.

[0059] For wood-type club heads such as driver-type, fairway-type and hybrid-type club heads, a measurement is used to determine the spring effect or springiness of the club face. This measurement is the characteristic time (hereafter “CT”). CT is defined as the amount of time, measured in microseconds (ps), that a golf ball contacts the club face at the moment of impact. The characteristic time is measured by impacting a specific spot on the striking surface several times using a small steel pendulum. A computer program measures the amount of time the steel pendulum contacts the club face at the moment of impact.

[0060] The terms “loft” or “loft angle” of a golf club, as described herein, refers to the angle formed between the club face and the shaft, as measured by any suitable loft and lie machine.

[0061] In embodiments where the club head is a driver type club head, the loft angle of the driver-type club head is less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, the volume of the driver-type club head is greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the volume of the driver-type club head can be approximately 400cc - 600cc, 425cc - 500cc, approximately 500cc - 600cc, approximately 500cc - 650cc, approximately 550cc - 700cc, approximately 600cc - 650cc, approximately 600cc - 700cc, or approximately 600cc - 800cc.

[0062] In embodiments where the club head is a fairway-type club head, the loft angle of the fairway wood-type club head is less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiment, the loft angle of the fairway wood-type club head is greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood-type club head can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

[0063] The volume of the fairway wood-type club head is less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the volume of the fairway wood-type club head can be approximately 150cc - 200cc, approximately 150cc - 250cc, approximately 150cc - 300cc, approximately 150cc - 350cc, approximately 150cc - 400cc, approximately 300cc - 400cc, approximately 325cc - 400cc, approximately 350cc - 400cc, approximately 250cc - 400cc, approximately 250 - 350 cc, or approximately 275-375 cc.

[0064] In embodiments where the club head is a hybrid-type club head, the loft angle of the hybrid-type club head is less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in other embodiments, the loft angle of the hybrid-type club head is greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0065] The volume of the hybrid-type club head is less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In other embodiments, the volume of the hybrid-type club head can be approximately lOOcc - 150cc, approximately 75cc - 150cc, approximately lOOcc - 125cc, or approximately 75cc - 125cc.

[0066] Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.

[0067] Clause 1. A golf club head comprising: a club face; a body comprising a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the flex structure is disposed within the closed interior cavity; wherein the flex structure is integrally formed with the club face and the sole; and wherein the flex structure comprises a curved shape with a nadir and an apex. [0068] Clause 2 The club head of clause 1 wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole.

[0069] Clause 3 The club head of clause 1 wherein the nadir of the flex structure is located closer to the sole than the apex of the flex structure.

[0070] Clause 4. The club head of clause 1, wherein the crown further defines an opening.

[0071] Clause 5. The club head of clause 4, wherein the opening is configured to receive a crown insert.

[0072] Clause 6. The club head of clause 5, wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

[0073] Clause 7. The club head of clause 6, wherein the crown insert and the recessed lip overlap to define a lap joint therebetween; and wherein the crown insert is adhered to the club head across the lap joint.

[0074] Clause 8. The club head of clause 1, wherein the flex structure defines a first radius of curvature at the nadir, and a second radius of curvature at the apex; and wherein the first radius of curvature and the second radius of curvature are equal.

[0075] Clause 9. The club head of clause 1, wherein the flex structure defines a first radius of curvature at the nadir, and a second radius of curvature at the apex; and wherein the first radius of curvature and the second radius of curvature are different.

[0076] Clause 10. A golf club head comprising: a club face; a body comprising a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the flex structure is disposed within the closed interior cavity; wherein the flex structure is integrally formed with the club face and the sole; wherein the flex structure comprises a curved shape with a nadir and an apex; and wherein the nadir of the flex structure is located closer to the club face than the apex of the flex structure. [0077] Clause 11. The club head of clause 10, wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole.

[0078] Clause 12. The club head of clause 10, wherein the nadir of the flex structure is located closer to the sole than the apex of the flex structure.

[0079] Clause 13. The club head of clause 10, wherein the crown further defines an opening.

[0080] Clause 14. The club head of clause 13, wherein the opening is configured to receive a crown insert.

[0081] Clause 15. The golf club head of clause 14, wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

[0082] Clause 16. The club head of clause 15, wherein the crown insert and the recessed lip overlap to define a lap joint therebetween; and wherein the crown insert is adhered to the club head across the lap joint.

[0083] Clause 17. A golf club head comprising: a club face; a body having a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the club face defines a loft plane tangent to the club face at a geometric center; wherein the club head defines a ground plane tangent to the sole when the club head is at an address position; wherein the club head defines a midplane through the geometric center and perpendicular to the loft plane, wherein the midplane extends in a direction from the heel to the toe, and rearward of the club face; wherein the flex structure is integrally formed with the club face and the sole; wherein the flex structure comprises a curved shape including a nadir and an apex; and wherein the nadir of the flex structure and the apex of the flex structure are located below the midplane.

[0084] Clause 18. The club head of clause 17, wherein the nadir of the flex structure is located closer to the club face than the apex of the flex structure.

[0085] Clause 19. The club head of clause 17, wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole. [0086] Clause 20. The club head of clause 17, wherein the nadir of the flex structure is located closer to the sole than the apex of the flex structure.

[0087] Clause 21. The club head of clause 17, wherein the crown further defines an opening.

[0088] Clause 22. The club head of clause 21, wherein the opening is configured to receive a crown insert.

[0089] Clause 23. The club head of clause 1, wherein a thickness of the club face ranges from 0.08 to 0.14 inch.

[0090] Clause 24. The club head of clause 1, wherein the crown further defines an opening configured to receive a crown insert; wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

[0091] Various features and advantages of the disclosure are set forth in the following claims.

Claims

CLAIMS What is claimed is:

1. A golf club head comprising: a club face; a body comprising a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the flex structure is disposed within the closed interior cavity; wherein the flex structure is integrally formed with the club face and the sole; and wherein the flex structure comprises a curved shape with a nadir and an apex.

2. The club head of claim 1, wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole.

3. The club head of claim 1, wherein the nadir of the flex structure is located closer to the sole than the apex of the flex structure.

4. The club head of claim 1, wherein the flex structure defines a first radius of curvature at the nadir, and a second radius of curvature at the apex; and wherein the first radius of curvature and the second radius of curvature are different.

5. The club head of claim 1, wherein a thickness of the club face ranges from 0.08 to 0.14 inch.

6. The club head of claim 1, wherein the crown further defines an opening configured to receive a crown insert; wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

7. The club head of claim 6, wherein the crown insert and the recessed lip overlap to define a lap joint therebetween; and wherein the crown insert is adhered to the club head across the lap joint.

8. A golf club head comprising: a club face; a body comprising a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the flex structure is disposed within the closed interior cavity; wherein the flex structure is integrally formed with the club face and the sole; wherein the flex structure comprises a curved shape with a nadir and an apex; and wherein the nadir of the flex structure is located closer to the club face than the apex of the flex structure.

9. The club head of claim 8, wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole.

10. The club head of claim 8, wherein the nadir of the flex structure is located closer to the sole than the apex of the flex structure.

11. The club head of claim 8, wherein the flex structure defines a first radius of curvature at the nadir, and a second radius of curvature at the apex; and wherein the first radius of curvature and the second radius of curvature are different.

12. The club head of claim 8, wherein a thickness of the club face ranges from 0.08 to 0.14 inch.

13. The club head of claim 8, wherein the crown further defines an opening configured to receive a crown insert; wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

14. The club head of claim 13, wherein the crown insert and the recessed lip overlap to define a lap joint therebetween; and wherein the crown insert is adhered to the club head across the lap joint.

15. A golf club head comprising: a club face; a body having a crown, a sole, a heel, and a toe; and a flex structure; wherein the club face and the body are secured together to define a closed interior cavity; wherein the club face defines a loft plane tangent to the club face at a geometric center; wherein the club head defines a ground plane tangent to the sole when the club head is at an address position; wherein the club head defines a midplane through the geometric center and perpendicular to the loft plane, wherein the midplane extends in a direction from the heel to the toe, and rearward of the club face; wherein the flex structure is integrally formed with the club face and the sole; wherein the flex structure comprises a curved shape including a nadir and an apex; and wherein the nadir of the flex structure and the apex of the flex structure are located below the midplane.

16. The club head of claim 15, wherein the nadir of the flex structure is located closer to the club face than the apex of the flex structure.

17. The club head of claim 15, wherein the nadir and the apex of the flex structure do not contact any portion of the club face or the sole.

18. The club head of claim 15, wherein a thickness of the club face ranges from 0.08 to 0.14 inch.

19. The club head of claim 15, wherein the crown further defines an opening configured to receive a crown insert; wherein a recessed lip extends around a perimeter of the opening; and wherein the recessed lip is recessed from an outer surface of the crown.

20. The club head of claim 19, wherein the crown insert and the recessed lip overlap to define a lap joint therebetween; and wherein the crown insert is adhered to the club head across the lap joint.