Golf club having interchangeable face plates

A novel golf club includes an elongated metal shaft and a metal club head secured to a lower end portion thereof. The club head comprises an integrally molded body having a hollow interior with an opening outwardly onto a planar front face. A plurality of metal face plates, each having a planar back face with an outer periphery matching the periphery of the front face of the club head body are adapted to be mounted on the body closing off the hollow opening thereof and secured in place with fasteners. Each face plate includes a ball engaging outer face having a set of characteristics comprising a curved bulge from toe to heel, a curved roll from bottom to top and a degree of angular loft relative to a bottom edge, and at least one of the characteristics of a selected face plate is different from that of the other(s) to impart a different path to a ball when struck thereby. The top and bottom walls, and the toe and heel portions of the club head taper from a minimum thickness rearwardly of the front face to a maximum thickness at the front face around the hollow opening.

FIELD OF THE INVENTION 
The present invention is directed to a golf club, and particularly a 
"wood", having a plurality of exchangeable face plates, particularly 
adapted for a metal, e.g. aluminum, stainless steel, magnesium, polymeric 
on composite polymers, such as epoxy reinforced with graphite-fiber 
reinforcement hollow-core wood. A plurality of face plates are provided so 
that a desired face plate can be secured to the face of the golf club to 
provide different degrees of loft, bulge, roll and/or weight. Further, a 
weight can be secured to a hollow head of hollow woods to provide a 
desired different center of gravity or overall swing weight to the club. 
BACKGROUND OF THE INVENTION AND PRIOR ART 
In accordance with U.S. Golf Association Rules governing golf clubs, rule 
2.a "the golf clubs shall be composed of a shaft and a head, and all of 
the various parts shall be fixed so that the club is one unit; the club 
shall not be designed to be adjustable except for weight". 
By definition, a "wood" club is one with a head relatively broad from face 
to back, and usually made of wood, plastic or a light metal. The degrees 
of loft on each wood numbered 1-5 vary significantly from manufacturer to 
manufacturer, presently as set forth below: 
__________________________________________________________________________ 
GOLF CLUB MANUFACTURERS' STANDARD SPECIFICATIONS - LOFT (MENS) 
#1 #2 #3 #4 #5 #2 #3 #4 #5 #6 #7 #8 #9 Pitch 
Sand 
Mfgr. Wood 
Wood 
Wood 
Wood 
Wood 
Iron 
Iron 
Iron 
Iron 
Iron 
Iron 
Iron 
Iron 
Wedge 
Wedge 
__________________________________________________________________________ 
Acushnet 
11 14 17 20 22 22 25 28 31 35 39 43 47 51 55 
Dunlop 
11 14 17 19 22 21 24 28 32 36 40 44 48 52 56 
Faultless 
12 -- 15 18 21 20 24 28 32 36 40 44 48 52 56 
H & B 11 13 16 19 21 20 24 28 32 36 40 44 48 52 58 
MacGregor 
11 13 151/2 
181/2 
22 22 25 28 32 36 381/2 
43 45 49 56 
No'western 
11 14 16 19 22 21 24 27 31 35 39 43 47 51 55 
P.G.A. 
11 14 17 20 22 21 23 26 29 33 37 41 45 50 54 
F'st Flight 
121/2 
14 17 20 23 21 24 27 31 35 39 43 47 51 55 
Pro-Dyne 
12 -- 161/2 
191/2 
221/2 
21 24 27 30 34 38 42 46 51 57 
Ram 11 -- 16.5 
19.2 
22 21 24.3 
27.8 
31.5 
35.3 
39.2 
43.3 
47.5 
51.6 
56.7 
Royal 11 14 17 19 21 21 24 27 31 35 39 43 47 51 57 
Spalding 
11 13 16 19 22 20 23 27 31 35 39 43 47 52 58 
Hagen 11 16 17 19 21 21 24 27 31 35 39 43 47 51 55 
Wilson 
11 14 16 19 21 21 24 27 31 35 39 43 47 51 55 
__________________________________________________________________________ 
A change in loft on a particular numbered wood sometimes enables a golfer 
to perform better with a particular club and, instead of purchasing that 
numbered wood from a different manufacturer having the desired loft, or 
instead of purchasing another complete set of woods to obtain a particular 
wood having a desired loft, the loft on a given wood can be altered. Wood 
lofts can be altered mechanically by fastening the head of the club 
securely in a vice and hand filing the face of the club with short firm 
strokes to try to prevent file slippage and consequent head damage. This 
procedures requires great expertise and workmanship since any removal of 
material from the face of the club requires great care so that the bulge 
or roll of the club head are not unintentionally changed. Further, removal 
of material from the face of the club alters the swing weight of the club. 
The loft, bulge, and roll are shown in the drawing and labelled Prior Art. 
Similarly, a golfer often finds that his game can be improved by changing 
the bulge and/or the roll of a particular wood club. The bulge and roll 
can be mechanically altered by filing the club face with great skill and 
workmanship. Great care, skill, workmanship and time is required to alter 
the loft, bulge, and/or roll of a particular wood since altering the 
facing on any wood in any respect (loft, bulge or roll) alters the other 
specifications as well in addition to the swing weight of the club. Filing 
of the club face to alter loft, bulge, or roll also generally requires 
cutting new face lines into the club face. 
Because of the skill, workmanship and effort required to alter a fixed face 
on a golf club, and the desirability of changing the facing specifications 
on a given golf club for a particular golf enthusiast, others have 
developed golf clubs having quickly adjustable facings. Examples of clubs 
having quickly changeable face specifications are as follows: U.S. Pat. 
Nos. 2,026,749; 2,056,335; 2,175,598; 2,201,638; 2,386,552; 3,190,651; and 
3,368,812. 
In accordance with rule 2 clause (a) of the U.S. Golf Association Rules, 
"the club shall not be designed to be adjustable, except for weight". Rule 
2-2(b) states that playing characteristics are not to be changed during a 
round. Accordingly, the quickly changeable golf clubs described in the 
above listed United States Patents, do not comply with the United States 
Golf Association Rules and are therefore only useful for experimentation 
purposes. The Clark U.S. Pat. No. 2,750,194 describes a wooden golf club 
having a weight adjustment. This club apparently complies with rule 2 
clause (a), but the Clark Pat. No. 2,750,194 does not disclose a golf club 
capable of being adjusted at the facing in loft, bulge or roll. 
Others have experimented with face plates of various metals of high modulus 
of elasticity permanently bonded to the face of the club, such as 
stainless steel and the like, as disclosed in the Lynn Pat. No. 3,567,228. 
Another patent, Aitken Pat. No. 1,525,352 discloses a permanently secured 
face plate of desired loft having a properly balanced weight secured 
within the club head. Pat. No. 4,121,832 to Ebbing, discloses a golf 
putter having a removable and invertable face plate and removable weights 
to change the loft and swing weight of the putter. 
SUMMARY OF THE INVENTION 
In brief, the present invention is directed to a new and improved golf 
club; a new and improved golf club kit; and a new and improved method of 
manufacturing a golf club wherein the club head is attachable to a 
plurality of removable and interchangeable face plates having varied 
specifications of loft, bulge, material, and/or roll. 
In accordance with one important embodiment of the present invention, the 
club head walls are enlarged or the club head otherwise weighted at a toe 
portion and a heel portion to weight the heel and toe portions surrounding 
a lighter weight cavity or central core of the club head. The heel and toe 
portions include fastener receiving means for receiving fasteners 
extending through the interchangeable face plates so that any desired face 
plate can be secured to the club head at the heel and toe portions. 
Enlarged heel and toe walls of the club head provide an enlarged "sweet 
spot" dimension extending over a greater length of the club face so that 
even the inexperienced golfer can achieve better golf ball control and 
placement using the golf clubs of the present invention. Further, because 
the heel and toe portions of the golf clubs of the present invention are 
substantially heavier than a central core portion of the club head via 
greater wall thickness at the heel and toe portions of the golf club head, 
when a ball is struck at an off center position on the club face, the golf 
clubs of the present invention have less tendency to pivot to cause a 
slice or a hook on the golf ball. The interchangeable face plates are 
manufactured having at least one different specification so that a golfer 
can interchange face plates to provide a different loft, bulge, roll 
and/or golf ball striking material for any given wood type golf club. 
Accordingly, an object of the present invention is to provide a wood type 
golf club having a plurality of interchangeable face plates. 
Another object of the present invention is to provide a wood type golf club 
having a plurality of removable and interchangeable face plates removably 
connected to the club head wherein the club head has enlarged and 
relatively dense heel and toe portions. 
Still another object of the present invention is to provide a golf club kit 
including a wood type golf club having a metal head and a plurality of 
interchangeable face plates each having at least one different 
specification of loft, bulge, and/or roll. 
Another object of the present invention is to provide a wood type golf club 
having a plurality of removable and interchangeable face plates having 
ball striking surfaces made of different materials. 
Accordingly, an object of the present invention is to provide a new and 
improved golf club head having a removable face plate and having a metal 
heel portion and a metal toe portion substantially heavier than a central 
core portion. 
Another object of the present invention is to provide a new and improved 
wood type golf club having an elongated shaft and a metal club head having 
a removable face plate wherein the heel and toe portions of the club head 
each include a fastener receiving member for attachment of an 
interchangeable face plate. 
Still another object of the present invention is to provide a new and 
improved golf club including a metal club head formed of materials at the 
club head toe portion and club head heel portion having substantially 
greater density than a club head core volume defined between the heel and 
toe portions of the club head. 
Another object of the present invention is to provide a new and improved 
golf club including a plurality of interchangeable face plates, each face 
plate having at least one different specification than the specifications 
of the other face plates. 
Still another object of the present invention is to provide a new and 
improved golf club having a metal golf club head including inner solid 
members extending from integral interior club head heel and toe walls, 
said solid members being elongated, curvilinear inner heel and toe wall 
extensions extending toward a central club head core portion. 
Another object of the present invention is to provide a new and improved 
golf club head having a substantially larger "sweet-spot" area on the club 
head face. 
Another object of the present invention is to provide a golf club kit 
including a wood type golf club having a metal head and a plurality of 
face plates with different specifications, the face plates being 
interchangeable on the metal head and removably secureable thereto. 
Still another object of the present invention is to provide a method of 
manufacturing a golf club. 
Another object of the present invention is to provide a new and improved 
method of manufacturing a golf club including casting metal in a general 
shape of a wood type club head while providing substantially more metal in 
the heel and toe areas than at back, top and bottom wall portions to 
concentrate the swing weight of the club head at the heel and toe 
portions. 
The foregoing and other objects of the present invention will be more fully 
understood from the following description when read in conjunction with 
the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Turning now to the drawings, and initially to FIG. 1, there is illustrated 
a prior art golf club head having a ball-contacting face with 
specifications of 11.degree. loft, 10 inch radius bulge, and 10 inch 
radius roll. As shown in FIG. 1, the wood-type golf club generally 
designated as 10 includes a club head generally designated 12 connectible 
to an elongated shaft 14. The club head 12 includes a face 16; a heel 
portion 18; a toe portion 20; a sole or lower wall portion 22; a curved or 
arcuate back wall portion 24 extending between the heel portion 18 and the 
toe portion 20; and an upper wall portion 26 comprising an upper surface 
of the club head, defined and bounded by an upper surface of the face 16, 
the heel portion 18, the toe portion 20, and the upper surface of the back 
wall portion 24. 
As shown, for example, in FIGS. 2 and 3, the golf club of the present 
invention, generally designated 30 is a wood type golf club 
distinguishable from an iron type golf club in being relatively broad from 
the face 32 to the back wall 34. The golf club of the present invention 
generally comprises an elongated shaft 36 connected to or integral with a 
club head generally designated 38. To achieve the full advantage of the 
present invention, the golf club head 38 is formed of metal, such as 
aluminum or a composite (fiber reinforced) polymer. In accordance with an 
important feature of the present invention, the golf club head 38 includes 
face plate 32 removable from the remainder of the golf club head 38. The 
golf club head 38 includes a heel portion 40; a toe portion 42; a sole 
wall or sole plate 44 forming a bottom wall of the golf clubhead 38; and 
an upper wall 46. With face plate 32 removed, as shown in FIG. 3, the golf 
club head 38 includes a generally planar front surface generally 
designated by reference numeral 50 adapted to receive the removable face 
plate 32 in mating, flush contact against a rear wall 52 of the removable 
face plate 32. The planar face plate receiving front surface 50 of the 
golf club head 38 is generally in the shape of an elongated donut having a 
central aperture or cavity 54, shaped generally in an oval or rectangular 
configuration, extending toward the back wall 34 of the golf club head 38 
to an inner surface 56 of the golf club head back wall 34 forming a 
lightweight central core of the golf club head 38, generally designated 
57. In accordance with an important feature of the present invention, the 
heel and toe portions 40 and 42, respectively, of the golf club head 38, 
are cast with metal or other material or otherwise filled with material, 
such as aluminum, to provide relatively thick walls 58 and 60 at the 
planar surface 50 of the club head 38 extending from the front planar 
surface 50 back toward the inner surface 56 of back wall 34 of the golf 
club head 38 forming enlarged heel and toe solid members, generally 
designated 62 and 64, respectively. The solid members 62 and 64 provide 
substantially more weight at the heel portion 40 and toe portion 42 of the 
golf club head 38 than in the central, open core portion 57 of the golf 
club head 38. The core portion 57 is unfilled (air only) or can be filled 
with a suitable lightweight material, for example a foam, such as a 
polyurethane or thermoplastic foam. 
The solid members 62 and 64 at the heel and toe portions of the golf club 
head 38, respectively, comprise elongated curvilinear inner heel and toe 
wall extensions extending (integral with the walls or insertable 
thereagainst) toward the central club head core portion 57 to provide 
substantially thicker club head walls at the heel and toe portions than at 
the upper wall 46 and lower or sole wall 44 and back 34. The thicker wall 
portions 58 and 60 at the heel and toe of the planer face plate receiving 
surface 50 include, in a preferred embodiment, threaded apertures 66 and 
68 at the heel and toe portions, respectively, adapted to receive a pair 
of fasteners or screws, such as phillips screws 70 and 72 receivable 
within apertures 74 and 76 in the removable face plate 32. The screws 70 
and 72 are not quickly changeable so that the golf clubs manufactured in 
accordance with the principles of the present invention comply with the 
U.S. Golf Association Rules. 
The club face apertures 74 and 76 include enlarged or flared truncated 
cone-shaped screw head receiving surfaces 74A and 76A at a ball striking 
surface 77 of the face plate 32 so that the heads 78 and 80 of the 
fasteners 70 and 72 are substantially flush with the ball striking surface 
77 of the face plate 32 when the fasteners 70 and 72 are fully received 
within the threaded apertures 66 and 68 in the planar surface 50 of the 
club head 38. 
In accordance with another important feature of the present invention, the 
interchangeable face plates 32 can be formed from a variety of materials 
to provide varied swing weights; and to provide varied hardnesses and 
stiffnesses to the ball contacting surface 77 to provide various 
compression effects to the interchangeable face plates 32. The face plates 
32 can be made from various materials, for example: graphite; epoxies; 
composite materials such as epoxies filled with strengthening fibers such 
as fiberglass, graphite and the like; unsaturated polyesters; composite 
materials comprising unsaturated polyesters filled with various amounts of 
fibrous fillers such as fiberglass or graphite; ceramic materials; 
thermoplastics such as linear polyethylene; metals such as aluminum, 
stainless steel, magnesium, or various suitable alloys; 
acrylonitrilebutadiene-styrene-epoxy or other polymer composite materials, 
and the like. Some of these materials are more suitable for face plates 
depending upon different conditions of temperature and different golf 
enthusiast's talents or lack thereof. 
In accordance with another important feature of the present invention, as 
shown in FIGS. 6 and 7, the interchangeable face plates 32 can be weighted 
by securing a suitable weight 90 to the back of the club head contacting 
surface 52 of the face plate 32. It has been found that a weight secured 
centrally behind a desired ball striking area 77 on a face plate 32, as 
shown in FIG. 6 and 7, enables the golf enthusiast to transmit the energy 
more directly into the balls. 
In accordance with an important feature of the present invention, as best 
shown in FIG. 3, a golf club kit is provided including a wood type golf 
club having a metal club head 38 and a plurality of face plates 32 and 
32A. As shown in FIG. 3, face plate 32A is formed from a different 
material than face plate 32. Similarly, a plurality of face plates can be 
provided in a golf club kit having different specifications for loft, 
bulge and/or roll. 
In accordance with one important embodiment of the present invention, as 
best shown in FIGS. 3 and 5, the golf club head 38 of the present 
invention includes an enlarged upper wall surface 92 and an enlarged lower 
wall surface 94 to achieve better support for and mating contact against 
the rear wall 52 of the removable face plates 32 or 32A. As shown in FIG. 
5, the enlarged upper and lower wall surfaces 92 and 94 are formed or cast 
as an integral part of upper and lower walls 46 and 44, respectively. The 
enlargement of upper and lower club head walls 46 and 44 at the face plate 
mating upper and lower surfaces, 92 and 94, respectively, provides more 
solid engagement of the club head 38 with the face plates 32 or 32A to 
enable more solid engagement with a golf ball at the resulting enlarged 
"sweet spot". The enlarged surfaces 92 and 94 are cast or formed by 
providing converging curvatures to upper and lower inner wall surfaces 96 
and 98, respectively, converging in a direction toward the club head front 
surface 50 to provide enlarged surfaces 92 and 94 thicker than the upper 
and lower walls 46 and 44 at a point spaced from the front club head 
surface 50. 
In accordance with the embodiment of the present invention best shown in 
FIGS. 3 and 6, the enlarged heel and toe solid members 62 and 64 of the 
club head 38 are formed or cast as extensions of inner heel 40 and toe 42 
club head walls to form curved inner heel wall 100 and curved inner toe 
wall 102 each having a curvature from the central aperture 54, at the face 
plate, toward the heel and toe outer walls to provide a larger cavity at 
the inner rear club head wall 56 than at the inner face plate wall 52 (see 
FIG. 6). 
The club head 38 can be cast or formed in various desired shapes to the 
solid heel and toe members 62 and 64 to provide various swing weights and 
other characteristics to the golf club while maintaining enlarged heel and 
toe portions 62 and 64, particularly at the front, face plate mating 
surface 50 of the club head 38. In another embodiment shown in FIG. 7, the 
heel and toe solid members 62A and 64A are formed having inner walls 100A 
and 102A formed generally planar from the lower or sole plate club head 
wall 44 to the upper club head wall 46 to form a generally rectangular 
central cavity having a curved inner rear wall 56A. 
In accordance with another important feature of the present invention, 
shown in FIG. 7, a face plate 32B can be attached to a club head 38A 
constructed in accordance with the present invention from a rear wall 34A 
having fastener receiving apertures 104 and 106 cut into the enlarged heel 
member 62A and enlarged toe member 64A. Elongated fasteners such as 
threaded bolts 70A and 72A extend through the heel member 62A and toe 
member 64A and thread into threaded openings 81 and and 83, respectively 
in the inner face plate surface 52 to secure the face plate 32B tightly 
against the front planar surface 50A of the club head 38A. In this manner, 
the balls striking or front surface 77A of the face plate will not have 
any fastener receiving apertures which might contact a golf ball when used 
by an inexperienced golfer. 
In accordance with another embodiment of the present invention, as shown in 
FIGS. 8-11, a club head 38B can be provided with a removable sole plate 
110 covering a bottom surface of the club head 38B and a suitable weight 
112 can be secured over a centrally disposed elongated club head rib 114 
to centrally dispose the weight 112 behind the face plate 32C, as best 
shown in FIGS. 10 and 11. The weight 112 can be made integral with the 
central rib 114, or a plurality of interchangeable weights 112 can provide 
different swing weights to the golf club head 38C. The sole plate 110 is 
secured over the bottom surface of the club head 38C with fasteners 116 
insertable through sole plate apertures 118. The fasteners 116 are 
received in threaded apertures 120 disposed within the enlarged club head 
38C, as shown in FIGS. 9 and 11. In accordance with this embodiment of the 
invention, a front face plate mating surface 50B of the club head 38B 
extends completely across the club head from sole plate 110 to an upper 
club head surface 46B and from heel 40B to toe 42B to assume flush mating 
contact between a back surface 52B of the face plate 32C and the front 
planar surface 50B of the club head 38B.