Golf club heads

Abstract: The subject-matter of the invention is a golf club head, iron and/or iron woods, comprising a main body member (1,5) with means for fastening a shaft and with a ball striking face and an insert (2,9) secured to or in this striking face. The insert (2,9) comprises a first metal layer (13) forming the surface for engagement with the golf ball and at least one second layer (15) constructed of a fiber reinforced metal composite laminated to said first layer (13).

Description: The present invention relates to golf club heads as defined in the preamble of Claim 1. Golf clubs were historically categorized as either woods or irons depending on the composition of the materials used to form the heads. Although the categories of woods and irons have continued, the materials have changed drastically. An active field of players have driven the technology of fabricating golf club heads a far way from the original designs. Along the way, metal was used to construct woods and the terminology "metal woods" came into usage. Both woods and irons were improved for long shots as they began to be constructed from composite materials, as opposed to monolithic metals. In one form or another, these changes were designed to extend the life of the ball-striking surface of the golf club head, to give an adjustable center of gravity, to selectively weight the perimeter of the golf club head so that the largest possible "sweet spot" could be achieved, to provide a desirable sonic characteristic when the golf club hits the ball, to provide an increase in the inertial moment of the golf club head during the swing, and/or to provide an improved feel of a solid impact and control when the club is swung and strikes the ball. Ideally, these goals are achieved without changing the basic look of the golf club head so that the player recognizes the club as either a wood or an iron. US-A-4 792 139 discloses an example of a golf Club head. Among the improvement suggested for golf club heads are the use of a fiber reinforced plastic insert positioned in a location remote from the club head strike face, as described in US 4 928 972. This fiber reinforced synthetic resin insert is disposed on the side of the golf club head remote from the shooting surface to provide an increase in the inertial moment of the club head. It is also intended to provide a center of gravity that can be more easily adjusted. Adjustment of the center of gravity is necessary during fabrication of golf clubs with different degrees of loft. Various powder metallurgy processes utilizing variable density materials in different portions of the club head to improve the sonic characteristics of the club and to extend the life of the ball-striking surface are disclosed in US 4 992 236. In each case, the process involves the use of a golf-Club shaped mold that is filled with metal powders. As an option, the mold may be designed to contain inserts of materials such as metal casting, wrought metal and green compacts of metal powders. Forged metal inserts have been suggested for the face plate (ball striking surface) to provide a more solid impact and better control and feel to the club. US 5 024 437 discloses forged metal inserts of materials such as stainless steel, beryllium, copper, titanium or aluminum. As noted in this document, forged metal is not amenable to casting and is not desirable for use in forming the entire head. However, inserts of a forged metal plate at the strike surface are disclosed as being desirable due to the inherently greater strength of the forged metal relative to a cast metal face plate, and its uniform hardness over the hitting area of the strike face. An improvement to the basic forged metal inserts is disclosed in US 5 261 663. This improvement gives added heel and toe region weighting to the golf club, as well as providing known benefits. The weighting of the forged metal face plate is achieved by increasing the thickness of the plate around the periphery. In yet a further improvement to the basic forged metal insert, US 5 261 664 discloses the casting of a main body member of the golf club head provided with a front opening and with ledges facing forward toward the front opening. These ledges are then available for connecting the forged metal strike face to the front of the main body member. Likewise, the strike face insert has ledges adapted to permit mounting by brazing or welding or otherwise fastening the strike face insert to the ledges of the main body member. In yet another improvement to the basic forged metal strike face insert US 5 255 918 discloses a golf club head construction with a completely enclosed recess at the rear of the strike face and a ledge configuration permitting a trapezoidal weld configuration between the strike face and the main body member. Additionally, the strike face may be a forged metal plate consolidated from a metal powder, such as steel powder. The forged metal plate is disclosed to have a thickness of 1/32 to one inch (0.8 to 25.5 mm). This invention provides a golf club head according to claim 1. The golf club head of the invention has a high resistance to deformation when the club head strikes a ball at speeds of more than 160 km/h (i.e. up to 225 km/h per hour). In a preferred embodiment, the golf club head contains a strike face insert which is a composite laminate of at least one ply of fiber reinforced metal and at least one ply of metal, laminated such that the fibers within the ply are oriented in a direction relative to the neutral axis of the strike face which provides maximum ball striking surface strength and stiffness. The preferred materials for this construction are titanium, and/or aluminum alloy composite, fabricated with a high modulus, high strength fiber such as silicon carbide or boron fiber. Such a composite construction provides a strike face characterized by up to a 20 percent increase in stiffness and up to a 30 percent decrease in weight of the strike face, relative to an equivalent strike face including an equivalent metal without fiber reinforcement. This provides a lighter strike face which allows additional perimeter weighting, additional control of the center of gravity, a lighter head and an improved feel and/or more desirable sonic characteristics. Brief Description of the Drawings Fig. 1 is a side elevational view of a metal wood golf club head constructed with a fiber reinforced metal strike face insert according to the invention; Fig. 2 is a bottom plan view of the metal wood shown in Fig. 1; Fig. 3 is an elevation showing an iron golf club head incorporating the fiber reinforced metal strike face insert of the invention; Fig. 4 is a cross section view taken on lines 5a - 5b of Fig. 3; Fig. 5 is a cross section view of a representative composite laminate used to construct the strike face inserts of the invention. Referring to Figs. 1 - 2, the embodiment illustrated is a metal wood driver having a main body member 1 formed by casting from a metal such as stainless steel, aluminum, titanium, copper or other ductile materials, preferably metals or metal alloys. A strike face insert 2 as described herein, is fabricated as a fiber reinforced metal composite and abutted against the front surface of the main body member casting and joined to the casting, preferably by brazing or welding, especially laser-welding, along the joints 3. The joints 3 run along the perimeter of the strike face insert 2 and a front opening of the main body member 1, thereby permitting integration of the strike face insert 2 with the main body member 1. The main body member 1 has a recess portion 4 into which the periphery of the strike face insert 2 is fitted and joined. The joint 3 is generally trapezoidal or ellipsoidal in shape with an elongated top and bottom and a curved surface, the top curved surface being upward convex and the bottom curved surface being downward convex. In Figs. 3, 4 an iron golf club head of the invention is illustrated. In Fig. 3, a main body member 5 is made of, for example, stainless steel, aluminum, cast iron or brass and has a substantially triangular transverse cross sectional profile so that its ball striking face 6 has a prescribed loft angle. As shown in Fig. 4, the sole face 7 is thicker than the top 8 of the head. The strike face insert 9 comprising a fiber'reinforced metal composite is inserted on the ball-striking face 6 of the iron. The insert 9 is secured to the ball-striking face 6 by brazing, welding or by some other fastening means such that a part or the entire interior surface 10 of the strike face insert 9 is fastened to the interior surface 11 of the main body 5. Fig 5 is a cross sectional view of a representative composite laminate strike face insert 2,9 of the invention. A metallic striking layer 13 is approximately 0.13 to 1.0 mm in thickness and is laminated to a fiber reinforced metal layer 15a which is approximately 0.13 to 1.0 mm in thickness. This fiber reinforced metal layer 15a is laminated to a metal layer 16 of approximately 0.13 to 1.0 mm in thickness, and this metal layer 16 is laminated to a second fiber reinforced metal layer 15b which is laminated to a third metal layer 14 which is about 0.13 to 1.0 mm in thickness. In a preferred embodiment, a silicon carbide fiber-reinforced titanium composite laminate serves as the club strike or hitting face of metal wood or iron golf clubs. A titanium composite laminate insert provides increased strength and stiffness at lower material densities. The high strength and light weight of the titanium composite laminate insert further allows redistribution of existing club head weight to selective perimeter and sole plate locations, thereby permitting alteration of the club head center of gravity. The titanium composite laminate insert 2,8 preferably consists of a combination of monolithic titanium in sheets, foil or powder tape (with a fugitive binder) and planar arrays of high strength, high modulus monofilaments 17 in a laminated layup. The absence of the fiber along the strike face surface permits the machining of the strike face grooves 12. Continuous fiber lengths are preferred in these composites. In a preferred embodiment the fiber reinforced layers 15a, 15b are as near the strike face surface 6 of the insert 2,9 as possible, and as far from the center-line of the long distance of the insert as possible. The metal wood insert preferably has a compound curvature design from toe to heel (known as bulge), and from top to bottom (known as roll). Any of the fiber/matrix preform methods currently used or known for titanium composite laminates are technically feasible for insert applications. For cost considerations, a titanium powder/silicon carbide monofilament preform is preferably produced by creating a parallel array of fibers and then introducing a slurry of titanium or titanium alloy powders and an appropriate fugitive binder system. Once the fiber/matrix preform has been produced, it is consolidated to monolithic titanium material by a thermal and pressure offgas densification cycle. The preferred fabrication method to achieve this consolidation involves stacking several large area laminate layups in a vacuum hot press and applying appropriate heat and pressure to achieve 100 % composite density (e.g., 500 to 2,000 °C at 100 to 10,000 psi for 5 min to 10 h). Individual club face inserts may be abrasive waterjet machined, stamped, or cut from the larger composite panels, and, optionally, have grooves machined or embossed into one face, followed by a brief forming operation (e.g., cold die pressure) to achieve the desired curvature for metal wood applications. Where silicon fibers are used, forging is undesirable due to the fiber interface degradation which can occur at the high temperatures needed in this operation. Preferred construction of the insert involves lamination of two to four layers 15 of fiber/titanium preforms placed between a top and bottom titanium sheet 13, 14. The titanium sheet layers 13, 14 are of a minimum thickness sufficient to form the insert without damage to the silicon carbide monofilaments 17 or the fiber matrix interface 18. The insert is preferably attached to a shelf within the main body member 1,5 of the club head by welding, adhesive (epoxy) bonding, or brazing (e.g., vacuum brazing), but it may be secured by any means known in the art. Specific enhancements observed for this fiber reinforced titanium composite insert include a 15 to 10 % increase in club face stiffness and a 20 to 30 % weight savings in the hitting surface, which can be redistributed to alter the center of inertial moment thereby increasing the desired hitting zone (i.e., a larger "sweet spot" can be achieved), relative to cast or forged metal strike face construction. Also suitable for use herein are other metals and combinations of metals, and other high strength and/or high modulus fibers. Lighter metals, such as aluminum and its alloys, magnesium and its alloys and beryllium and its alloys, are preferred. Fibers of boron, carbon, graphite and various ceramics having a modulus of at least about 30 Mpsi are preferred. Fiber combinations may also be used. In a preferred embodiment, the exterior surfaces of the insert are two plies of titanium sheets. These sheets are laminated to an inner construction of an aluminum sheet face on each side with an aluminum/silicon carbide fiber composite preform. This construction is consolidated to a monolithic composite in a vacuum hot press. Other methods of composite fabrication, including molding of individual inserts, may be used, provided the fabrication method does not comprise fiber strength or composite integrity. Thin foils of dissimilar metal (e.g., aluminum foil for titanium sheets and preforms) or similar metal may be employed in the lay-up of the preform to enhance bonding during consolidation of the composite. A fiber orientation suitable for providing a maximum strike face strength and stiffness is preferred and may be selected by the practitioner. In a silicon carbide fiber reinforced metal for woods, an orientation of 90° from the length direction (toe to heel) of the strike face is most preferred. A parallel or a crosswise orientation of 45° to 135° from the length direction of the strike face is also preferred. In the fabrication of the composite the fiber is preferably located as close as possible to the strike face insert surfaces and as far away as possible from the center line (or neutral axis) of the club head (running in the length direction of the insert). This fiber positioning maximizes strike face stiffness (modulus) and optimizes golf club performance. Multiple plies of fiber preforms and metal may be used. For cost and weight reasons, two and four ply fiber preform/metal sheet are preferred, however, strength and stiffness generally improve as the number of laminated plies increases. In addition, a single ply of composite may be attached to the back face of the insert, providing that a low temperature bonding or brazing process is utilized in joining the fiber composite to the insert. Example 1 A laminated composite of titanium metal and a silicon carbide fiber reinforced titanium was prepared by layering: (a) 0.9 mm thick titanium foil (Ti-6-4), (b) four plies of 0.25 mm thick tape preform of a single layer parallel array of silicon carbide fibers 17 in a preform tape of titanium powder; and (c) 0.9 mm thick titanium (Ti-6-4). The laminated preform was consolidated in a vacuum hot press to give a composite. Strike face inserts were machined with an abrasive waterjet from the composite panel. Grooves (0.5 mm, the maximum USGA striking face groove depth) were machined into the surface. Individual inserts were curved with a cold die and pressure to achieve the desired toe to heel and top to bottom curvature. A strike face insert, measuring about 64 mm in the length direction, and about 38 mm from top to bottom and 2.8 mm thick, was tested for surface deformation. For testing, the insert was screw-mounted onto a contoured shelf which was machined into the face of a test fixture fabricated from mild steel. The test fixture was made in the general shape of a golf club head for a wood (driver). The test fixture head was attached to a golf club shaft mounted in a holder positioned such that golf balls shot by an air cannon at the strike face insert would hit the insert at controlled speeds. A depth gauge was used to measure surface deformation at 6 fixed locations on the insert surface before and after testing with golf balls striking at a speed of about 225 km/h. A comparative test was run on the same insert having a thickness of only 2.7 mm. Results are shown in Table I below, 1 Inch = 2,54 cm. Deformation Depth (inches) 0.110 Inch Insert 0.105 Inch Insert Number of Golf Ball Strikes 0 50 100 150 0 25 50 Location of Gauge Measurement: 1 (toe) .148 .148 .149 .150 .320 .320 .300 2 (top) .168 .167 .170 .170 .680 .660 .650 3 (heel) .130 .131 .135 .135 .004 .004 .008 4 (bottom) .172 .171 .175 .174 .670 .660 .660 5 (center) .174 .171 .175 .174 .720 .660 .660 6 (center) .173 .170 .173 .173 These results show the inserts are suitable for use in golf club heads. The resistance to deformation from golf ball strikes at 225 km/h was excellent for a 2.8 mm thick insert comprising a fiber reinforced metal composite. Similar resistance to deformation performance was obtained with fiber reinforced inserts having thicknesses of 3.1 and 2.9 mm. This is an improvement over non-reinforced metal strike inserts of the art which must be used at a greater thickness and a higher weight to achieve the same performance. Results also demonstrate that a thickness in excess of 2.7 mm is preferred for a titanium/silicon carbide fiber strike face insert mounted in a wood-type club. Example 2 Strike face inserts were prepared as described in Example 1, except that various lay-ups were prepared, and the inserts were tested in iron clubs so that no curvature was made in the inserts. The lay-ups prepared included: (a) 2 plies, each, of fiber reinforced titanium tape cast preform and of titanium foil (Ti-6-4) to yield a 3.1 mm thick insert; (b) the same as (a) except the insert was 2.8 mm thick; and (c) the same as (a) except the insert was 2.5 mm thick. The neutral axis of each insert was free of fiber reinforcement and comprised only titanium. Each insert was tested in an iron club and performed as good as, or better than, monolithic iron clubs. Example 3 A driver golf club was assembled from an insert (2.5 mm thick) fabricated as in Example 1. The insert was welded onto a 0.25 to 0.13 mm deep shelf in the face of the cast metal main body member of the driver head. The insert was fitted to the shape of the shelf to provide a continuous joint between the main body member of the driver and the strike face insert. The assembly performed well in the air cannon apparatus when struck with golf balls shot at 225 km/h.

Claims: Golf club head comprising a metal body (1, 5) and an insert plate (2, 9) secured in the forward striking surface of said metal body and made of a fiber reinforced metal laminated with an outer metal layer (13) formed with back spin grooves, characterized in that said insert plate (2, 9) is a monolithic laminated fiber reinforced metal composite composed of the outer metal layer (13), of a fiber reinforced metal layer (15a) adjoining said outer metal layer (13) and of one further metal layer (16) adjoining said fiber reinforced metal layer (15a), wherein the fiber reinforced metal layer (15) is displaced from the neutral axis of the insert plate (2, 9) and comprises at least one ply (18) of reinforcing fibers (17) in parallel orientation within the metal matrix (18). Golf club head according to claim 1, characterized in that the insert (2; 9) further comprises a central metal layer (16) laminated to a second fiber reinforced metal layer to interface with a further backward metal layer (14), (15b) to interface with a further backward metal layer (14). Golf club head according to claim 1 or 2, characerized in that the metal layers (13, 14, 16) are constructed of a metal selected from the group of Titanium and its alloys, Aluminum and its alloys, Magnesium and its alloys, and Beryllium and its alloys. Golf club head according to one of the claims 1 to 3, characterized in that the enforcing fibers (17) are selected from the group consisting of Boron, Carbon, graphite and ceramic fibers having a modulus of at least 30 Mpsi. Golf club head according to one of the claims 1 to 4, characterized in that the metal matrix (18) of the fiber reinforced layers (15a, 15b) is constructed of a metal selected from the group of Titanium and its alloys, Aluminum and its alloys, Magnesium and its alloys, and Beryllium and its alloys. Golf club head according to one of the claims 1 to 5, characterized in that the parallel enforcing fibers (17) extend transverse to the length direction of the golf club head. Golf club head according to claims 2, characterized in that the outer layers (13, 14) are constructed of Titanium or Titanium alloy, the fiber reinforced layers (15a, 15b) consist of silicon carbide fibers (17) within an Aluminum or Aluminum alloy matrix (18), and the core layer (16) is constructed of Aluminum or Aluminum alloy. Golf club head according to one or more of the preceding claims 1 to 7, characterized in that the thickness of the insert (2; 9) is more than 2.5 mm.

Inventors: BUCK MICHAEL EUGENE, KRAUS STEPHEN ANTHONY, SHAHOOD THOMAS WILLIAM, BUCK, MICHAEL EUGENE, KRAUS, STEPHEN ANTHONY, SHAHOOD, THOMAS WILLIAM
Applicants: TEXTRON SYSTEMS CORP TSC, TEXTRON SYSTEMS CORPORATION (TSC)
Application year: 1996
Main classification: A63B53
IPC codes: A63B53, C22C47, B32B15