Abstract:
A golf club head in accordance with various aspects of the present invention, may have a higher volume and/or higher strength. The golf club head may also comprise a variously configured and/or detachable face, allowing various faces of differing materials to be attached to the body. A detachable face further allows the head to be tuned via placement/rearrangement of weights within the head to change the center of gravity and moment of inertia.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a Continuation-In-Part application which claims priority to U.S. Continuation patent application Ser. No. 11/969,693 entitled “Multi-Material Golf Club Head,” filed Jan. 4, 2008, which claims priority to U.S. Non-Provisional patent application Ser. No. 10/712,401 entitled “Multi-Material Golf Club Head,” filed Nov. 12, 2003, which claims priority to U.S. Provisional Patent Application Ser. No. 60/425,244 entitled “Multi-Material Hybrid Golf Club Head Design/Construction,” filed Nov. 12, 2002, which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to golf club heads having faces of various configurations and various mechanisms for changing golf club head characteristics. 
       BACKGROUND OF THE INVENTION 
       [0003]    Current high-performance golf club heads are often manufactured from various metal and/or graphite structures and combinations of these and other materials. In attempts to maintain low weight, while having large volumes, in the case of drivers (commonly referred to as “woods”), the heads are often made of materials such titanium, steel or graphite composites. 
         [0004]    Many performance characteristics are desirable in the case of driver heads, including size, strength, mass distribution/inertia properties and the sounds they make. For example, generally, as the size of the heads increases (many approaching 500 cc), the heads tend to be more “forgiving” for off-center hits. 
         [0005]    Further still, more and more, golfers seek club heads with specific centers of gravity locations and moments of inertia to control drive characteristics. Further yet, golfers increasingly seek to change certain objective and subjective characteristics such as contact time between the face of the club and the ball and the sound and/or acoustic profile made upon impact between the club head and the ball. For example, some golfers prefer the hollow “ping” sound of a titanium driver, while others prefer the “dead” or solid sound of a composite head (more like a traditional wood driver). 
         [0006]    Club designers attempt to use these various performance attributes to tune or enhance certain characteristics of club performance. However, conventional metal design/construction methods are limited by basic properties (e.g., stiffness, strength and density) of the materials used as well as by manufacturing limitations (e.g., casting, welding and forming). 
         [0007]    Thus, while the above-mentioned attributes are sought, many remain unrealized. Improved heads which can vary stiffness and strength areas redistribute total weight allowing control of the location of center of gravity and moment of inertia and/or are made of lighter and stronger materials, allowing bigger club heads with correspondingly larger “sweet” spots. Further still, clubs which provide “tunable” centers of gravity and moments of inertia are also desirable. Additionally, faces may be made more flexible (“hotter”) or less flexible (“colder”) to increase or decrease contact time. Such clubs may be further capable of producing varying impact sounds, and are therefore desirable. 
       SUMMARY OF THE INVENTION 
       [0008]    While the way that the present invention addresses the disadvantages of the prior art is discussed in greater detail below, in general, the present invention provides an improved golf club head. For example, a golf club head in accordance with various aspects of the present invention, may be manufactured with an ability to add additional weight to specific locations on the clubs, thereby allowing the weight, center of gravity, and moment of inertia to be controlled/adjusted. 
         [0009]    In some embodiments, the golf club head also may have a detachable face, allowing various faces of differing materials and configurations to be attached to one body and/or providing access to an interior of the golf club head. A detachable face further allows the head to be tuned via addition/placement/rearrangement of weights within the head to change the center of gravity and moment of inertia as well as sound. In various embodiments, weights within the golf club head may also be positioned via mechanisms on internal and/or external surfaces of the golf club head at least partially eliminating the need to “open” the golf club head (e.g., via the detachable face). Further yet, by tuning the weight and the face, the sound and/or acoustic profile of the golf club head (e.g., when striking a golf ball) may likewise be changed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the Figures, where like reference numbers refer to similar elements throughout the Figures, and: 
           [0011]      FIG. 1  is a perspective view of a body structure of a golf club head in accordance with the present invention; 
           [0012]      FIG. 2  is a perspective view of a faceplate in accordance with the present invention; 
           [0013]      FIG. 3  is a perspective view of another faceplate in accordance with the present invention; 
           [0014]      FIG. 4  is a perspective view of another faceplate in accordance with the present invention; 
           [0015]      FIG. 5  is a perspective view of another faceplate in accordance with the present invention; 
           [0016]      FIG. 6  is a cross-sectional view of a faceplate attached to a club structure in accordance with an embodiment of the present invention; 
           [0017]      FIG. 7  is a cross-sectional view of a faceplate attached to a club structure in accordance with another embodiment of the present invention; 
           [0018]      FIG. 8  is a cross-sectional view of a faceplate attached to a club structure in accordance with another embodiment of the present invention; 
           [0019]      FIG. 9  is a plan view of a club structure with a damping material in accordance with an embodiment of the present invention; and 
           [0020]      FIG. 10  is a plan view of a club structure with a damping material in accordance with another embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The following description is of exemplary embodiments of the invention only, and is not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments of the invention. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the invention as set forth herein. For example, though various portions of the specification refer to particular materials used in connection with golf club heads, numerous other materials, now known or as yet unknown, having desirable properties should be considered within the scope of the present invention. 
         [0022]    Additionally, briefly, each and every process for manufacturing hollow items from various materials is not explained herein, however, one skilled in the relevant art will appreciate that various conventional golf club forming techniques may be used in accordance with the present invention. 
         [0023]    That being said, in accordance with various aspects of the present invention and with reference to the exemplary embodiment illustrated in  FIG. 1 , the present invention comprises a golf club head  100  having a body structure and a faceplate  140 . As described in more detail below with respect to various exemplary embodiments, faceplate  140  may be configured from a variety of materials and may have a number of configurations for changing the properties of club head  100 . Additionally, as described further below, club head  100  may be hollow, allowing the variable positioning of tuning weights  200  within club head  100  to suitably adjust performance characteristics (such as the location of the center of gravity and moment of inertia) of club  100  as well as change the sound of club  100  via damping the structural elements of club  100 . 
         [0024]    In accordance the present invention with to  FIG. 1 , faceplate  140  is a surface which is intended to make contact with the golf ball during use, transferring energy of the swing to the ball. Faceplate  140  comprises any of numerous materials, such as steel or titanium, but may comprise many other materials, now known or as yet unknown, depending on desirable properties, such as the desired weight and flexure properties. 
         [0025]    As noted above, faceplate  140  may also have a various shapes and configurations. For example, with reference to  FIG. 2 , faceplate  140  may have a generally uniform thickness. Alternatively, faceplate  140  may be thinner on an inside, center portion of faceplate  140 . For example, as illustrated in  FIG. 3 , faceplate  140  may have a “depressed” area  142  on the inside surface of faceplate  140 . The depressed areas  142  leaves faceplate  140  having a gradually thinner cross section towards the bottom of the depression. Because faceplate  140  becomes thinner, it is possible to design faceplate  140  to have more flexure, and thereby increase contact time with a golf ball. Similarly, spring characteristics of faceplate  140  may be changed based on the thickness(es) used. 
         [0026]    Additionally, in various embodiments, the depressed area may contain a filler material  144  which is added to the inside surface to fill out faceplate  140 . Filler material  144  may generally be any material such as composites, epoxies, elastomers, or the like, and are generally dictated by desired properties, such as to change the acoustic profile of club head  100  or to reduce or otherwise change flexure properties. 
         [0027]    Various other configurations of faceplate  140  may have varying cross-sections on an inside, center portion. For example, as illustrated in  FIG. 4 , faceplate  140  comprises an “undulating” cross-section. Stated otherwise, faceplate  140  has one or more depressed areas  142  on the inside surface of faceplate  140 , but also has at least one higher area  146 , for example, generally centrally located within depressed area  142 . Again, as described above, this embodiment may also have filler material  144  in depressed area  142 , and may also cover higher area  146 . 
         [0028]    In another embodiment, faceplate  140  comprises a progressively stepped down depressed area. For example, with reference to  FIG. 5 , depressed area comprises a series of steps  142   a ,  142   b ,  142   c , etc. culminating in a thinnest thickness of faceplate  140  at a bottom of the depression. As with the embodiments described above, a filler material may be added to the depression. Likewise, stepped depression  142   a ,  142   b ,  142   c , etc. may undulate, that is, they may step down and then up again, similar to the embodiment illustrated in  FIG. 4 . 
         [0029]    In general, one skilled in the art will appreciate that, in accordance with the present invention, faceplate  140  may be configured in many ways from many materials and thus, particularly in embodiments where faceplate  140  is releasably attachable, allow for “tuning” the properties of club head  100  by virtue of selecting different faceplates  140 . 
         [0030]    In this regard, in accordance with various non-limiting embodiments of the present invention, faceplate  140  may be suitably detachable from body structure  110 . For example, referring back to  FIG. 1 , in one embodiment, body frame structure  122  comprises a faceplate aperture  128  having a perimeter  142  substantially contiguous with the perimeter of faceplate  140 . Thus, when faceplate  140  is attached to body structure  110 , faceplate  140  and body structure  110  integrate substantially seamlessly. 
         [0031]    Additionally, in accordance with various alternative aspects of the present invention, body structure  110  may be permanently bonded with faceplate  140  through a now known or as yet unknown welding processes, and preferably, using a coolant system and/or heat sinks such as a thermal putty (e.g., Bloc-It® available from LA-CO Industries, Inc./Markal Company) or other coolant system such as welding in a liquid bath (e.g., oil, water or the like). 
         [0032]    As mentioned above, in various embodiments of the present invention, body structure  110  further comprises mechanisms for facilitating releasable attachment of faceplate  140  to body structure  110 . For example, with reference back to  FIG. 1 , body structure  110  may comprise a faceplate receiving ridge  144  upon which faceplate  140  is retained. In such embodiments, receiving ridge suitably comprises a recessed “lip” or series of “tabs” (not shown) which prevents faceplate  140  from passing completely within body structure  110 , and, moreover may suitably assist in maintaining a striking surface  146  of faceplate  140  contiguous with an outer surface of body structure  110 . Moreover, in embodiments using a releasably attachable faceplate  140 , no thermal protection is needed as no welding is required. 
         [0033]    In still further embodiments, receiving ridge  144  further facilitates attachment of faceplate  140  to body structure  110 . For example, receiving ridge  144  may further comprise mounting mechanisms for attaching and detaching faceplate  140 . For example, mounting mechanisms may comprise body holes  148  in body structure  110 , faceplate holes  150  in faceplate  140 , and screw  149  combinations or other similar fastening devices connect faceplate  140  to body structure  110  via corresponding faceplate holes  150 . 
         [0034]    In accordance with various alternative embodiments, any number of other configurations for facilitating releasable attachment of faceplate  140  to body structure  110  may be used. For example, with reference now to  FIG. 6 , body structure  110  again comprises faceplate receiving ridge  144  upon which faceplate  140  is retained by one or more body holes  148 , faceplate holes  150  and screw  149  combinations. Optionally, various washers (not shown) may likewise be employed. In various embodiments body holes  148  and faceplate holes  150  may be configured in club head  100  (e.g., body structure  110  and/or faceplate holes  150 ) by any conventional or unconventional means, such as during casting and/or subsequent machining or EDM. 
         [0035]    In still another embodiment, faceplate  140  may be attached by a laterally extending screw  151 . In this regard, a screw  151  extends from one side of club structure  110 , into the inner volume of club head  100 , and attaches to faceplate  140 . In various embodiments, screw  151  may enter from various sides of club structure  110 , though in an exemplary embodiment such as illustrated in  FIG. 7 , screw  151  enters through the back of club head  100 . Optionally, a built-up area  152  on club structure  110 , which may or may not be threaded, may likewise included for purposes of reinforcement, screw/fastener guidance and/or to adjust the center of gravity of club head  100 . In this embodiment, screw  151  attaches to a rear side of faceplate  140 , for example, by threads, press fit, adhesive, or other attachment mechanism. Similar to built-up area  152 , faceplate  140  may optionally comprise another built-up area  153 , for similar purposes of reinforcement, screw/fastener guidance and/or to adjust the center of gravity of club head  100 . 
         [0036]    In yet another embodiment such as illustrated in  FIG. 8 , faceplate  140  may be attached to club structure  110  via a key mechanism  160 . Key mechanism  160  suitably allows a tool to interact with an engagement portion  161 , for example, through a key hole  162 , allowing one more engagement bolts  163  to be retracted or extended into body structure  110 , for securing faceplate  140  to body structure  110 . For example, in the illustrated embodiment, faceplate  140  is located in faceplate aperture  128 , and by inserting the noted tool (e.g., a key), and rotating, engagement bolts  163  extend into engagement slots  164  in club structure  110 , securing or releasing faceplate  140  from club head  100 . 
         [0037]    Though not illustrated, one skilled in the art will appreciate that any number of screw combinations similar to that illustrated in  FIGS. 6 ,  7 ,  8  and others may be used in accordance with the present invention. Likewise, the various embodiments described herein may be used in various combinations. 
         [0038]    In various exemplary embodiments, tuning, damping or “intermittent” materials may be located on various portions of club head  100  to impart or change various characteristics of club head  100 . Damping materials may be any material which changes the damping properties of club head  100 . For example, various elastomers, rubbers, plastics, and the like may be used. Such materials absorb energy and damp vibration, which can effect club feel, sound, and performance. Alternatively, more rigid materials may be used as the “intermittent” material. For example, metals or ceramics may be used to effect club feel, sound, and performance. 
         [0039]    Still further, various visco-elastic materials may be used as tuning inserts in connection with the present invention such as damping or “intermittent” materials. Visco-elastic materials are generally those materials characterized by having both elastic and viscous behaviors. For example, elastic materials store and release all or nearly all of the energy during loading, while a viscous material is opposite of elastic materials and returns little or no energy from the loading. 
         [0040]    Tuning inserts in the form of damping materials discussed herein may be situated between club structure  110  and faceplate  140 . In one embodiment, for example as illustrated in  FIG. 9 , damping materials are a series of individual damping pieces  145 , for example, located on receiving ridge  144 . Alternatively, damping material may be a single unitary washer-like structure  145  such as illustrated in  FIG. 10 . 
         [0041]    Additionally, as noted above, club heads  100  in accordance with the present invention, allow inertia properties can be improved, positively impacting performance by repositioning weight inside the head body to alter the location of center of gravity and/or inertia values to help improve trajectory (CG) or forgiveness on off-center hits (inertia properties) or it can be allocated to an adjustable secondary center of gravity/sound type tuning insert(s)/mechanism(s). 
         [0042]    For example, tuning inserts in the form of tuning weights  200  can be positioned within club  100  to change such characteristics. For example, experienced golfers may wish to move the center of gravity of club  100  higher up the club, and more toward the crown of the club to reduce backspin, while less experienced golfers may prefer the opposite. Tuning weights may be positioned within club head  200  in any number of manners now known or as yet unknown, preferably using access through faceplate aperture  128 . 
         [0043]    For example, with reference to  FIG. 1 , a weight retaining stud  132  is illustrated. It should be appreciated that numerous weight retaining studs may be placed in various locations in club head  100 , providing the ability to not only adjust gross weight, bust also center of gravity location and moment of inertia. For purposes of illustration, however, only one stud  132  is shown. Weight retaining stud  132  is configured to allow a weight  134  to be attached. For example, in the presently described embodiment, weight  134  is a rubber, “washer-like” piece weighing approximately 30 g which is attached to stud  132  with a typical machine screw, bringing the total weight of club head  100  to the “ideal” weight of about 200 g, with a center of gravity in a desired location and/or a desired moment of inertia. 
         [0044]    Further still the use of weights and/or damping materials attached to club head  100  suitably provides sound changing effects. For example, a weight attached to club head  100  may suitably provided a more “solid” sound when club head  100  strikes the ball, giving the impression club head  100  is not substantially hollow. Additionally, other materials may be added to the interior of club head  100  to achieve similar sound changing results. For example, club head  100  may contain some filler material such as fiberglass, silicone, rubber or other materials. 
         [0045]    Thus, in addition to the tangible “objective” benefits of this new design/construction golf head (such as improved inertia/CG properties/magnification capabilities), several more “subjective” benefits exist as well. In addition to the ability to tune the sound characteristics by changing the type/location of materials and/or dampers, the aesthetic elements can also now be optimized. 
         [0046]    Finally, it should be appreciated that the present invention has been described above with reference to various exemplary embodiments. However, many changes, combinations and modifications may be made to the exemplary embodiments without departing from the scope of the present invention. For example, the various components may be implemented in alternate ways. These alternatives can be suitably selected depending upon the particular application or in consideration of any number of factors associated with the operation of the system. In addition, the techniques described herein may be extended or modified for use with other types of devices. These and other changes or modifications are intended to be included within the scope of the present invention.