# Patent

## Title
Iron-type golf club head

## Abstract

The present invention discloses an iron-type golf club head having a body with at least one sole pocket and a cap sized to at least partially close the sole pocket. The pocket is bounded on one side by a face plate, which is only partially affixed to the body via welding, and may be completely or partially filled with the cap. The cap, which can be made of multiple materials having different densities, is located within the pocket such that one or more gaps are disposed between the cap and the sidewalls of the pocket.

## Background
CROSS REFERENCES TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application No. 61/719,811, filed on Oct. 29, 2012, the disclosure of which is hereby incorporated by reference in its entirety herein.


STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an iron-type golf club head. More specifically, the present invention relates to an iron-type golf club head having a plurality of cavities, weights, and caps of different shapes, sizes, and compositions to improve forgiveness and refine the club head mass properties.
2. Description of the Related Art
The prior art discloses various types of weighting and cavities for golf club heads, especially iron-type golf club heads. In particular, tungsten alloy, with a density of around 17 g/cc, has been inserted into cavities in the sole to weight golf club heads for many years. Although the prior art provided useful methods for weighting iron type golf club heads, it has not optimized weighting in a way that achieves an ideal combination of forgiveness and golf club head mass properties.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a golf club that is forgiving and allows for optimization of feel, sound, backspin, launch angle, compliance, and ball speed, as well as club head mass properties such as center of gravity and moment of inertia.
One aspect of the present invention is an iron-type golf club head comprising a body comprising a top portion, a sole portion, and a front opening, and a face plate, wherein the face plate covers the front opening, wherein the sole portion comprises at least one sole pocket, and wherein the at least one sole pocket is bounded on at least one side by the face plate. The face plate may be only partially affixed to the body, and in one embodiment may be welded to at least one corner of the sole pocket. In some embodiments, the club may further comprise a cap sized to cover the sole pocket. In some further embodiments, the cap may not be affixed to and may not make contact with the face plate. In other embodiments, the cap may fit within the sole pocket and comprise at least one cavity. In still other embodiments, the cap may fit within and fill the sole pocket. In some embodiments, the cap may be composed of multiple materials having different densities. In still other embodiments, the body may be forged, and the face plate may have variable thickness.
Another aspect of the present invention is an iron-type golf club head comprising a body comprising a top portion, a sole portion, a face portion, a rear cavity, and a sole pocket, and a cap sized to fit within the sole pocket, wherein the cap comprises at least one cavity, and wherein when the cap is disposed within the pocket, the cavity faces towards the top portion, and the pocket comprises an empty space. In some embodiments, the body may further comprise at least one secondary pocket. In other embodiments, the cap may comprise two cavities.
Yet another aspect of the present invention is an iron-type golf club head comprising a body comprising a top portion, a sole portion, a face portion, a rear cavity, and a sole pocket, and a cap sized to fit within the sole pocket, wherein the cap is composed of at least two materials having different densities, and wherein the cap completely fills the sole pocket. The body may further comprise at least one secondary pocket, and in some embodiments may be integrally cast.
Another aspect of the present invention is an iron-type golf club head comprising a body comprising a top portion, a sole portion, a face portion, a rear cavity, and a sole pocket, and a cap, wherein the sole pocket has a first width and at least two opposing walls, wherein the cap has a second width that is smaller than the first width, wherein when the cap is disposed within the sole pocket, at least a first gap and a second gap are formed between the walls of the sole pocket and the cap, wherein the first gap has a third width, wherein the second gap has a fourth width, and wherein the third width is not equivalent to the fourth width. In some further embodiments, the gaps may be filled with a low-density dampening material, while in other embodiments, the gaps may be empty. In one embodiment, the cap may comprise at least one cavity.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.



BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a sole perspective view of a first embodiment of the present invention.
FIG. 2 is a cross-sectional view of the embodiment shown in FIG. 1 along lines 2-2.
FIG. 3 is a cross-sectional view of a second embodiment of the present invention.
FIG. 4 is a cross-sectional view of a third embodiment of the present invention.
FIG. 5 is a cross-sectional view of a fourth embodiment of the present invention.
FIG. 6 is a rear perspective view of a fifth embodiment of the present invention.
FIG. 7 is a cross-sectional view of the embodiment shown in FIG. 6 along lines 7-7.
FIG. 8 is a sole perspective view of a sixth embodiment of the present invention.
FIG. 9 is a sole perspective view of a seventh embodiment of the present invention.
FIG. 10 is a rear perspective view of an eighth embodiment of the present invention.
FIG. 11 is an exploded view of the embodiment shown in FIG. 10.
FIG. 12 is a top perspective view of the cap shown in FIGS. 10 and 11.
FIG. 13 is a cross-sectional view of the embodiment shown in FIG. 10 along lines 13-13.
FIG. 14 is a cross-sectional view of a ninth embodiment of the present invention.
FIG. 15 is a cross-sectional view of a tenth embodiment of the present invention.
FIG. 16 is a cross-sectional view of an eleventh embodiment of the present invention.
FIG. 17 is a cross-sectional view of a twelfth embodiment of the present invention.
FIG. 18 is a cross-sectional view of a thirteenth embodiment of the present invention.
FIG. 19 is a side perspective view of an exemplary, multi-material insert for use with any of the embodiments of the present invention.
FIG. 20 is a cross-sectional view of a fourteenth embodiment of the present invention.
FIG. 21 is a cross-sectional view of a fifteenth embodiment of the present invention.
FIG. 22 is a cross-sectional view of a sixteenth embodiment of the present invention.
FIG. 23 is a sole perspective view of a seventeenth embodiment of the present invention.
FIG. 24 is a sole perspective view of an eighteenth embodiment of the present invention.
FIG. 25 is a sole perspective view of a nineteenth embodiment of the present invention.



DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the iron-type golf club head 10 of the present invention is shown in FIGS. 1-2. The golf club head 10 has a body 15 comprising a top portion 12 (also called a top rail), a sole portion 14, a heel portion 16, a toe portion 18, a rear cavity 30 encircled by the top portion 12, sole portion 14, and heel and toe portions 16, 18, a front opening 35, and a hosel 20, and also comprises a separate face plate 25 disposed proximate the front opening 35. The sole includes a sole pocket 40 proximate the front opening 35 and extending at least part of the way across the sole portion 14, as shown in FIG. 1, and upwards towards the rear cavity 30 as shown in FIG. 2. The pocket 40 is bounded partially by the body 15 and partially by the face plate 25, which is only partially (non 360°) attached by welding or brazing to the body 15 to close the front opening 35.
In the preferred embodiment shown in FIG. 1, the weld line 32 formed between the face plate 25 and the body 15 does not extend to the forwardmost edge of the pocket 40, even if the pocket 40 is filled with or includes a weldable material. In the preferred embodiment, the pocket 40 is covered with any of the caps 50 disclosed herein, but in alternative embodiments it may be left uncovered or filled with a dampening material of various durometer values for fine-tuning the performance and/or sound and feel of the golf club head 10. In the preferred embodiment, the body 15 is cast and the face plate 25 comprises variable thickness, though in alternative embodiments the body 15 may be forged and/or machined, or the face plate 25 may have constant thickness.
In other embodiments, the pocket 40 may vary in size and in shape, as viewed from the sole portion and also via cross-section, and may have any of the cross-sectional shapes configurations shown in FIGS. 3-6 and outline shapes shown in FIGS. 23-25. In these other embodiments, the pocket 40 may not be bounded on one side by the face plate 25, which may instead be formed integrally with the golf club head 10. The club head 10 may also include secondary pockets 42, 44, 46 located at other positions in the sole portion 14, including extending into a rear surface 14a of the sole portion 14 or located within the rear cavity 30, as shown in FIGS. 6 and 7. The sole portion 14 may also comprise more than one pocket 40a, 40b, as shown in FIG. 8, which may have any size or shape and may be located anywhere in the lowermost surface of the sole portion 14. In another embodiment, the pocket 40 may extend along the entire length of the sole portion 14 from the heel portion 16 to the toe portion 18 as shown in FIG. 9. In each of these embodiments, the pockets 40, 42, 44, 46 may be covered with any of the caps 50 disclosed herein, filled with one or more dampening materials of various durometer values, or left uncovered.
Another embodiment of the golf club head 10 of the present invention, shown in FIGS. 10 and 11, includes a cap 50 disposed within the pocket 40 via bonding, welding, soldering, brazing, or mechanical fastening. Though the cap 50 may fill the entire pocket, as shown in FIG. 12, the cap 50 can include multiple cavities 52, 54, or a single cavity 56 as shown in FIG. 13. The function of these cavities 52, 54, 56 is to create an enclosed space within the pocket 40 to hold dampening or weight materials, or to adjust the sound and feel of the golf club head 10. The orientation of the cavities 52, 54, 56 of the cap 50 within the pocket 40 of the golf club head 10 is also variable, as shown in FIGS. 14-16. These Figures also show the inclusion of a secondary insert 60 in the cavities 52, 54, 56, which may be a single dampening or weight material having a density of 1.47 to 17 g/cc, or a combination of said materials. In the case of FIGS. 14 and 15, a tertiary insert 62 may be included in the secondary pockets 44, 46.
In other embodiments, shown in FIGS. 17-19 the cap 50 does not include one or more cavities 52, 54, 56 but is instead inserted into the pocket 40 in combination with the secondary insert 60. As shown in FIG. 17, the cap 50 may be a plug that is affixed to the secondary insert 60 and disposed within the pocket 40 so that the pocket 40 is entirely filled, or, as shown in FIG. 18, the cap 50 and secondary insert 60 combination may only partially fill the pocket 40, leaving some extra space empty within the pocket 40. As shown in FIG. 19, in these embodiments, the cap 50 effectively is an insert 70 having multiple materials 72, 74 that may have different densities, ranging from 1.47 g/cc to 17 g/cc. In all embodiments disclosed herein, the cap's 50 or insert's 70 configuration of materials and geometry can be varied within the optimal pocket 40 for a specific iron's loft to fine-tune the characteristics of the iron or create a progression of center of gravity and moment of inertia through a set of the irons, as well as to control sound and feel characteristics of the set.
The location of the cap 50 within the pocket 40 can also be fine-tuned to adjust properties of the face and head, including feel, sound, backspin, and launch angle along and across the face, as well as face compliance and ball speed. For example, the cap 50 may not be sized to fit snugly within the pocket 40. Instead, as shown in FIGS. 20-22, gaps 80, 82 may be disposed between one or more of the walls of the cap 50 and the walls of the pocket. As shown in FIGS. 21-22 and 24, the gaps 80, 82 may be of equal width or, as shown in FIGS. 20, 23, and 25, the gaps 80, 82 may have different widths W1, W2. The gaps 80, 82 can be partially or completely filled with welding, soldering, or brazing material, or with an adhesive material, to affix the cap 50 within the pocket 40, or may be left empty if the cap 50 is mechanically fastened within the pocket through a different surface, or is affixed within the pocket 40 by connecting an upper portion 51 of the cap 50 directly to an innermost surface 41 of the pocket 40. Because the gaps 80, 82 provide access to the interior of the pocket 40, they can be filled with a vibration dampening material to prevent debris from entering into the pocket 40 and to adjust the sound and feel of the golf club head 10 during use. Gaps 80, 82 can also be included with the secondary and tertiary inserts 60, 62 included in pockets 40, 42, 44, 46 shown in other embodiments of the present invention disclosed herein.
The embodiments disclosed herein may be combined in any number of ways to create many different iron club head structures. For each of the embodiments disclosed herein, the cap 50 may be removably attached within the pocket, and may include surface features that affect interaction between the sole portion 14 and the turf during play, such that a user can switch caps 50 to adjust the turf interaction of a selected golf club. The embodiments disclosed herein may also include discontinuously attached face plates 25, such that the face plate is only attached to the body 15 of the club head 10 at specific points.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.

## Claims

1. An iron-type golf club head comprising:
a body comprising a top portion, a sole portion, and a front opening; and
a separate face plate comprising a front surface and a rear surface,
wherein the face plate covers the front opening,
wherein the sole portion comprises at least one sole pocket,
wherein the at least one sole pocket is bounded on at least one side by the rear surface of the face plate, and
wherein no part of the cap is affixed to or makes contact with the rear surface of the face plate.

2. The iron-type golf club head of claim 1, wherein the face plate is only partially affixed to the body.

3. The iron-type golf club head of claim 2, wherein the face plate is welded to at least one corner of the sole pocket.

4. The iron-type golf club head of claim 1, further comprising a cap sized to cover the sole pocket.

5. The iron-type golf club head of claim 4, wherein the cap fits within the sole pocket and comprises at least one cavity.

6. The iron-type golf club head of claim 5, wherein when the cap is disposed within the sole pocket, the cavity faces towards the top portion, and the sole pocket comprises an empty space.

7. The iron-type golf club head of claim 6, wherein the body further comprises at least one secondary pocket.

8. The iron-type golf club head of claim 6, wherein the cap comprises two cavities.

9. The iron-type golf club head of claim 4, wherein the cap is composed of multiple materials having different densities.

10. The iron-type golf club head of claim 1, wherein the body is forged.

11. The iron-type golf club head of claim 1, wherein the face plate has variable thickness.

12. An iron-type golf club head comprising:
a body comprising a top portion, a sole portion, a face portion, a rear cavity, a sole pocket, and at least one, uncovered secondary pocket; and
a cap sized to fit within the sole pocket,
wherein the sole pocket comprises at least first and second walls,
wherein the at least one secondary pocket is disposed in the sole portion,
wherein the cap is composed of at least two materials having different densities,
wherein the cap is disposed within the sole pocket, and
wherein no portion of the cap is affixed to any portion of at least one of the first and second walls.

13. The iron-type golf club head of claim 12, wherein the body is integrally cast.

14. An iron-type golf club head comprising:
a body comprising a top portion, a sole portion, a face portion, a rear cavity, and a sole pocket; and
a cap,
wherein the sole pocket has a first width and at least two opposing walls,
wherein the cap has a second width that is smaller than the first width,
wherein when the cap is disposed within the sole pocket, at least a first gap and a second gap are formed between first and second walls, respectively, of the sole pocket and the cap,
wherein the first gap has a third width,
wherein the second gap has a fourth width,
wherein the third width is not equivalent to the fourth width,
wherein at least one of the first and second gaps is empty, and
wherein no portion of the cap is affixed to any portion of at least one of the first and second walls.

15. The iron-type golf club head of claim 14, wherein one of the gaps is filled with a low-density, vibration dampening material.

16. The iron-type golf club head of claim 14, wherein each of the first and second gaps is empty.

17. The iron-type golf club head of claim 14, wherein the cap comprises at least one cavity.