US20130178306A1 - Golf club head with separable component - Google Patents

Abstract

The present invention relates to a golf club, and more particularly to a wood-type club head with a separable body component. In certain aspects, the invention provides a golf club head with a face and hosel body member and one or more of an interchangeable aft body member. The invention further provides a variety of insights and mechanisms for coupling the interchangeable member to the body member.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a continuation-in-part of U.S. patent application Ser. No. 13/185,324, filed Jul. 18, 2011, which is a Continuation of U.S. patent application Ser. No. 12/696,468, filed Jan. 29, 2010, which is a continuation of U.S. patent application Ser. No. 11/110,733, filed Apr. 21, 2005, the contents of which are herein incorporated by reference in their entirety. This application is also a continuation-in-part of U.S. patent application Ser. No. 13/539,958, filed Jul. 2, 2012, which claims priority to U.S. Provisional patent application Ser. No. 61/503,509, filed Jul. 29, 2011, the contents of which are herein incorporated by reference in their entirety. This application also is a continuation-in-part of U.S. patent application Ser. No. 13/407,087, filed Feb. 28, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 12/643,154, filed Dec. 21, 2009, the contents of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
• The present invention relates to a golf club, and more particularly to a wood-type club head with separable components.
BACKGROUND
• Historically, an engineer will design a golf club in way that seeks to optimize multiple properties of the finished club. The engineer will chose a shape and size for a club head based on aerodynamics, PGA rules, manufacturing capabilities, and consumer preferences. Within a club head, the engineer will design a mass distribution that provides an acceptable overall compromise of moment of inertia, center of gravity, and weight for the variety of customers who may purchase the club. Once the structure of the club head is designed, it will be finished with colors, surface treatments, logos, and trim in hopes that wide range of people will find the club head attractive. Sometimes a golf company will offer a club in two or a few different finishes and trim levels, in hopes of appealing to more golfers.
• Because a number of properties of a club head are influenced by mass distribution and materials, designing a golf club has traditionally been a one-size-fits-all exercise. While some clubs are offered with adjustable weight members or shafts, many properties such as mass distribution, color, aerodynamics, and turf interaction reflect a lowest-common-denominator design paradigm. To offer consumers variety in these properties, golf companies generally must design an entirely new club.
SUMMARY
• The invention provides a club head with interchangeable components or body members. Components of the invention can be interchanged manually or through the use of tools. In some embodiments, components may be assembled without the use of adhesives, screws, and/or welding. Providing club heads with interchangeable components allows a golf company to provide personalized clubs. Each club can be made to appeal to an individual golfer, and the qualities of the club can rise to meet the individual golfer's highest standards, rather than reflecting the lowest-common-denominator found in integrally formed, mass-produced club heads.
• Further, the invention includes the insight that the hosel and a fore portion of the ball-striking area embody core structural functionality and are well-suited to being provided as a body component to be coupled to interchangeable aft body components. Further, by extending the fore body component or face body component rearwards in the sole area, the aft body components can be provided with light-weight materials such as plastics or composites yielding a desirable distribution of strength and mass within a club head. The connection between the hosel and the ball-striking area is strong, and mass is distributed to lower a center of gravity, optimize a moment of inertia, or both.
• Further, the invention adopts the insight that modern club heads may benefit from releasable functional components, such as weight elements or face-angle adjusters on a sole, and that these components offer an unexpected benefit in terms of a fastening mechanism for releasable/interchangeable aft bodies and similar components. Similarly, the invention provides the insight that mechanisms associated with interchangeable and repositionable shafts can be developed to provide a fastening mechanism for an interchangeable component.
• In certain aspects, the invention provides a golf club head with a first body member and a second body member interchangeably coupleable to the first body member at an attachment perimeter to create a playable club. The invention further provides a variety of insights and mechanisms for coupling the interchangeable member to the body member. For example, a first body member can include a boss for receiving a releasable shaft and the second body member can include a portion, such as an extended tab with a shaft screw bore, that is adapted so that the second body member is fastened in place by fastening the shaft to the first body member. In some embodiments, the first and second bodies are coupled by mating a plurality of posts on one of the two bodies with a plurality of corresponding holes on the other of the two bodies.
• In some embodiments, the second body member is coupled to the first through the use of a functional component that releasably couples to the club head. The functional component can be, for example, a weight screw with a threaded post dimensioned to pass through a hole in the second body member and be screwed into a threaded hole in the first body member.
• A strong club head is provided with good sound characteristics and a good coefficient of restitution by optimizing the distribution of material between the components. For example, in certain embodiments, the second body member is an aft body member with a majority of a crown of the club head, a majority of a heel-side skirt of the club head, and a majority of a toe-side skirt of the club head. In such embodiments, the aft body couples to the main body to provide a driver. The main body member includes a face cup, a hosel, and a majority of a sole of the club head.
• An aft body member can connect to, and separate from, a fore body member at an attachment perimeter that circumscribes the club head. For example, the attachment perimeter can define a “clean break”—i.e., the attachment perimeter can lie substantially within a plane. In some embodiments, the attachment perimeter lies substantially with a plane that is substantially vertical when the club is at address, such that the aft body pulls cleanly away from the fore body.
• Further, the invention provides attachment lines, or seams, that need not be straight. The invention includes the insight that non-straight coupling edges exhibit functional benefits not expected to be found in straight coupling edges. For example, attachment along a wavy edge ensures that two components come together in a proper orientation and gives a user a visual clue as to which components will fit together.
• In related aspects, the invention provides a fore body member comprising a hosel, a portion of a sole, and at least a portion of a ball-striking face and one or more interchangeable aft body members releasably couplable to the fore body member by a mechanism. The mechanism can include a snap-fit mechanism, such as a cantilever with a protruding tip and a corresponding a recess to receive the protruding tip. In certain embodiments, the mechanism includes barbed posts, adhesives, slots with corresponding press-fit tabs, magnets, or other suitable mechanisms. In some embodiments, the invention provides a cam-based mechanism for coupling the aft body to the fore body.
• A cam can provide the leverage needed so that a golfer can manually create a powerful press-fit between two components. In some embodiments, operation of a cam causes engagement hooks to engage with a receiving portion to fasten the aft body member to the fore body member. A cam can include a tool engagement surface or can be adapted to be fully manually operated.
• In another aspect, the invention provides a kit for assembling a golf club head. The kit includes a fore body having a hosel, part of a ball-striking face, and an attachment mechanism. The kit further includes multiple aft bodies that can be interchanged.
• Another aspect of at least one of the embodiments described herein includes the realization that it would be advantageous to have a club head with a removable insert panels that include materials of different weights and densities so that different panels can be interchanged to distribute mass differently. This allows weight to be distributed within a club head according to a golfer's individual desires.
• In certain aspects, the invention provides a club head in which a body member has an opening for a crown insert and an attachment feature (such as a flange) with a crown insert attached there. The crown insert can be a lightweight material (e.g., plastic). In some embodiments, a crown insert is divided by strut-like divider elements, which can modulate the club head physics properties. For example, the dividers may be flexible, non-plastic ribs that divide the crown insert into four plastic sections.
• In some embodiments, a club includes a releasably attached weight member that can be added or interchanged with one another to adjust the club head weight, center of gravity, moment of inertia, or a combination thereof. The weight members may have threaded posts that can be screwed into corresponding threaded holes in the club head.
• In certain aspects, the invention provides a club head having a body with an opening to receive an insert panel. An attachment feature (such as a flange) at the opening presents a surface for attaching the insert panel. The surface may optionally have holes on or through it. The holes can increase surface area and thus increase bonding strength of an adhesive used to attach the insert. Alternatively, the insert may have a plurality of protrusions to extend through the holes for attachment (e.g., posts that exhibit a tight press-fit; barbed posts; threaded posts to receive a nut element; etc.). A gasket may be positioned at the flange to dampen vibration or modulate weight.
• In some embodiments, the insert is attached to the body by a snap-fit assembly, without the use of adhesives or welding. For example, the snap-fit assembly can include cantilevers with protruding tips and a recess corresponding to each tip (e.g., cantilevers on body member and recesses on insert, or vice versa). In some embodiments, the snap-fit assembly includes a collar adapted to be swaged onto a post for attachment and unscrewed with a wrench for removal.
• Different inserts can be provided as a set, or as a variety of individual items to be purchased at a store, thus allowing a golfer to customize their club.
• In certain aspects, the invention provides a large wood-type golf club head with a concave insert. The club head is formed of a plurality of body members that define an interior volume. A first body member is made of an optionally metallic material and includes a sole portion and a face portion. A second body portion is made of a light weight material, such as plastic, composite, or a very thin sheet of low density metallic material. The second body portion makes up at least a portion of the club head skirt, and includes one or more concave indentations that extend into the interior volume of the club head. These indentations provide structural integrity to the second body portions, which may be very thin panels.
• The second body member optionally may also include one or more convex bulges that generally extend away from the interior volume. Inserts, such as weight inserts, may be positioned within the convex bulges. Careful positioning of the weight inserts allows the designer to enhance the playing characteristics of the golf club and tailor the club for a specific swing type. The first body member may form a large portion of the club head sole, and the second body member may form a large portion of the club head crown. This weight positioning further enhances the playing characteristics of the golf club.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 shows a golf club head of the present invention.
• FIG. 2 shows a body member of the golf club head ofFIG. 1.
• FIG. 3 shows a second club head of the present invention.
• FIG. 4 shows a bottom view of the club head ofFIG. 3.
• FIGS. 5A-5C give additional views of the club head shown inFIGS. 3 and 4.
• FIGS. 6A and 6B show a club head with concave component as separable aft body.
• FIG. 7 is a cross-section of the club shown inFIGS. 6A and 6B.
• FIG. 8 is a cutaway view of the club shown inFIGS. 6A and 6B.
• FIG. 9 shows a cutaway view of a club head with separable aft body and cantilevers.
• FIG. 10 is a perspective view of the club head shown inFIG. 9.
• FIGS. 11A and 11B show a club head with separable aft body fastened by weight members.
• FIG. 12 is a cutaway view of the club head shown inFIGS. 11A and 11B.
• FIG. 13 shows the aft body of the club head inFIG. 12.
• FIG. 14 shows a club head with a removable aft sole panel.
• FIG. 15 shows components of the club head shown inFIG. 14.
• FIGS. 16A-16C show a club head with separable aft body.
• FIG. 17 shows a cutaway view of the aft body of the club head inFIGS. 16A-16C.
• FIG. 18 is a bottom perspective view of a golf club head of the invention.
• FIG. 19 is a cross-sectional view, taken along line2-2, of the golf club head ofFIG. 18.
• FIG. 20 is a top view of the club head ofFIG. 18 with a crown portion removed.
• FIG. 21 is a cross-sectional view, taken along line4-4 ofFIG. 20, of the golf club body member ofFIG. 18, with the crown member attached.
• FIG. 22 is a top plan view of a plastic crown insert.
• FIG. 23 is a top plan view of an alternative embodiment of the crown insert ofFIG. 22.
• FIGS. 24 and 25 are embodiments of detail C, shown inFIG. 21.
• FIG. 26 is a partial view of a club head and insert according to an embodiment.
• FIG. 27 shows a club with sole plate.
• FIG. 28 is a bottom view of a club head with detachable sole plate.
• FIG. 29 shows a sole plate according to certain embodiments.
• FIG. 30 is a cross section across the line inFIG. 28.
• FIG. 31 illustrates a detachable sole plate fixed into a place with a weight member.
• FIG. 32 shows a weight member for fixing a sole plate into place.
• FIG. 33 shows a club head configured to receive a sole plate.
• FIG. 34 shows a club head with slotted flange and deformable crown panel.
• FIG. 35 shows a club head with slotted flange.
• FIG. 36 shows insertion of a deformable crown panel into slotted flange.
• FIG. 37 shows a club head with flange with holes.
• FIG. 38 shows a crown panel with barbed posts for insertion into holes in a flange.
• FIG. 39 shows a cross-sectional view of barbed posts and flange with holes.
• FIG. 40 is a side view of a club head and crown panel with barbed posts.
• FIG. 41 shows a club head with button tabs and attachable crown panel.
• FIG. 42 shows the club head and panel inFIG. 41 assembled.
• FIG. 43 shows a club head and sole plate with pre-attached adhesive strips.
• FIG. 44 shows a club head with cage structure and attachable crown panel.
• FIG. 45 is a cross-sectional view of a club head assembled with a rapid fastening system.
• FIG. 46 illustrates a method of rapidly fastening a sole plate to a club head.
• FIG. 47 shows a threaded post for use in a rapid fastening system.
• FIG. 48 shows a barbed post for attachment to a hole.
• FIGS. 49A-49C illustrates a mechanism of a rapid fastening system.
• FIG. 50 shows a hosel/face member and a body member.
• FIG. 51 shows the components ofFIG. 50 assembled with a rapid fastening system.
• FIG. 52 shows a club head with voids and a translucent insert panel.
• FIG. 53 shows an opaque insert panel for a club head with voids.
• FIG. 54 shows a club head assembled with an insert panel.
• FIG. 55 shows a face member and body member with corresponding threaded portions.
• FIG. 56 is a top view of a face member and body member with threaded portions.
• FIG. 57 shows a club head body with closeable strap and crown panel with groove.
• FIG. 58 shows an assembled club head with crown panel strapped to body.
• FIG. 59 is a top view of the club head shown inFIG. 58.
• FIG. 60 shows a club head face member with cantilevered posts.
• FIG. 61 shows a tool for separating a cantilevered attachment point.
• FIG. 62 shows a club head body member with recesses for receiving cantilever tips.
• FIGS. 63-66 show configurations of cantilevered posts and recesses.
• FIGS. 67A-67C show a club head with component with cam mechanism.
• FIG. 68 is a detail view of the cam mechanism ofFIGS. 50A-50C.
• FIG. 69 illustrates radii around a cam axis.
• FIGS. 70A-70D show a club head with cam and engagement hooks.
• FIGS. 71A-71B show an engagement member for engagement hooks.
• FIGS. 72A-72B show a component coupling system.
• FIG. 73 shows a shaft collar for using a coupling system.
• FIGS.74 and75A-75C show a club head with crown component.
• FIG. 76 shows a club head with crown component.
• FIG. 77 shows a snap-fit catch for a component.
• FIG. 78 shows a club head with a flap component.
• FIGS. 79A and 79B show use of a flap component to fasten a club head component.
• FIG. 80 shows a club head with removable sole component with magnets.
• FIG. 81 is a top view of a boss member with magnet therein.
• FIG. 82 is a cross-sectional view of a set of magnet bosses.
• FIG. 83 shows an insert panel.
• FIG. 84 shows a club head body.
• FIG. 85 shows magnets coupling an insert to a club head body.
• FIG. 86 is a perspective view of a golf club head of the present invention.
• FIG. 87 is a cross-sectional view, taken along line2-2, of the golf club head ofFIG. 86.
• FIG. 88 is a perspective view of an embodiment of a body member of the golf club head ofFIG. 86.
• FIG. 89 is a top view of the body member ofFIG. 88.
• FIG. 90 is a top view of a body member included in another embodiment of a golf club head of the present invention.
• FIG. 91 is a cross-sectional view of a golf club head, taken along a plane generally corresponding to line6-6 ofFIG. 90.
• FIG. 92 is a partial cross-sectional view of detail A, shown inFIG. 90.
• FIG. 93 is another partial cross-sectional view of detail A, shown inFIG. 90.
• FIG. 94 is a top view of another embodiment of a golf club head of the present invention.
• FIG. 95 is a cross-sectional view, taken along line10-10, of the golf club head ofFIG. 94.
• FIGS. 96-102 are partial cross-sectional views of alternative embodiments of detail B, shown inFIG. 95.
• FIG. 103 is a side view of a club head according to certain embodiments of the invention.
• FIG. 104 is a cross-sectional view of the club head shown inFIG. 103.
• FIG. 105 is a cross-sectional view of a club head according to certain embodiments of the invention.
• FIG. 106 is a cross-sectional view of a club head according to certain embodiments of the invention.
• FIG. 107 is a detail view of a club head shown inFIG. 95.
• FIG. 108 illustrates a seam according to certain embodiments of the invention.
• FIGS. 109-113 each show a flange according to certain embodiments of the invention.
• FIG. 114 shows the flange ofFIG. 113 with idealized bounding lines.
• FIG. 115A is a side view of a club head according to certain embodiments of the invention.
• FIG. 115B is a cross-sectional view of the club head shown inFIG. 115A.
• FIG. 116 shows a display for receiving option selections.
• FIG. 117 is a block diagram of a method for providing a customized club head or golf club according to certain embodiments.
• FIG. 118 is a block diagram of a system for providing a customized club head or golf club.
DETAILED DESCRIPTION
• Other than in the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials, moments of inertias, center of gravity locations, loft and draft angles, and others in the following portion of the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
• Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
• FIG. 1 shows agolf club head801 of the present invention. Theclub head801 includes abody810 having astrike face811, a sole812, acrown813, askirt814, and ahosel815. Thebody810 defines a hollow,interior volume816. Foam or other material may partially or completely fill theinterior volume816. Weights may optionally be included within theinterior volume816. Theface811 maybe provided with grooves or score lines therein of varying design. Theclub head801 has a toe T and a heel H.
• Theclub head801 is comprised of a plurality of body members that cooperatively define theinterior volume816. In certain embodiments, afirst body member901 includes a sole portion and a face portion (i.e., is a fore body member). The first body member may include acomplete face811 and sole812. Alternatively, either or both theface811 and the sole812 can be inserts coupled to thefirst body member901. Theclub head801 also includes at least onesecond body member902 coupled to thefirst body member901 along theskirt814 in known fashion. Thecrown813 can be unitarily a portion of eitherbody member901,902 or it may be an insert coupled to either of thebody members901,902. Thesecond body member902 includes aconcave portion820 that, when thebody members901,902 are coupled together, extends inward into theinterior volume816.FIG. 2 shows an isolated view of an exemplarysecond body member902.
• Thefirst body member901 preferably is formed of a metallic material such as stainless steel, aluminum, or titanium. The material of thefirst body member901 is chosen such that it can withstand the stresses and strains incurred during a golf swing, including those generated through striking a golf ball or the ground. Theclub head1 can be engineered to create a primary load bearing structure that can repeatedly withstand such forces. Other portions of theclub head801, such as theskirt814, experience a reduced level of stress and strain and advantageously can be replaced with a lighter, weight-efficient secondary material. Lighter weight materials, such as low density metal alloys, plastic, composite, and the like, which have a lower density or equivalent density than the previously mentioned metallic materials, can be used in these areas, beneficially allowing the club head designer to redistribute the “saved” weight or mass to other, more beneficial locations of theclub head801. These portions of theclub head801 can also be made thinner, enhancing the weight savings. Exemplary uses for this redistributed weight include increasing the overall size of theclub head801, expanding the size of the club head “sweet spot,” which is a term that refers to the area of theface811 that results in a desirable golf shot upon striking a golf ball, repositioning theclub head801 center of gravity, and/or produce a greater moment of inertia (MOI). Inertia is a property of matter by which a body remains at rest or in uniform motion unless acted upon by some external force. MOI is a measure of the resistance of a body to angular acceleration about a given axis, and is equal to the sum of the products of each element of mass in the body and the square of the element's distance from the axis. Thus, as the distance from the axis increases, the MOI increases, making the club more forgiving for off-center hits since less energy is lost during impact from club head twisting. Moving or rearranging mass to the club head perimeter enlarges the sweet spot and produces a more forgiving club. Increasing the club head size and moving as much mass as possible to the extreme outermost areas of theclub head801, such as the heel H, the toe T, or the sole812, maximizes the opportunity to enlarge the sweet spot or produce a greater MOI, making the golf club hotter and more forgiving.
• FIG. 2 showssecond body member902, which is preferably light-weight, which gives the opportunity to displace the club head center of gravity downward and to free weight for more beneficial placement elsewhere without increasing the overall weight of theclub head801. When the wall thickness of thesecond body member902 is at the minimum range of the preferred thickness, a reinforcing body layer can be added in the critical areas in case the member shows deformations. These benefits can be further enhanced by making thesecond body member902 thin. To ensure that the structural integrity of theclub head801 is maintained, these thin panels may preferably include aconcave portion820. Inclusion of theseconcave portions820 allow thesecond body member902 to withstand greater stress—both longitudinally and transversely—without sustaining permanent deformation, ensuring the structural integrity of theclub head801 is maintained. In some embodiments, thicknesses for thefirst body member901 include from 0.03 inch to 0.05 inch, while thicknesses for thesecond body member902 include from 0.015 inch to 0.025 inch. Preferably, theconcave portion820 displaces at least 10 cubic centimeters. More preferably, theconcave portion820 displaces at least 25 cubic centimeters. While theclub head801 can be virtually any size, preferably it is a legal club head. A plurality ofconcave portions820 may be used with theclub head801. For example,concave portions820 of uniform or varying size may be positioned in the toe, heel, back, etc.
• FIG. 3 shows a cross-sectional view taken substantially perpendicular to theface811 of asecond club head802 of the present invention. In this illustrative embodiment, theconcave portion820 is positioned at the back of theclub head802.
• FIG. 4 shows a bottom view of theclub head802. Theconcave portion820 preferably is not visible to the golfer at address. In addition to theconcave portion820, thesecond body member902 further includes aconvex bulge822 that extends generally away from theinterior volume816. Aninsert823 may be positioned within the convex bulge.
• In certain embodiments, insert823 is not visible from outside theclub head802. In a preferred embodiment, theinsert823 is a weight insert. The convex nature of thebulge823 allows the weight to be positioned to maximize the mechanical advantage it lends to theclub head802. As shown inFIG. 4, theclub head802 may include a plurality ofconvex bulges822, such as on a heel side and on a toe side of theclub head802. The club designer may placeinserts823 as desired within thebulges822. The masses of the inserts may be substantially equal. Alternatively, one of the inserts may have a greater mass than the other. This may be beneficial to design the club to correct a hook swing or a slice swing. A preferred mass range for theweight insert823 is from 1 gram to 50 grams.
• As shown inFIG. 3, thefirst body member901 may comprise a majority of the sole812 and thesecond body member902 may include a majority of thecrown813. This beneficially removes a large majority of the mass from the upper part of theclub head802. In this embodiment thefirst body member901 includes anattachment perimeter818 that extends around its edge. Thesecond body member902 is coupled to thefirst body member901 along theattachment perimeter818. The first andsecond body members901,902 cooperatively define theinterior volume816. Theattachment perimeter818 preferably may contain a step defining twoattachment surfaces818a,818b. As illustrated, thesecond body member902 maybe coupled to both of thesesurfaces818a,818bto help ensure a strong bond between thebody members901,902.
• While thebody members901,902 may be formed in a variety of manners, some embodiments include forming a complete club head shell (first body member901) in known manner and removing material to create openings to which thesecond body member902 can be coupled. The opening may be created in any desired manner, such as with a laser. Thesecond body member902 may be joined to thefirst body member901 in a variety of manners, such as through bonding or through a snap-fit in conjunction with bonding. If a composite material is used for the concave inserts, molding six plies of 0/90/45/-45/90/0 is preferred.
• FIGS. 5A-5C give several views of the club head shown inFIGS. 3 and 4 to aid in seeing the relation of afore body member901 to an interchangeableaft body902 in certain embodiments. In some embodiments, one of the body members includes a protruding flange around the attachment perimeter such that the club head can be assembled with a press fit by simply pressing the two body members together. In other embodiments, a first and second body member are coupled by a mechanical fastening system.
• FIGS. 6A and 6B show mechanical fastening system adaptable for use in a club head with an interchangeable or repositionable shaft.Fore body member823 includes arecess831 in a heel-sole area where a shaft sleeve screw is inserted to engage an end of a shaft.
• FIG. 7 is a cross-section of the club shown inFIGS. 6A and 6B. The shaft engagement mechanism is primarily provided byfore body member821 and can be seen inFIG. 8.
• FIG. 8 is a cutaway view of the club shown inFIGS. 6A and 6B.Aft body member823 includes aprotruding arm825 with a hole therethrough.Fore body member821 includeshosel boss829 and insert boss827 (i.e., the inside shell of recess831). Whenaft body member823 is mated tofore body member821, the body members come together to form a club head substantially as shown inFIGS. 5A-5C, but withrecess831.Arm825 slips betweenhosel boss829 and insertboss827. When a shaft is attached to the club head, a shaft sleeve screw passes through the bore hole througharm825. In certain embodiments, pressingaft body823 intofore body821 substantially provides an assembled club head in which the two components have a firm attachment to one another via a press-fit attributable to flanges at the attachment perimeter. Assembly of the interchangeable/repositionable shaft provides an additional securing mechanism to fully fasten the club head together with ample strength to withstand high-impact drives.
• A fastening mechanism of the invention can be used alone or in combination with others. As discussed above, a press-fit can cooperate with a shaft fastening mechanism. Further, in some embodiments, a mechanism includes deformable cantilevers for assembly.
• FIG. 9 shows a cutaway view of a club head with separable aft body and cantilevers. Two ofcantilever173 are depicted, but any number is possible. As seen inFIG. 9,aft body843 includes arecess177 in a crown area that does not extend entirely through the body shell (i.e., a depression).Aft body843 also includes arecess177 in a sole area that does extend as a hole through the body shell (i.e., a hole). Any combination of depressions and holes is possible. Whenaft body843 is mated withfore body841, they snap together when protrudingtips176 oncantilevers173 engage withrecesses177.
• FIG. 10 is a perspective view of an assembled club head includingaft body843 andfore body841 as were shown inFIG. 9. As can be seen, protrudingtip176 is visible throughhole177. Further,aft body843 can be disengaged fromfore body841 by pressing in ontip176. In certain embodiments,hole177 andtip176 are dimensioned so that aft body853 can be disengaged manually (e.g., without a tool). In alternative embodiments,hole177 is dimensioned so that a tool must be inserted.
• In some embodiments, a club head can be provided along with a specialized tool for uncoupling an aft body. A specialized tool can be used to uncouple a cantilever-based fastening mechanism, or other mechanisms. In some embodiments, a club head with a separable aft body is assembled and fastened through the use of a functional component, which can optionally be formed to interact with a specialized tool.
• FIGS. 11A and 11B show a club head with separableaft body863 fastened by afunctional component58. As shown inFIG. 11A,fore body861 includes a portion of a sole of the club head.Aft body863 completes the overall morphology of the club head. Two offunctional component58 are provided in optional recessed areas on the sole offore body861.
• Afunctional component58 can be any component that adds a feature or tunes the mass distribution or affects the environmental interaction of a club head. For example, in some embodiments, a functional component has a non-uniformly dimensioned morphology and modulates a face angle or a lie angle or a loft angle (effective angle) by being positioned on the club head in different ways. In certain embodiments, a functional component is rotated to modulate an effective angle. Portions of the component that have different thicknesses interact differently with the ground to tune the effective angle. In alternative or additional embodiments, a functional component is a weight. For example, a club head as shown inFIG. 11A can be provided with a number ofcomponents58, having a variety of different masses. A golfer can tune a mass distribution of a club head by interchangingcomponents58. A particular insight of the invention is that such a system provides an unexpectedly good way to fasten an interchangeable aft body to a club head.
• FIG. 11B shows a side view of the club head shown in11A. On the depicted toe side, one offunctional component58 is visible and can be seen to fit into a shallow, semi-circular recess, although any recess or no recess is possible.
• FIG. 12 is a cutaway view of the club head shown inFIG. 11A along line A-A. In the depicted embodiment,functional members58 each include a threadedpost63 that threads into a corresponding hole inaft body member863.
• FIG. 13 shows theaft body863 of the club head inFIG. 12.Aft body863 is substantially surrounded at its edge by an attachment perimeter that includes a flange. At two portions, the flange extends intotabs865. Each oftab865 includes threadedhole867. Whenaft body863 is coupled tofore body861,functional components58 thread through holes infore body861 and into threadedholes867. When thefunctional components58 are tightened into place, the club head is fastened together.
• This attachment mechanism using functional components can be employed for body components or insert panels in any of a number of dimensions, morphologies, and placements around a club head.
• FIG. 14 shows a club head with an interchangeable aftsole panel883 fastened into place through the use offunctional component58. As depicted inFIG. 14, afunctional component58 can include a tool engagement surface. In certain embodiments, a tool engagement surface of afunctional component58 is provided to be operated by a tool that is also the tool for coupling and releasing a shaft. By these means, a golfer may interchange components of a club head and also interchange shafts.
• FIG. 15 showsbody member881 including a crown, face, and hosel of a club head, and having a cutaway void dimensioned to receivesole panel883.Sole panel883, the cutaway void ofbody member881, or both have engagingflange portions818. As shown inFIG. 15, a portion offlange818 onfore body881 extends intotab865 with threadedhole867 wherefunctional component58 can be fastened. As depicted inFIG. 15,sole panel883 includesoptional component recess885. The fastening mechanism depicted inFIGS. 14 and 15 is not limited to use with a sole panel. A single (or multiple)functional component58 can be employed to couple interchangeable components of a club head even where each component provides a substantial portion of the overall exterior area of the club head (e.g., a first component and a second component each provide over 25% or over 40% of an overall exterior area of an assembled club head).
• FIGS. 16A-16C show a club head with separableaft body893 in which each ofaft body893 andfore body891 provide a substantial portion of the exterior surface area of the assembled club head (here, each provides at least more than about 35%). As shown inFIG. 16B and inFIG. 16C,aft body893 is fastened tofore body891 through a singlefunctional component58.
• FIG. 17 shows a cutaway view of the aft body of the club head inFIGS. 16A-16C.Aft body893 has a flange at an edge that extends intotab portion865 withhole867 to receivefunctional component58.
• In certain embodiments, the invention provides golf club heads with multi-component structures. While the embodiments disclosed herein include club heads for wood-type clubs, it is contemplated that one or more of the concepts described herein can further be used for other types of club heads, including but not limited to irons and putters.
• With reference toFIGS. 18-21, agolf club head10 can comprise aball striking face12, acrown14, a sole16, and ahosel18. Thegolf club10 can further comprise abody member20, aface insert22, at least onesole insert24, and at least onecrown insert26. In some embodiments, thebody member20 can comprise a metallic member that includes a plurality of openings for receiving theface insert22,sole insert24, and/orcrown insert26. In some embodiments, thebody member20 can be comprised, at least in part, of a 6-4 titanium alloy, though other types of material are also possible. As illustrated inFIGS. 18-21, in some embodiments thebody member20 can comprise a portion or portions of theball striking face12,crown14, and/or sole16.
• With reference toFIG. 20, in some embodiments thehosel18 can comprise asleeve28 that permits interchangeability and/or adjustability of a golf club shaft. In some embodiments thesleeve28 can be comprised of 6062 aluminum, though other types of materials are also possible.
• In some embodiments, thesleeve28 can be adjusted so as to adjust the lie angle of theclub head10. Other types of material and/or structure can also be used for thesleeve28. U.S. Pat. No. 7,789,766, the entire contents of which are incorporated by reference herein, describes various adjustability features of a sleeve similar tosleeve28.
• FIG. 18 shows an embodiment in which hosel18 ofclub head10 includes ahosel sleeve screw30 configured to releasably attach one or more components of thehosel18 to theclub head10. Thescrew30 can be comprised, for example, of 304 stainless steel produced using a traditional screw machine with a T20 head, though other types of materials and screws are also possible. Additionally, other types of fasteners besides screws can be utilized. In some embodiments, thescrew30 can be inserted within arecess31 in thebody member20.
• FIG. 19 is a cross-sectional view showingface insert22 inclub head10.Face insert22 can comprise at least a majority, for example by volume and/or mass, of theball striking face12. In some embodiments, theface insert22 can form approximately 60 percent of the volume and/or mass of theball striking face12. In some embodiments, theface insert22 can form approximately 70 percent of the volume and/or mass of theball striking face12. In some embodiments, theface insert22 can form approximately 80 percent of the volume and/or mass of theball striking face12.
• Theface insert22 can be comprised of metal, or other suitable material. In some embodiments theface insert22 can be comprised of the same material as thebody member20. In some embodiments theface insert22 can be comprised of 6-4 titanium. In some embodiments theface insert22 can be comprised of more than one type of material and/or more than one layer of material.
• In some embodiments, theface insert22 and/orball striking face12 can transition into thecrown14 and sole16 at a transition point or area. The transition point or area can be a location where a line drawn perpendicular to a tangent line extending along the surface of theclub head10 at the transition point or area forms an approximately 45 degree angle relative to a vertical plane passing through theclub head10.
• FIG. 19 shows crowninsert26 inclub head10 in cross-sectional view.
• FIG. 20 is a top view ofclub head10 showing a mountingsurface48 for receivingcrown insert26.
• FIG. 21 shows crowninsert26 in cross-sectional view. In some embodiments thecrown insert26 can comprise at least a majority, for example by volume and/or weight, of thecrown14. In some embodiments, theface insert22 can form approximately 60 percent of the volume and/or mass of theball striking face12. In some embodiments, theface insert22 can form approximately 70 percent of the volume and/or mass of theball striking face12. In some embodiments, theface insert22 can form approximately 80 percent of the volume and/or mass of theball striking face12.
• Thecrown insert26 can be comprised of composite, reinforced plastic, thermoplastics, or other suitable material. With reference toFIG. 22, in some embodiments thecrown insert26 can be comprised entirely of injection molded material. In some embodiments, theinsert26 can be comprised of single or multi-density metallic or non-metallic material.
• FIG. 23 illustrates an embodiment in which thecrown insert26 can have one ormore portions38 that are comprised of plastic, along with one or moreflexible divider elements40 that connect theportions38 together. In some embodiments, a majority of thecrown insert26 is a thermoset or thermoplastic material, which may optionally be reinforced with secondary fibers, such as carbon, glass, wood, plant or metal such as, for example, a plastic. In some embodiments, theportions38 can be interchangeable. Thedivider elements40 can be comprised, for example, of any metallic or non-metallic material desirably having a density less than that of thebody member20. In some embodiments, thedivider elements40 can be bonded with the remainingportions38 of thecrown insert26. In some embodiments thedivider elements40 can be formed integrally with the remainingportions38. In some embodiments, thedivider elements40 can divide thecrown insert26 into fourportions38, though other numbers of portions are also possible. Thedivider elements40, along with theplastic portions38, can give thecrown insert26 flexibility and reduced weight as compared with crown inserts made of metal or carbon fiber. The added flexibility can inhibit the plastic material of crown insert26 from cracking or fracturing. In some embodiments, if the flexibility is too great, and negatively affects the sound/tuning of theclub head10, additional measures can be taken to reinforce theclub head10 and/or to create better sound qualities. For example, a gasket can be added between thecrown insert26 and thebody member20, or material such as latex can be added between thecrown insert26 and thebody member20, to act as a sound barrier. In some embodiments, a support member can extend generally from the sole16 to thecrown14 can be added to theclub head10.
• In some embodiments, theclub head10 can have a density ratio between thebody member20 and an insert. For example, in some embodiments the ratio of the density of thebody member20 to thecrown insert26 can be 1.5. In some embodiments, the density ratio between thebody member20 and one of the inserts can be approximately 2.0, 2.5, 3.0, 2.5, 4.0, or higher than 4.0. Other density ratios are also possible.
• Overall, the use of plastic (such as, for example, polyurethanes, polyesters, epoxy resins, phenolic resins, and carbon composites) in thecrown insert26 can, at least in some embodiments, not only reduce weight but also facilitate a generally transparent, or at least partially transparent,club head10. Transparency can allow a user to view whether material has accumulated inside the club, and/or whether theclub head10 is damaged or showing signs of wear on the inside. In some embodiments, thecrown insert26 can be translucent. In some embodiments thecrown insert26 can be comprised of a photochromic material. The plastic can reduce weight in the crown314, thus allowing the weight that otherwise would been located in the crown314 to be optimally redistributed to other areas of the club head310 to optimize a location of a center of gravity, for example, or optimize moments of inertia in the club head310.
• With continued reference toFIGS. 19-21, thecrown insert26 and/orbody member20 can comprise at least one mountingfeature42. The mounting features42 can be used to attach thecrown insert26 to thebody member20 or other component of theclub head10. For example, with reference toFIG. 21, in some embodiments the mounting features42 can comprise attachment flanges, permitting thecrown insert26 to be adhesively attached, for example, or welded, to thebody member20. In some embodiments, mounting features can comprise non-threaded attachments that clamp and unclamp with the push of a finger, hand, or tool. The mounting features can include one-touch fasteners and may have internal springs. A press-fit or snap-fit assembly can be used. In some embodiments, a tool can be used to release an insert, such as the crown insert, to replace it with a different crown insert.
• FIG. 24 shows a detail view of section C fromFIG. 21. As illustrated inFIG. 24, mounting features42 on thecrown insert26 can comprisepost-like structures44 that are configured to be received within corresponding mounting features42 on thebody member20. The corresponding mounting features42 on thebody member20 can comprise, for example,openings46 on a mountingsurface48 of thebody member20.
• FIG. 25 illustrates a detail view of section C fromFIG. 21 according to certain embodiments in which agasket member47 is placed between thebody member20 andcrown insert26. For example, thegasket member47 can be adhesively attached to thebody member20. In some embodiments, instead of thebody member20 havingopenings46, thegasket member47 instead can include theopenings46. Alternatively, in other embodiments both thegasket member47 andbody member20 can include openings, and thepost-like structures44 can be inserted through thegasket member47 and into thebody member20.
• With continued reference toFIGS. 20,21,24 and25, thepost-like structures44 andopenings46 can be spaced around theclub head10, such that thecrown insert26 is secured firmly to thebody member20 in a plurality of locations. For example, the mountingsurface48 can include sixopenings46 spaced generally equally around theclub head10, and thecrown insert26 can include sixpost-like structures44 that are configured to be received within the sixopenings46. In some embodiments, thepost-like structures44 can press or snap-fit into theopenings46, and thecrown insert26 can be held in place without the use of any additional adhesive, welding, etc. In some embodiments, additional adhesive can be used, for example between an outer edge of thecrown insert26 and the mountingsurface48. In some embodiments, thecrown insert26 can be mounted to the mountingsurface48 without the use ofpost-like structures44 oropenings46. For example, in some embodiments thecrown insert26 can be attached purely by adhesives, welding, mechanical attachment, etc.
• With reference toFIGS. 18,19 and21, in some embodiments thesole insert24 can comprise at least a majority, for example by volume, of the sole16. Thesole insert24 can include composite, plastic, or any other suitable material. In some embodiments,sole insert24 is made of injection molded plastic. Further,sole insert24 may have secondary coatings or be co-molded to other materials. Co-molded materials and secondary coatings can include ceramics, anodizing, or similar. In some embodiments, a secondary coating or co-molded material includes a low-friction polymer. For example,sole insert24 may have a hard-anodized coating infused with a low-friction polymer such as a fluorinated polymer (e.g., poly-tetrafluoroethelyne (PTFE), sold under the trademark TEFLON by DuPont). Suitable coatings are discussed in U.S. Pub. 2011/0118057, the contents of which are hereby incorporated by reference in their entirety for all purposes.
• Sole insert24 can have a variety of shapes and sizes. For example, thesole insert24 can have an oblong and/or generally hourglass-like shape, such as that shown inFIG. 18. Other shapes and sizes are also possible. As with thecrown insert26, thesole insert24 can also be comprised of a material that is lightweight, and/or less dense, than that of thebody member20, so that weight can be redistributed as desired to other areas of theclub head10, and a center of gravity of theclub head10 can for example be pushed towards the back and heel side of theclub head10, and/or moments of inertia can be optimized. In some embodiments, a movement of weight can advantageously increase a moment of inertia of theclub head10, causing reduced unwanted twisting or movement of theclub head10 upon impact with a golf ball.
• In some embodiments, there can be more than onesole insert24. In some embodiments, asole insert24 can have a divider, similar to at least one of the embodiments of the crown insert described herein.
• With continued reference toFIGS. 18,19, and21, thesole insert24 can comprise at least one mountingfeature42. The mounting features42 can be used to attach thesole insert24 to thebody member20 or other component of theclub head10. With reference toFIG. 19, in some embodiments the mounting features42 of thesole insert24 andbody member20 can comprise one or more attachment flanges. For example, thesole insert24 can include afirst attachment flange50 that extends inwardly from thesole insert24. In some embodiments, thefirst attachment flange50 can extend at a right angle relative to a surface of thesole insert24. Theattachment flange50 can be configured to contact and/or mate with acorresponding attachment flange52 on thebody member20. Theattachment flange52 can have a bent profile, for example, and extend inwardly from the body member20 (e.g. towards an interior volume of the club head10).
• In some embodiments, thesole insert24, and/or other inserts on the club head, can be configured to snap-fit into thebody member20. For example, in some embodiments, at least one surface ofattachment flange50 can contact and press against at least one surface of theattachment flange52 of thebody member20, helping to hold thesole insert24 in place relative to thebody member20. Theinsert24 can be held in place by friction. In some embodiments thesole insert24 can include anadditional flange54, which contacts aflange56 on thebody member20. Theflanges54 and56 can also be configured to contact one another, and/or snap-fit in place or be attached by adhesive, welding, etc. In some embodiments, thebody member20 can include a flange or flanges that are biased in a first direction, such that when an insert is positioned within theclub head10, the flanges are forced away from the first direction towards a second direction, the flanges pressing back against the insert towards the first direction to hold the insert in place again once the insert has been attached. For example, in some embodiments theflange52 can be biased in a first direction towards the back end of the club head, and pushed towards a second direction towards the front of the club head when thesole insert24 is attached. In some embodiments, thebody member20 can include flanges with ends that are initially biased towards one another, and when an insert is attached, the ends are pressed away from one another, the force of the ends of the flanges holding the insert in place. In some embodiments, adhesive, welding, and/or mechanical structures can be used to help hold one or more inserts (e.g. the sole insert24) in place within thebody member20.
• In certain embodiments, either crown insert, sole insert, any other insert such as a face insert or skirt insert (or combination thereof), or any other component is fastened to form a playable club by a mounting feature that uses a threaded mechanism. For example, a mounting feature may include a screw well such as, for example, those described in U.S. Pub. 2011/0111885, the contents of which are hereby incorporated by reference in their entirety for all purposes. Further, an insert may be fastened into place by a screw through another portion of a club head. Threaded elements are discussed in U.S. Pat. No. 8,033,930; U.S. Pat. No. 7,771,290; U.S. Pat. No. 5,776,011; and U.S. Pat. No. 5,429,365, the contents of which are hereby incorporated by reference in their entirety for all purposes.
• In some embodiments, one or more inserts, such as sole insert and/orcrown insert24,26 can be configured to have a size larger than that of a corresponding opening on thebody member20. When the sole insert and/orcrown insert24,26 is inserted into the opening in thebody member20, the sole insert and/orcrown insert24,26 can flex initially, and/or thebody member20 can flex initially, and the sole insert and/orcrown insert24,26 can be held in place frictionally once positioned inside the opening. In some embodiments, the sole insert and/orcrown insert24,26 can force one ormore flanges50 to act as a spring mechanism, applying a force on the sole insert and/or crown insert to hold the sole insert and/orcrown insert24,26 in place within thebody member20.
• Other snap-fit constructions can also be used.
• FIG. 26 shows a snap-fit construction according to certain embodiments.Body member20 of a club head can include one or more recesses, channels, openings, orother structures858 along the inside or outside of the club head configured to receive anattachment flange860 on aninsert862, and to temporarily lock theattachment flanges860 and theinsert862 into place within the club head. Theinsert862 can be removed, for example, by pressing on one or more areas of theinsert862, such as the outside edges of the insert.
• In some embodiments, screws, clamps, or other fasteners can be used to connect, remove, and/or replace the inserts. In some embodiments, adhesive can be used to help hold an insert or inserts in place that will not be replaced.
• In certain embodiments, two club head components can be joined, or a component can be joined to a body part, by an assembly method such as staking, ultra-sonic welding, or heat staking. For example, The seams as shown inFIG. 21 provide surfaces that can be attached by these methods. In certain embodiments, components are assembled by heat staking.FIG. 46 illustrates one way in which an assembly tool can access seams for assembly by heat staking.
• Heat staking is a means of locking club head components together. In general, one of the parts to be assembled is designed to include a plastic post or tab which can be inserted through a hole or aperture in another part and then permanently and inelastically deformed by the generation or application of heat by some tool surface which effects plastic deformation. The variables which can be tuned include the characteristics of the particular plastic material employed including its flow and melt temperatures, the nature and characteristics of the tooling employed and the geometries thereof, means by which the tooling may be brought to bear against the plastic elements to be deformed, the choice of method for effecting heating, and the parameters of pressure, time, and heat energy applied.
• In one embodiment, a plurality of first thermoplastic components, or heat-stakes, may be located sporadically around the periphery of a component and a second component may comprise a plurality of second thermoplastic components, or encapsulates, comprising receiving holes located in corresponding locations to the heat-stakes of the first automotive component. The heat-stakes may be inserted into the receiving holes and a staking device may be used to heat-treat a leading end of each heat-stake. This use of the staking device results in the deformation of the heated leading end of the heat-stake such that a “mushroom cap” may be formed. The mushroom cap of each heat stake commonly covers the corresponding receiving hole of the encapsulate. This resulting overlap results in the mechanical coupling of the first and second components. The resulting retention force of a heat staking process may be tuned by varying the amount of surface area of the encapsulate contacted by the heat-stake's mushroom cap as well as the composition states of the encapsulate and heat-stake.
• A particular advantage of heat stake in club head assembly is that such methods operate well with dissimilar materials. For example, a plastic component with stakes can be fastened to a metal component with receiving holes by heat staking. Heat staking is discussed in more detail in U.S. Pat. No. 6,840,755; U.S. Pat. No. 6,296,470; U.S. Pat. No. 5,871,784; U.S. Pat. No. 4,767,298; and U.S. Pub. 2008/0230948, the contents of each of which are hereby incorporated by reference in their entirety for all purposes.
• In certain embodiments, two club head components can be joined, or a component can be joined to a body part, through the use of magnets, discussed in more detail below.
• In some embodiments, theclub head10 can include an entire set of different inserts that can be easily removed and replaced. This can facilitate consumer customization of theclub head10. For example, a club head set could include aclub head10 with abody member20, and a plurality of different thickness, density, weight, and/or transparency crown or sole inserts. A user can select a desired insert or inserts, and quickly and easily attach the desired inserts. Advantageously, in some embodiments the inserts can press-fit or snap-fit into place within thebody member20. The inserts can be interchangeable, and in some embodiments can comprise a kit, the parts of which can be tailored to specific golfer needs. In some embodiments, the customization could include choosing from a plurality of inserts with different indicia, designs, etc., including but not limited to country flags, favorite teams, etc.
• With continued reference toFIG. 18, theclub head10 can further include at least oneweight member58. Theweight member58 can removable, and can be inserted into a portion of thebody member20. In some embodiments, addition of aweight member58 can advantageously permit more weight to be moved towards the heel of theclub head10. In some embodiments, the weight member can have ahead60 that has an outer surface that is generally flush with an outer surface of thebody member20. Theweight member58 can comprise a weight screw, formed for example from tungsten, stainless steel, such as 17-4, aluminum, or other suitable materials. Other types and materials are also possible. In some embodiments, theweight screw head60 can include one ormore tool cavities62. The tool cavities can be configured to receive a tool, such as a specialized tool, that is configured to remove theweight screw58. In some embodiments thetool cavities62 can comprise two separate openings. In some embodiments the tool cavity can comprise a generally star-shaped opening for receiving a correspondingly-shaped tool. Other shapes and types of tool cavities are also possible. In some embodiments theclub head10 can be configured to receive various weight screws58 of different weight, so that the swing weight of theclub head10 can be altered. For example, in some embodiments theweight screw58 can be comprised of tungsten, and weigh approximately 10 grams. In some embodiments theweight screw58 can be comprised of stainless steel, and weight approximately 6 grams. In some embodiments theweight screw58 can be comprised of aluminum and weight approximately 2 grams. Other materials and weights are also possible. The type and weight ofweight screw58 used in theclub head10 can depend on an overall club head weight, a desired swing weight, a desired location of a center of gravity of theclub head10, and/or a desired moment of inertia of the club head310. For example, theclub head10 can be designed, and aweight screw58 can be selected, such that a center of gravity of theclub head10 is located approximately 4 mm rearward from a geometric center point on theface insert22, and approximately 4 mm above a lowest point on the sole16 when theclub head10 is at address. Other locations for the center of gravity are also possible.
• In some embodiments, the ratio of the weight screw material density to body material density (i.e. betweenweight screw58 and body member20) can be approximately 1.5. In some embodiments the density can be approximately 2.0, 2.5, 3.0, 3.5, 4.0, or higher than 4.0. Other density ratios are also possible.
• In some aspects, the invention provides a club head with a removable or interchangeable component, such as a crown panel or sole plate, that is affixed to the a club head body through the use of a mechanism in a club head that also provides other functionality. Through the use of mechanisms that also provide other functionality, it is possible to provide a club head with one, two, three or more separable panels that further include no visible assembly mechanisms (e.g., protruding plastic tabs, recessed holes, etc.) other than the mechanism associated with the other functionality.
• FIG. 27shows club head864 withinsert862.Insert862 is shown here as a sole plate, and may be textured or contoured for turf interaction or to tune the stability of the club head when sitting on the ground in the address position. As shown in this embodiment, insert862 is held in place, at least in part byhosel sleeve screw30.
• FIG. 28 is a bottom view ofclub head864.Sole insert862 covers more than about 50% of the visible area of the club head sole when looked at from underneath (e.g., about 75% of the visible area). In certain embodiments, asole insert862 covers less than about 50% of the visible area of a sole when looked at from underneath (e.g., less than about 25%).
• FIG. 29 shows insert862 havingboss863 andclasp866.Club head864 is assembled by positioningclasp866 on the inside edge of the insert hole in the bottom of the body ofclub head864.Insert862 is then closed, usingclasp866 as a hinge, so thatboss863 comes proximal torepositionable shaft housing865.
• Club head864 includeshousing65 to receive and mount a repositionable shaft in various dispositions. When a shaft is mounted in a hosel of club head64,hosel sleeve screw30 fastens the shaft into place.
• FIG. 30 shows hoselsleeve screw30 fixinginsert862 into position. Wheninsert862 is installed inclub head864,clasp866 is entirely within the club head.Insert862 is held in place securely byhosel sleeve screw30, which is associated with other functionality of the club head (e.g., an interchangeable/repositionable shaft). Golf clubs including adjustable mechanisms, or adjustable mechanisms for golf clubs, suitable for operation with the invention, are discussed in U.S. Pub. 2010/0041493; U.S. Pub. 2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat. No. 1,879,117 and U.S. Pat. No. 3,096,982, incorporated by reference herein in their entirety.
• FIG. 31 shows an embodiment in which aninsert862 is held in place through the use of areleasable element58. As discussed herein,releasable element58 can be a weight member or another functional element. For example, in some embodiments,releasable element58 is a disc-like structure (e.g., mounted on a post for insertion into a sole) with non-uniform thickness. By rotatingelement58 into different positions, a sole can be given a different contour geometry so that an assembled golf club, when resting on a flat surface at an address position, interacts with the ground in different ways (i.e., rests in different positions). In such a fashion,release element58 can be used to tune an effective parameter of a club, such as face angle.
• FIG. 32 shows areleasable component58 having twotool cavities61 and a threadedpost63. As shown inFIG. 32,releasable component58 is a simple, monolithically formed weight.
• FIG. 33shows club head864 configured to receive insert862 (here, a sole plate).Club head864 includesboss67 having a threaded hole to mate with threadedpost63.Club head864 further includesattachment flange56 andrepositionable shaft housing65.Insert862 can be positioned on the base ofclub head864 with866 hooked therein.Releasable component58 andshaft screw30 can then be tightened (e.g., with a tool), fixinginset862 there in place. One insight of the invention associated with clubs with most beneficial properties is the dual functionality of a releasable component to provide a customizable mass distribution while also providing a mechanism for fastening a separable component to a club head. Separable components are discussed in U.S. Pub. 2011/0294589, the contents of which are hereby incorporated by reference in their entirety for all purposes. Here, the invention provides the ability to finely-tune a club head to correct for a golfer's hook or slice by positioning the weight on a heel side, toe side, or both, through the use of a releasable weight component. Rather than simply adding a mass of weight, the fastening mechanism of the present invention derives most desirable additional utility in unexpected ways by harmonizing the placement of releasable weights used to aid in improving a golfer's shot with the fastening of releasable body components.
• In some aspects, the invention provides club heads with separable components that can be attached or removed without the use of tools.
• FIG. 34 shows aclub head71 with slottedflange77 anddeformable crown panel75. As shown inFIG. 35, slotted flange can extend around an aperture in a club head, completely or in part.Crown panel75 is then positioned so that athin edge79 is pressed against slottedflange77, as shown inFIG. 36.Crown panel75 deforms plastically or elastically.
• FIG. 36shows panel75 being bent so that it bows outwards, allowingthin edges79 to be inserted intoslot76 in slottedflange77. Aspanel75 is released, it tends to return to its original shape such thatthin edge79 fully inserts intoslot76. In some embodiments, it is pushed entirely into place and adjusted by hand.
• In some embodiments, a separable component is attached to a club head without tools through the use of one or more barbed posts.FIGS. 37-40 show a tool-less removable panel attachment system. As shown inFIG. 37,club head81 includes aflange87 having one or more ofhole83 therethrough.
• FIG. 38 shows an insert having one or morebarbed post89 positioned and dimensioned to correspond to theholes83.FIG. 39 shows a detailed cross-sectional view ofbarbed posts89 andflange87 withholes83. Wheninsert panel85 is pushed into place, eachbarbed post89 pushes through ahole83. The barbs deform plastically/elastically and retaininsert85 mounted securely onclub head81.
• FIG. 40 is a side view ofclub head81 andcrown panel85 withbarbed posts89 positioned to be attached together.
• In certain embodiments,club head81 is provided for use with one or more disposable inserts85. Eachinsert85 can have a novel or interesting color or pattern. A golfer chooses one that he or she finds pleasing and inserts it intoclub head81 through the use of the barbed posts (or any of the other suitable mechanisms such as those described elsewhere herein). When the golfer wishes to removeinsert85, pulling it away fromclub head81 snaps all of the barbed posts off, and the insert is set aside. A golfer may use a tool, such as a thin, flat screwdriver, to lift a first edge ofinsert85 to aid in removing it.
• In certain embodiments, the invention provides a club head with a removable and re-attachable panel through the use of depressable engagement tabs.
• FIG. 41 shows aclub head91 with four ofdepressable engagement pad92 andattachable crown panel95.Crown panel95 has four receivingholes93 dimensioned to correspond to a button portion of thedepressable engagement pads92. Whencrown panel95 is pushed ontoclub head91,pads92 deform (e.g., bend inwards) and then snap into place.
• FIG. 42 shows an assembledclub head91. To removepanel95, the button portion ofpads92 is depressed andpanel95 is lifted off. Any suitable number ofpads92 may be included, and in any suitable arrangement.
• In some embodiments, a removable or disposable panel is provided to be attached via adhesive.
• FIG. 43 shows aclub head101 andsole plate103 with pre-attached adhesive strips105. Adhesive strips105 can be located to correspond toflange107. Alternatively,plate103 may not includeadhesive strips105, and they can be provided separately (e.g., as double-stick tape). In some embodiments,plate103 is fastened into place through the use of VHB adhesive tape, wet epoxy, or a combination thereof. Fastening is discussed in U.S. Pub. 2011/0045921, the contents of which are hereby incorporated by reference in their entirety for all purposes.
• In various embodiments, providing a club head with a body member and one or more outer panels provides a club designer with opportunities for novel arrangements of material to tune a mass distribution, to enhance strength, to refine sound tuning, or modify coefficient of restitution of a club head. For example, certain embodiments, a panel will be used to cover what would otherwise be one or more holes in a club head body. Where the club head body includes a metal or other heavy material, and the panel includes a plastic, composite, or other lightweight material, this can provide significant weight savings.
• FIG. 44 illustrates aclub head111 having acrown panel115 to cover acage portion113 that includes one or more ofhole119a,119b, . . . etc.Cage portion113 can be surrounded bylip117 dimensioned to correspond to an edge ofpanel115. It may be found that this construction of a club head provides excellent durability and coefficient of restitution, while allowing for significant mass savings (relative to a club head without holes119). Furthermore,panel115 can be customizable or interchangeable. In certain embodiments,panel115 has adhesive on an inner surface, barbed posts corresponding to holes inclub head111, a thin edge corresponding to a slotted flange onclub head111, or any other suitable attachment mechanism such as those described herein.
• In certain embodiments, a club head with a multi component construction makes use of a rapid fastening system such as the bolt assembly sold under the trademark POPBOLT by Emhart Technologies (Shelton, Conn.).
• FIG. 45 is a cross-sectional view of aclub head121 assembled with a rapid fastening system. As shown inFIG. 45, apanel125 is mounted to a flange inclub head121. Abolt post member124 protrudes through a hole in the flange, and acollar127 is affixed thereto. In certain embodiments,post member124 is a threaded bolt andcollar127 is a threaded nut. In some embodiments,post member124 andcollar127 are components of a rapid fastening system.
• FIG. 46 illustrates a method of rapidly fastening a sole plate toclub head121. As shown inFIG. 46,post member124 is provided by a separate bolt.Collar127 is positioned thereon andtool129 is used to fastencollar127 to postmember124. When using a system such as the bolt assembly sold under the trademark POPBOLT,collar127 is swaged to postmember124. Post member is threaded to begin with andswaging collar127 to postmember124 causescollar127 to become threaded.Collar127 can then be removed through the use of a wrench.Swaging collar127 to postmember124 is described inFIG. 49.
• FIG. 47 shows apost member128 formed integrally withinsert125 and protruding from a surface of the insert.
• FIG. 48 illustrates an embodiment in which a protruding post is abarbed post89.Insert125 withbarbed post89 can be used inclub head121, even whereclub head121 can also, separately, be used with a rapid fastening system. In some embodiments,club head121 has a rapid fastening system used to fasteninsert125 in place (e.g., by swaging collar127). Then,collar127 is removed with a wrench and insert125 is removed and set aside. Anotherinsert125 that includesbarbed posts89 is then fixed toclub head121 using the same holes. By these means, a club head can be customized with a tool (for example, in a pro shop) by one method, but then can be “field stripped” and re-customized out on the course without the benefit of the tool system.
• FIGS. 49A-49C illustrate the operation of a rapid fastening system such as the bolt assembly sold under the trademark POPBOLT by Emhart Technologies (Shelton, Conn.). As shown inFIG. 49A, a bolt or post is inserted through a hole (e.g., post124 protruding frominsert125 is inserted through a hole in a corresponding flange on a club head body).FIG. 49B showspositioning collar127 overpost124 through the use oftool129. In certain embodiments, atool129 of a rapid fastening system carriescollar127 and positions it overpost124. As illustrated byFIG. 49C, operating a trigger ontool129swages collar127 to post124 (simultaneously forming a threaded connection).Operating tool129 also breaks off an excess portion ofpost124 and removes it.Tool129 can then be taken away from the assembly site.
• FIG. 50 shows a hosel/face member131 and anaft body member135 adapted to be coupled together with a rapid fastening system.Face member131 can include one or a number ofpost member124, whilebody135 has a corresponding number ofinset boss133 dimensioned so thatpost124 slides through a hole therein. In certain embodiments,collar127 is then positioned onpost124 and fastened into place as discussed above and as shown inFIG. 51. Suitable club heads for use with systems of the invention are discussed in U.S. Pat. No. 7,959,522, the contents of which are hereby incorporated by reference in their entirety for all purposes.
• In some embodiments, the invention provides a club head with a sole or crown insert that press-fits or snap-fits into place from within the inside of the club head.
• FIGS. 52-54 show aclub head body142 configured to receiveinternal insert145. As shown inFIG. 52,club head body142 can be separated fromface member141.Face member141 is mounted to club head body by one or more of cantilever173 (discussed in more detail with respect ofFIGS. 60-66, below).
• To attachinsert145 toclub head body142,face member141 is removed.Insert145 is pushed intobody142 from the front aperture. Insert154 deforms slightly (e.g., by plastic/elastic deformation) and then snaps into place withinclub body142. As shown inFIG. 52,body142 hasband143 dimensioned to correspond to groove147 oninsert145. Onceinsert145 is snapped into place, it can be held in place because an outer edge ofinsert145 deforms (compresses) to be insert, and then returns to original shape such that the edge overlaps the edge of the corresponding void inbody142.Insert145 can similarly be removed by squeezing it from a heel side and a toe side such that the outer edge compress, and then pushing it into the inner volume ofbody142 and removing it from the aperture at the front ofbody142. As shown inFIG. 52,insert145 is translucent or transparent.
• FIG. 53 illustrates anopaque insert146 that functions in the same manner.
• FIG. 54 shows an assembled clubhead including body142 and insert146 or insert145.
• In certain embodiments, the invention provides a club head in which a face component can be separated from a body component through the use of a threaded connection.
• FIGS. 55 and 56show face member151 andbody member155 with corresponding threaded portions. As shown here,face member151 bears male threadedmember153 andbody member155 bears female threadedrecess155. Body member can be threaded ontoface member153 and screwed tightly into place. In some embodiments, a club head as shown inFIGS. 55 and 56 is provided as a demonstration. For example, any part of the club head is transparent, and the threaded members allow the club head to be separated (e.g., by unscrewing) allowing a golfer to visually inspect an inside detail of the club head, such as layers of construction of a crown, skirt, or sole. In certain embodiments, such a club head is not meant for playing golf, but is provided primarily as a tool for displaying other features in a club head. In some embodiments, such a separable club head is provided as a novelty item, such as a toy for children, a canteen or flask, a tee case, or a gag gift or marketing prop. In certain embodiments, one of male threadedmember153 and female threadedrecess155 corresponds in dimensions to some commonly available threaded item (such as a mason jar or wide mouth drink bottle) allowing a golfer to make amusing assemblies.
• In certain embodiments, the invention provides a strap-based assembly system that uses Velcro, snaps, clasps, or adhesives.
• FIG. 57 illustrates aclub head161 with acrown member165 having agroove167 therein. When thecrown member165 is positioned onclub head161,first strap162 can be fastened tosecond strap164, holding thecrown member165 in place.
• FIG. 58shows club head161 withstrap164 holdingcrown member165 in place.Crown member165 can be translucent, transparent, or opaque. In certain embodiments, the straps fasten by Velcro. A club head of the invention can have one or more straps, individually or in combination, that bind to or surround a portion of a club head for functional or aesthetic purposes. For example, in some embodiments, a club head includes a strap (e.g., nylon, rubber, or leather) that extends in a face-aft direction, as shown inFIG. 57. In certain embodiments, a strap member extends around a club head, entirely or in part, in a heel-toe direction. Further, straps may extend in both directions or at angles relative to those directions.
• FIG. 59 is a top view ofclub head161. Straps may be used to carry weight members or electronics-related items (e.g., devices such as shot-tracking devices with accelerometers or LCD screens). In embodiments in whichcrown member165 is translucent or transparent, such an arrangement can provide a golfer a view of an element within the club head such as, for example, a digital screen or readout. Straps may be provided as described (e.g., as wrapping elements) in U.S. Pat. No. 7,896,753, the contents of which are hereby incorporated by reference in their entirety for all purposes.
• In some aspects, the invention provides club heads that include cantilevered attachments.FIGS. 60-66 show cantilevers.
• FIG. 60 shows aface member171 having a number ofcantilever173 protruding therefrom.Body member175, shown inFIG. 62, has a number ofrecess177 located and dimensioned to correspond totips176 ofcantilevers173. Whenface member171 is mated tobody member175,cantilever tips176 snap into place inrecesses177, fastening the club together.
• Either of the face member or body member may further include sets ofcorresponding tab187 and slot180 to aid in positioning the body members together.
• In some embodiments (not pictured), recesses177 are holes through a part of the club head, and the cantilevered component can be removed from the component with holes by pressing in on thetips176. It will be appreciated that this describes a functionality that is related to that described with reference toFIGS. 41 and 42.Depressable engagement pad92 and receivinghole93 can be a related embodiment ofcantilever173 andrecess177, and vice versa.
• In some embodiments, abody member175 includes decoupling holes183. Atool181 is provided, as shown inFIG. 61, having a prong set185 dimensioned to be inserted into decoupling holes183. Prong set185 pushes cantilevertips176 out ofdepressions177, allowing club head components to be separated from one another.
• FIGS. 63-66 show configurations of cantilevered posts and recesses.FIG. 63 shows acantilever173 having a squaredtip176 designed to inseparably couple two components of a club head.
• FIG. 64 shows anangled tip176 designed to be slid out fromrecess177 allowing components to be decoupled.
• FIG. 65 shows another embodiment of decoupling holes183 arranged so that prong set185 pushes on a distal tip ofcantilever173.
• FIG. 66 shows aspring cantilever174 having a protrudingtab178 available from an outside of a club head that can be manually squeezed to decouple components of a club head.
• In certain aspects and embodiments, the invention provides separable components of multi-component club heads that employ a cam mechanism for releasably joining components.FIGS. 67A-67C show aclub head301 withcomponent305 havingcam mechanism313. As shown inFIG. 67A,club head301 has avoid opening311 dimensioned to mate withcomponent305. One portion of component engages at a perimeter ofvoid opening311. Here,component305 is shown having hooks to catchbar307. Any suitable engagement mechanism can be used. With a portion ofcomponent305 engaged at void opening322,cam mechanism313 can be rotated into place to produce a fastened-together club head as shown inFIG. 67B.FIG. 67C is a cross-section ofclub head301 showingbar307 receiving hooks ofcomponent305, andcam mechanism313 rotated into place.
• FIG. 68 is a detail view of the cam mechanism ofFIGS. 67A-67Cillustrating cam axis321 throughcam mechanism313.FIG. 69 illustrates radii around a cam axis. In certain embodiments, as shown inFIGS. 67-68,component305 is dimensioned to engage withclub head301 such that some deformation ofcomponent305 is required to remove it. As shown inFIGS. 67A and 67C, an aft portion ofcomponent305 bends under and forward, while an aft portion of the perimeter ofvoid opening311 extends upwards and aft-ward. These two portions hook together (i.e., requiring some deformation ofcomponent305 to put it into place on club head301). Whencam313 is rotated into place, it abuts a surface ofcomponent305 and prevents the deformation ofcomponent305 that would be necessary to remove the component from the club.
• As shown inFIG. 67A,cam mechanism313 may have atool engagement surface319 capable of engaging with a tool. A golfer can engage the tool withtool engagement surface319 to have leverage from the handle of the tool to releasecam mechanism313 from the fastened position.
• FIG. 69 illustrates the operation ofcam mechanism313. As shown inFIG. 69, an outer surface ofcam mechanism313 defines a non-constant radius aroundcam axis321. Whencam mechanism313 is fastened into place on an assembled golf club,cam axis321 is spaced away from an adjacent portion of the club head by an engaged radius Rx.Cam mechanism313 may further be dimensioned such that, when it is fully released (e.g., in the “up” position compared toFIG. 67A),cam axis321 is spaced away from the adjacent portion of the club head by a minimum radius R_min. Releasingcam mechanism313 requires pushing it through an orientation in whichcam axis321 is spaced away from the adjacent portion by a maximum radius R_max. The relative dimensions of the radii (e.g., R_min<R_X<R_Max) prevents cam mechanism from releasing unexpectedly. Force must be applied (e.g., through the use of a tool) to deformcomponent305 enough to allow R_Maxto pass the adjacent portion of the club head. Becausecam mechanism313 presents the minimum radius R_minto the adjacent portion when it is in the released position.component305 has the most space to allow for easy removal fromclub head301.
• In certain embodiments, the amount of deformation required to removecomponent305 fromclub301 is close to the limit of perception for most people. A user may intuitively realize that they are deformingcomponent305 to attach it and remove it, butcomponent305 may not exhibit substantial deformation. In some embodiments, deformation ofcomponent305 is elastic, plastic, or a combination thereof.
• In some embodiments, a cam-based mechanism (e.g., as illustrated inFIG. 68) is used with another fastening mechanism. For example, a cam can be provided with a cantilever173 (e.g., as illustrated inFIG. 60) such that, when the cam is engaged,cantilever173 is prevented from exhibiting any deformation such that, for example,aft component175 is fixed to face component171 (making reference toFIGS. 60 and 62).
• In certain embodiments, a cam is integrally formed with a fastening member. For example,FIGS. 70A-70D show aclub head331 withcam member339 integrally formed with engagement hooks338.
• FIG. 70A showsclub head331 withremovable crown333 includingcam member337.
• FIGS. 17B and 70C show removable sole335 includingcam member339. Either or both cam member may have a tool engagement surface to be operated through the use oftool181.FIG. 70D shows a detail view ofcam member337.Cam member337 rotates aboutcam axis349 bringing engagement hook aroundengagement member341.
• FIGS. 71A and 71B showengagement member341 supported by one or more ofarm342 onclub head331. A surface ofcam member339 engages with a surface at a perimeter of removable sole335 (the relevant portion of the perimeter of removable sole335 may be thickened, folded inwards, or provided with an engagement block). Whencam member339 is engaged, it cannot freely release because force is required to push the portion ofcam member339 having RMax past the surface of the perimeter of removable sole335. However,cam member339 can be rotated by a golfer. In some embodiments, a golfer can manually rotatecam member339, for example, because an elongated edge member provides a handle or lever. In certain embodiments, a golfer inserts atool181 intotool engagement surface319 and uses the tool to release the component from the golf club.
• In certain embodiments, the invention provides a golf club head with a removable component that fastens to a shaft of the golf club. Without being bound by theory, fastening a removable component to a shaft may provide for a very securely assembled club head due to the fact that the shaft provides a carriage function in that it carries the club head and it carries the energy of a golfer's swing. A component secured to the shaft can transmit any stress energy it is subject to through the shaft to the golfer—just as energy of impact is transmitted from a center of percussion at the club head to the golfer. Thus, when a golf ball is hit, the impact energy is transferred from the club head body through the shaft to the golfer and, simultaneously, from the separable component through the shaft and to the golfer. Accordingly, fastening the separable component to the shaft may tend to inhibit relative stresses between the component and the club head body.
• FIGS. 72A-72B show aseparable component355 forclub head351 including a mechanism for coupling to ashaft361 of a golf club.Club head body351 includes a cutaway, or void, dimensioned to correspond tocomponent355.Shaft361 extends through a hosel ofclub head body351, and may include aferrule359.Component355 has a fastening mechanism that includesshaft collar357 dimensioned to pass intoclub head body351 and engage a portion ofshaft361.
• As shown inFIG. 72B,component355 includes a slot that extends in a vertical direction when the club is at address. Whencomponent355 is mounted tobody351,shaft collar357 is disposed beneath an end ofshaft361. A golfer then lifts the mechanism, sliding shaft collar over the end ofshaft361.FIG. 73 showsshaft collar357. In some embodiments,shaft collar357 has a cylindrical portion and two tabs that extend from the cylindrical portion. In some embodiments, the two tabs are spaced apart from one another, at least proximal to the cylindrical portion, whileshaft collar357 is not subject to any stress. Slidingshaft collar357 upwards through the slot incomponent355 can push the tabs together if a portion of the slot has an inverted V shape. Thus, slidingcollar357 up overshaft361 forms a press-fit betweencollar357 and the shaft. Once positioned so,tab363 can be swung into a closed position, pushingpost365 into hole369 (which can be a press-fit or snap-fit engagement) so thatcollar357 remains firmly mounted toshaft361. In this way,component355 is securely mounted toclub body351 to provide a playable club.
• In some aspects, the invention includes the realization and development of the idea that a multi-component golf club head may be provided with optimized characteristics by coupling a component to a club head body or another component by fastening the component to the shaft or fastening the component into place through the use of a mechanism that also provides other functionality in the club head. A component may be securely fastened to a club head body through integration with the shaft by a variety of suitable mechanisms. FIGS.74 and75A-75C illustrate a mechanism for removably coupling a component to a club head body via the shaft. As seen inFIG. 75A,club head body371 includes a cutaway void in the crown area dimensioned to receive an insert. While illustrated here as a portion of the crown, a cutaway void and a corresponding insert could define any suitable portion of the club head.
• Club head371 includeshosel recess383 dimensioned to mate withhosel insert387 oncomponent375.Component375 is coupled toclub head body371 by insertinghosel insert387 intohosel recess383 to form an assembledclub head390 as shown inFIGS. 75A-75C. As can be seen inFIG. 74, the cutaway void inclub head body371 has a flange around at least a portion of the perimeter of the void.
• Further, as illustrated inFIG. 75A, the cutaway void and thecomponent375 have corresponding wavy edges. The perimeter edge of the cutaway void is wavy in that it defines one ormore lobe377 corresponding to complementary wavy portion ofcomponent375. The wavy portion ofcomponent375 may further include awebbed portion379 to slip underlobe377 to help positioncomponent375 correctly and hold it in place. One insight of the invention is that coupling lines in conformations other than straight may provide unexpected benefits in terms of durability, ease of assembly, sound tuning, among other things. More will be said about non-straight coupling seams below.
• Assembledclub head390 may be fastened together for playing by any suitable mechanism. In certain embodiments,club head390 takes advantage of an interchangeable or repositionable shaft that may, for example, also provide other functionality to a golf club (such as multiple loft angles or different shaft lengths). Interchangeable and repositionable shafts are discussed elsewhere herein. In certain embodiments, a shaft with a fixed ferrule is inserted into the hosel ofcomponent375.Club head body371 has a bore, or hole, for a shaft sleeve screw in the heel region of the sole. A shaft sleeve screw extends through the club head and threads into an end of the shaft. When the shaft sleeve screw is tightened, a compressive force is exerted between the fixed ferrule and the screw head/washer, thereby firmly grippingcomponent375 toclub head body371. Other mechanisms for coupling the shaft and ferrule tobody371, thereby holdingcomponent375 in place, may include a bayonet mounting mechanism with J-shaped slots (see, e.g., U.S. Pub. 2010/0261543, the contents of which are hereby incorporated by reference in their entirety for all purposes), a threaded portion inhosel recess383 corresponding to a threaded member on the shaft (see, e.g., U.S. Pat. No. 7,819,754, the contents of which are hereby incorporated by reference in their entirety for all purposes), or other methods known in the art. Mechanisms for golf clubs suitable for operation with the invention, are discussed in U.S. Pub. 2010/0041493; U.S. Pub. 2011/0098128; U.S. Pat. No. 8,057,323, U.S. Pat. No. 1,879,117 and U.S. Pat. No. 3,096,982, incorporated by reference herein in their entirety.
• As discussed above, in certain embodiments, a component mates with a club head body or with another component via a non-straight seam line (e.g., not a straight line when viewed along a surface of an assembled club head).FIGS. 75A-75C andFIG. 76 show embodiments including non-straight seams. In some embodiments, coupling seams include wavy lines. Wavy can include, for example, lines that—when projected onto a surface—have at least three inflection points that can be connected by an arc. Wavy can include lines or edges that may generally be described as lobed, scalloped, or wavy.
• One insight of the invention is that a golf company may desire to provide a family of similar, but not identical, club heads, each having a separable component. For example, a golf company may provide two drivers having the same model name, wherein one is a few cubic cm larger than the other (e.g., men's and women's models). Each club head can be provided with a separable component that has a functionally similar coupling mechanism and occupies a similar portion of an assembled club head. To avoid golfer confusion, different clubs can be provided with distinct wavy line patterns in the coupling seams. For example, the 455 cubic cm driver may have a wavy assembly seam line with three lobes on the club head body that interlock with two lobes on the separable component, whereas a 425 cubic cm driver may have a “tight wave” assembly seam line with seven lobes on the club head body that interlock with six lobes on the component. Through this mechanism, the separated components will each have a distinct appearance such that a golfer can easily reach for and pick up only the appropriate one when assembling a golf club.
• For example, according to this example, a golfer who owns the 425 cubic cm model could enter a pro-shop seeking to purchase a newly-released component with some attractive feature (such as a translucent material in the component that reveals a digital LED screen of an electronic component within the club head). Knowing that their club head included the seven-lobed edge, the golfer—when looking at the components in the display case—can easily focus their attention on only those that fit with their club head.
• Moreover, it is an insight of the invention that wavy lines may provide functional and structural advantages. For example, when coupling a component to a club head body (e.g., outdoors in the elements), it may be easier to achieve a proper fitting (i.e., easier to “seat” the part in place) if the wavy edges guide the component into the proper seating.
• Further, the stability of the coupling of multi-components may be limited by degrees of freedom of relative motion between the two components. For example, when a cross sectional-profile of a component is curved (see, e.g.,component26 inFIG. 19), coupling the component to the club head body may leave open certain degrees of freedom (e.g., lateral translation in a front-back direction of the component relative to the club head). Providing a wavy coupling seam as shown inFIG. 75A can remove a degree of freedom of relative translation, thereby increasing the security of the coupling of the multiple club head components.
• Beyond aiding a golfer in seating a component, and removing degrees of freedom to prevent uncoupling, a wavy seam may provide mating contact lines and surfaces that are oriented desirably relative to a direction of propagation of an impact-associated wave of compression energy. When a club head strikes a ball with force, energy may be transferred through the club head as compression waves that propagate through the materials. Where the waves encounter boundaries between separate components, they may reflect or refract in an undesired fashion if the wave-boundary intersection defines solely and only one certain angle (e.g., less than 45°). For example, given that driver heads may have shapes that have been optimized by generations of engineering design, placing a coupling seam between two components along a substantial portion of the driver head may interfere with impact wave propagation in ways that adversely affect the playability of a club, for example, diminishing its coefficient of restitution, contributing to rapid materials fatigue, or causing very uncomfortable transmissions of vibrations to a golfer's arms. Providing wavy boundaries may tend to preserve the existing, optimized energy propagation characteristics of a club head with multi-component construction.
• FIG. 76 shows a club head with multi-component construction in which a boundary seam betweencomponent389 andclub head body381 is wavy.Club head body381 includes a cutaway void space dimensioned to receivecomponent389. The void space may bear one or more ofsupport flange386 spaced around the perimeter. The wavy edge generally defines a series oflobe377.Component389 may be provided withwebbed portion379 corresponding to lobe377 and fitted to extend under an edge oflobe377, holdingcomponent389 in its proper place in an assembled club head. As shown inFIG. 76,component389 includes a snap-fit mechanism388 for removably coupling the component to the club head.
• FIG. 77 shows a cross-sectional view of snap-fit mechanism388.Cantilever60 includes a protrusion that can mate withslot358. In certain embodiments, a portion of cantilever600 can be manually manipulated from the outside of an assembled club head to releasecomponent389 fromclub head body381.
• In some aspects, the invention provides a club head with multi-component construction in which a component includes a malleable material such as rubber.
• FIG. 78 shows aclub head393 with amalleable component395 capable of being pulled away from the club head by a peeling, or folding-back action. In some embodiments, as shown inFIG. 78, one edge of a malleable component is permanently fixed the club head (e.g., through cement, or rivets, or similar suitable attachment mechanism). In other embodiments,malleable component395 is fully removable from club head393 (e.g., for replacement/interchangeability with another component).
• As shown inFIG. 78,malleable component395 includes agasket ring397.Club head399 bears acorresponding boss portion399. In some embodiments as shown inFIG. 78,boss portion399 is rigid (e.g., plastic, metal, or composite) and dimensioned to be pressed into an internal space ofgasket ring397. The pressure betweengasket ring397 andboss portion399 creates a press-fit that holdscomponent395 toclub head393 during play.Boss portion399 can provide functionality to the club head. For example, in certain embodiments,boss portion399 surrounds a feature such as an opening into the club head, a weight-mounting port, or a mini-USB port. An opening can be provided that allows a golfer to insert a tool into the club head to interact with some other feature within the club head, such as, for example, a tunable mass-distribution mechanism or an assembly tool similar to the one depicted inFIG. 46.
• FIGS. 79A and 79B show use of a flap component to fasten a separable component to club head body. As shown inFIG. 79A,club head body409 includes a cutaway void space dimensioned to receiveinsert401. The perimeter of the void space includes one or a number of mountingflanges411 that can holdinsert401 in place. Further, a portion ofinsert401 my include one or number of mounting tabs dimensioned to slip under an edge of the perimeter of the void space.Insert401 includes aboss portion399 dimensioned to mate withgasket ring397 onmalleable component395.
• As shown inFIG. 78B, insert401 can be positioned in the cutaway space ofclub head409. Then,malleable component395 can be used to fasteninsert401 in place, for example, through the use of a press fit betweengasket ring397 andboss portion399. Whileinsert401 is here shown as having a wavy perimeter edge to mate with a corresponding wavy edge of the perimeter of the cutaway void inclub head409, this is just one illustrated embodiment.Insert401 can have any suitable shape including, for example, a rectangle (e.g., to cover a compartment for two AA or AAA batteries), circular (e.g., to cover a screw or weight port), or irregular (e.g., to provide access to some interior mechanism or mass-distribution assembly).
• Use of one component to aid in connecting another component allows for benefits in design and manufacturing that may not otherwise be available to club head designers. For example, when an assembled club head includes a separable component joined to the club head body (or another component) along an attachment perimeter, if a portion of the attachment perimeter is covered (for example, by a flexible flap395), that portion may be manufactured to less precise manufacturing tolerances than if it were uncovered in an assembled, playable club head.
• To illustrate,FIG. 78B showsinsert component401 assembled toclub head body409. An aft edge ofinsert401, as shown, does not meet and mate with the perimeter of the cutaway void space inclub head body409. However, whenflexible flap395 is pushed into place, no gap betweeninsert401 andclub head body409 will appear under visual inspection. Accordingly, in certain embodiments, the invention provides a club head having a club head body and a separable insert in which an outer perimeter of the insert and an inner perimeter of a cutaway space in the body define an attachment perimeter. When the insert is coupled to the body, they make contact along a portion of the attachment perimeter and they are optionally spaced away from one another along a portion of the attachment perimeter. Another component of the club head is provided to cover the spaced away portion of the attachment perimeter such that, when the club head is fully assembled, no gaps are visible from the outside of the club head. This allowsclub head body409 to be designed and manufactured with a cutaway provided to receive an insert. Then, insert401 can be designed or manufactured with less stringent attention given to the fit along a portion of the insert, which may allow manufacturing to be faster or less expensive.
• In some aspects, the invention provides a component for a club head that forms an assembled, playable club head through the use of magnets.
• FIG. 80 shows aclub head body501 having a cutaway portion with a protrudingflange defining slot507. A separablesole member505 has protrudingtabs509 dimensioned to slide intoslot507 to form an assembled club head. Each ofclub head body501 andsole member505 have one or more ofboss513, shown here on an inside surface, holding at least onemagnet523. Any magnet may be used in the invention. In some embodiments, a high-strength magnet such as a rare earth magnet is used (e.g., magnets including neodymium or samarium-cobalt).Magnet523 can be press-fit into boss519, held in place by adhesives, threaded in, or held in place by any other suitable method (including, for example, being embedded in plies of pre-peg using, for example, manufacturing methods as discussed in U.S. Pat. No. 6,695,608 the contents of which are hereby incorporated by reference in their entirety for all purposes). Further, magnets may be employed to fix a mass element in place, such as a mass ring as disclosed in U.S. Pub. 2011/0081986, the contents of which are incorporated by reference herein in their entirety for all purposes.
• FIG. 81 is a top-down view ofboss member513 withmagnet523 therein. As can be seen fromFIG. 81,boss513 can be positioned to expose a surface of a magnet for interaction with another magnetic material.
• FIG. 82 shows another embodiment of the invention using magnets to fasten a component to a club head. Here,insert panel605 is hooked intoclub head body601 via a flange oninsert panel605 received byslot607. Distal to the flange is a mating surface presented by magnet-including bosses oninsert605 andclub head body601. Looking, for example, atclub head body601, aboss portion609 extends upwards and includesmagnet613 mounted therein (for example, by one of the methods mentioned above).
• Magnetized coupling points can be positioned at any suitable location on a club head. In certain embodiments, separable components are designed to be held in place through the use of magnets that, when on an assembled club head, are located so as to optimize mass distribution (e.g., to increase MOI around a center of percussion on a strike face or to lower a center of gravity).
• FIGS. 83-85 illustrate another embodiment using magnets to couple an insert to a club head body. Here, insert705 is coupled toclub head body701 through one or more of protrudingpost706 dimensioned to be received by correspondingslot708. An aft end of inert705 includes one or more of magnet709 (not visible inFIG. 83) exposed on an underside thereof.Club head body701 further includes one or more ofmagnet707.
• FIG. 85 is a face-aft cross sectional view through magnetic coupling mechanism ofinsert705 andclub head body701.Magnet709 ininsert705 matches up tomagnet707 inclub head body701, thereby fastening the club together for playing golf.
• In certain aspects and embodiments, the invention provides club with inserts and components that connect via one or more flanges or seams.
• FIG. 86 shows aclub head1001 that includes a ball-strikingface1002, acrown1004, a sole1006, askirt1008 that extends betweencrown1004 and sole1006, and ahosel1010.Golf club head1001 is generally constructed from abody member1012, acrown member1014, and asole member1016. In the present embodiment,crown1004, sole1006 andskirt1008 each include a multi-material construction.
• FIG. 87 illustrates certain embodiments in which a portion ofcrown1004 is constructed frombody member1012 and another portion is constructed fromcrown member1014. A portion of sole1006 is constructed frombody member1012 and another portion is constructed fromsole member1016. Furthermore, a portion ofskirt1008 is constructed frombody member1012 and another portion ofskirt1008 is constructed from sole member.
• Body member1012 includes acrown portion1023 that forms a forward portion ofcrown1004, asole portion1022 that forms a forward portion of sole1006, a skirt portion that forms either a discontinuous, or continuous, portion ofskirt1008, and at least a peripheral portion offace1002 ofgolf club head1001. The crown portion isadjacent face1002 and extends aft-ward fromface1002 and generally extends laterally from a toe side of the golf club head to a heel side of the golf club head andadjacent hosel1010. The fore-aft length of each of the crown portion and the sole portion ofbody member1012 may be any selected length, but is preferably in a range of about 0.100 inch to about 3.00 inches. The length of sole portion extending fromface1002 may be selected so that a desired ground contact location, when the club is in an address position, is located on the sole portion. The length may also be selected so that the center of gravity ofgolf club head1001 is located vertically above the sole portion when the club is in an address position.
• Sole portion1022 andskirt portion1018,1020 ofbody member1012 provide mounting features for attachingsole member1016 tobody member1012. The mounting features may be any feature that provides structure for attaching a portion ofsole member1016 tobody member1012 such as an attachment flange or cavity. In the illustrated embodiment,body member1012 includes an attachment flange having portions with different configurations for attaching sole member. In particular, the attachment flange is configured so thatsole member1016 is coupled tobody member1012 with both a lap joint and a butt joint over portions of the attachment.
• Crown portion1023 andskirt portion1018,1020 ofbody member1012 provide mounting features for attachingcrown member1014 tobody member1012. The mounting features may be any feature that provides structure for attaching a portion ofcrown member1014 tobody member1012. As shown, a peripheral portion ofcrown member1014 overlaps and is coupled tobody member1012 with a lap joint.Body member1012 andcrown member1014 may be coupled using any attachment method suitable for the selected materials, such as adhesive bonding, ultrasonic welding, welding, brazing, soldering, etc.
• FIG. 86 illustrates certain embodiment in whichbody member1012 includes a discontinuous skirt portion that includes atoe portion1018 and aheel portion20 that do not meet at an aft portion of the golf club head. As a result,body member1012 includes a gap in the skirt portion that is located at an aft portion ofbody member1012.Skirt1008 in the completedgolf club head1001, however, is continuous because a portion ofsole member1016 is inserted into the gap and forms a portion ofskirt1008. It should be appreciated that the skirt portions may be configured so that gap is located at any portion ofskirt1008. For example, the gap may be located heel-ward, toe-ward or at-ward onskirt1008.
• FIG. 87 is a cross-sectional view ofclub head1001, showing thatsole member1016 is coupled tosole portion1022 and the heel andtoe skirt portions1018,1020 ofbody1012. Anaft portion1024 ofsole member1016 includes aflange1026 that provides an attachment feature for an aft portion ofcrown member1014 and additional reinforcement to that portion of the skirt. In the present embodiment,flange1026 extends betweentoe skirt portion1018 andheel skirt portion1020 ofbody member1012 to form acontinuous skirt1008. It should be appreciated that an insert may be co-molded, bonded or inserted intoflange1026 to provide additional strength and/or stiffness.
• The structure ofgolf club head1001 provides manufacturing advantages over many previous multi-material constructions. Because only a portion ofskirt1008 is formed frombody member1012, the manufacturing method ofgolf club head1001 creates less waste.
• FIG. 88 illustrates a step in a method of constructingbody member1012 andgolf club head1001.Body member1012 is constructed as a monolithic structure. Preferably,body member1012 is constructed from a metallic material such as titanium, magnesium, steel, etc. such as by casting.Body member1012 may alternatively be constructed from a non-metallic material, such as a fiber reinforced plastic or a thermoset plastic by molding. Additionally, the construction allows the mass to be distributed more easily to manipulate the center of gravity and the moment of inertia ofgolf club head1001.
• Body member1012 is initially constructed with adiscontinuous skirt1008 and crown and sole portions with greater surface area than the final configuration. The crown and sole portions include asole support1030 and acrown support1032, as shown by dotted line inFIGS. 88 and 89, which are recessed at the at end of the body member to create a gap in the skirt such that the body member includes anopening1028.Sole support1030 andcrown support1032 are formed during the initial formation ofbody member1012 and extend acrossbody member1012 so thattoe skirt portion1018 andheel skirt portion20 are supported during the formation ofbody member1012. The support portions provide structural support to the skirt portions rather than forming them as cantilevered members relative to the remainder ofbody member1012. As a result, the support portions prevent dimensional changes of the body member and improve the flow of material during the forming process.
• A portion of each of thesole support1030 and thecrown support1032 extend to the extremities oftoe skirt portions1018 andheel skirt portion1020. The angle of intersection of a respective extremity and support portion is predetermined to provide sufficient support to the skirt portion during manufacturing.
• FIG. 89 illustrates an angle α at which crown/sole supports intersect a tangent to the skirt. Afterbody member1012 is formedsole support1030 andcrown support1032 are removed and discarded.Sole support1030 andcrown support1032 may be removed by any known method, such as milling, laser or plasma cutting, water jetting, etc.Sole support1030 andcrown support1032 are cut so that asole flange1034 and acrown flange1036 remain part ofbody member1012. The sizes ofsole support1030 andcrown support1032 are preferably minimized to reduce the amount of material that is discarded while providing adequate support to the heel and toe skirt portions to resist bending and twisting during manufacture. Preferably, each of thesole support1030 and thecrown support1032 and a tangent to theskirt1008 intersect at an angle α of about 30° to about 120°, and more preferably the support and the skirt intersect at an angle of about 50° to about 100°, more preferably at an angle of about 70° to about 90°.
• The remaining portion ofskirt1008 has an outer surface having a generally parabolic shape in cross-section having an apex that lies on an outer most edge of the club head. Preferably, the crown and sole flanges extend for a distance of between about 0.10 inch to about 0.5 inch inward from the outer most edge of the club head. The crown and sole portions may also include a step, or shoulder at an intermediate location.
• Aftersole support1030 andcrown support1032 are removed,sole member1016 is coupled tosole flange1034 ofbody member1012 to form a complete sole. Furthermore, the atportion1024 ofsole member1016 provides a structure for attachment of anaft portion1025 ofcrown member1014. In the present embodiment,aft portion1024 ofsole member1016 includes a skirt structure and a flange1038 that completes the discontinuity incrown flange1036 andskirt1008.Crown member1014 is coupled tocrown flange1036 andaft portion1024 ofsole member1016 to completecrown1004 ofgolf club head1001.
• Referring toFIGS. 90-92, another embodiment including an alternative attachment structure for a sole and/or crown member will be described.Golf club head1050 generally includes a sole1052, acrown1054, ahosel1056, a ball-strikingface1058 and askirt1060. Abody member1062 is constructed to include sole1052, acrown portion1063,hosel1056, aface portion1064 andskirt1060 as integral parts thereof. In particular,body member1062 is generally formed as a monolithic body, such as by casting a metallic material, and includes a crown opening that extends over a portion ofcrown1054 and a face opening that extends through ball-strikingface1058. Aface insert1065 is inserted into the face opening and is preferably suspended across the opening.Face insert1065 may provide any portion of ball-strikingface58 and may be constructed with a constant thickness or with portions having different thicknesses.
• The crown opening is covered by acrown member1066 which is attached tobody member1062. Preferably,crown member1066 is suspended across the crown opening and the perimeter ofcrown member1066 is attached tobody member1062. Where components are attached at or around a perimeter, the attachment need not be continuous and multiple attachment geometries or mechanisms may be employed along a perimeter.
• FIG. 90 illustrates an attachment flanges with multiple portions.Crown member1066 is attached to attachment features that are formed oncrown portion1063 andskirt1060 ofbody member1062. The attachment feature includes afirst flange portion1068 and asecond flange portion1070.First flange portion1068 includes a single faceted portion that provides a bonding surface forcrown member1066 to crownportion1063 and a portion ofskirt1060.Second flange portion1070 includes a multi-faceted portion that provides multiple bonding surfaces forcrown member1066 on a portion ofskirt1060. In the present embodiment,first flange portion1068 extends around a forward portion of the perimeter of the crown opening andsecond flange portion1070 extends around an aft portion of the perimeter of the crown opening.
• First flange portion1068 provides a single faceted attachment feature that extends along a forward edge of the crown opening and along forward portions ofskirt1060 on both the heel side and toe side of the golf club head. Thefirst flange portion1068 is joined withcrown member1066 by a single lap joint configuration. In particular, the corresponding portion ofcrown member1066 includes a single wall that overlaps and is coupled tofirst flange portion1068.
• Second flange portion1070 provides a multi-faceted attachment feature that extends along an aft portion ofskirt1060. By constructing a portion of skirt with a multi-faceted attachment feature, the mass ofskirt1060 may be more efficiently located by creating a compact mass in the skirt while providing sufficient bonding surface area for the crown member. Additionally, the attachment feature allows more precise location ofcrown member1066 during manufacture because the interaction between the multi-faceted feature ofskirt1060 andcrown member1066 are self-locating.
• FIG. 91 shows a cross-sectional view ofclub head1050 along line6-6 inFIG. 90. As shown in area “A”, an aft portion ofcrown member1066 includes a multi-faceted, or non-planar, attachment feature that complements the attachment feature ofbody member1062.
• FIG. 92 is a detail view of area “A” fromFIG. 91, showing an aft portion ofcrown member1066 including a pair ofattachment surfaces1072 that are angled relative to each other and that complement a pair ofattachment surfaces1074 included on the skirt. In the present embodiment, attachment surfaces1072 ofcrown member1066 are formed on a pair of atflanges1076,1078. A first atflange1076 forms a portion of the outer surface ofcrown member1066 which has a continuous curved outer contour. Asecond flange1078 branches away from first atflange1076 toward the internal cavity of the golf club head so that the two flanges are angled relative to each other and are configured for attachment to themulti-faceted skirt1060. It should also be appreciated that the flanges may create a continuous curved mounting surface that interfaces a curved mounting surface of the skirt.
• The angle betweenflanges1076,1078 is selected to match the particular configuration of the skirt and the desired method of attachment. For example, the draft angle of the attachment surfaces of the skirt and the manufacturing tolerances of the crown member are considered. Additionally, the method of attaching the crown member is considered such as if, during attachment of the crown member, the entire periphery of the crown member contacts the body member at the same time or if a portion of the crown member is contacted and the remainder is rotated into position. In one method, the portion of the crown member closest to the face of the golf club is installed and the crown member is rotated so that the aft portion comes in contact with the body member However, the angle is generally between about 40° and about 140°, more preferably between about 60° and about 120°, and even more preferably between about 80° and about 100°.
• Second flange1070 ofskirt1060 andaft flanges1076,1078 are dimensioned so that acavity1080 is formed betweencrown member1066 andskirt1060 after assembly of the golf club head.Cavity1080 is provided so that in embodiments utilizing adhesive to couplecrown member1066 tobody member1062, the adhesive may flow away from the contact surfaces of the flanges and the skirt and toward the intersection of atflanges1076,1078. In other embodiments, a compressible gasket may be inserted intocavity1080 to provide a more forgiving it during construction. In still further embodiments, the cavity may be omitted.
• FIG. 93 gives a detailed view of an alternative embodiment ofskirt1060. In the embodiment, the construction of the crown member is identical to that described above and the skirt has been modified. In particular,skirt1090 includes acavity1092.Cavity1092 is configured to receive one ormore inserts1094, but may be left empty if desired. In embodiments utilizing a plurality ofinserts1094, the inserts may be provided with different masses to alter the weight distribution, such as by adding more weight heel-ward or toe-ward. Insert94 may be constructed to do one or all of the following: to alter the mass ofskirt1090, to provide damping or sound-tuning and/or to provide strength or stiffness toskirt1090. For example, insert94 may be constructed from a material that has a density, stiffness, and/or strength that is different than the material ofskirt1090 orinsert1094 may be constructed from a material that has desired dampening properties.Insert1094 may be constructed from metallic materials such as aluminum, magnesium, titanium, tungsten, and alloys thereof, or it may be constructed from non-metallic materials, such as polyurethane, tungsten loaded urethanes.
• Referring now toFIGS. 94-96, another embodiment of a golf club head having an improved structure will be described.
• FIG. 94 shows a golf club head with a ball-strikingface1102, acrown1104, a sole1106, askirt1108 that extends betweencrown1104 and sole1106, and ahosel1110. In the present embodiment,crown1104 includes a multi-material construction and includes abody member1112, acoupling member1116, and acrown member1114.Body member1112 includes an opening in the crown that receives crown member114.
• FIG. 95 is a cross-sectional view of the club head inFIG. 94, showing assembly and construction details.Crown member1114 is coupled tobody member1112 throughcoupling member1116.Coupling member1116 is included and constructed to simplify the manufacturing process required to couplecrown member1114 tobody member1112, especially when anon-metallic crown member1114 is coupled to ametallic body member1112. For example, acomposite crown member1114 may be coupled tocoupling member1116, such as by adhesive bonding, and excess adhesive may be removed before the combinedcrown member1114 andcoupling member1116 is secured tobody member1112. As a result, excess adhesive that would otherwise add additional weight to the assembled golf club may be removed. Additionally, a more difficult coupling process and/or configuration may be utilized to couplecrown member1114 andcoupling member1116 when the two are separate frombody member1112, where they may be worked on and manipulated more easily. Alternatively,coupling member1116 and crown member may be co-molded.
• Preferably, the material ofcoupling member1116 is selected to provide improved bonding strength between it and the material ofbody member1112 so that the overlapping bonding surfaces can be minimized to avoid adding unnecessary mass and to improve the integrity of the joint. For example, when ametallic body member1112 and a generallynon-metallic crown member1114 are coupled, the crown member preferably includes a multi-material construction so at least the bonding portion provides a material high surface free energy because non-metal materials generally do not have very high surface free energy. For example, material having high surface energy, such as a metallic material like metallic mesh, may be added to the crown member to improve the efficiency of the bond. For example, including titanium mesh in a portion of the crown member may be used to increase efficiency during bonding of that component to a titanium body member. Ideally, the surface free energy of the members being bonded is greater than the surface tension of the bonding material so that the bonding material wets the bonding surfaces to provide a strong bond.
• Additionally, forming the bond between the components separate from the club head body member may also be used to improve efficiency of the bonding because preparation of the bonding surfaces, post bonding processes and control over the fit of the components may be improved. For example, properly cleaning the bonding surfaces is important to maintain the surface energy of the material as high as possible. Methods of raising, and maintaining, the surface free energy of thermoset composites include abrasion using an abrasive material, such as an abrasive pad (e.g., Scotch-Brite pads, a registered trademark of 3M Company, St. Paul, Minn.) or sand paper, and grit blasting, then removing dust and debris using solvent wipes or dry wipes. Methods for maintaining high free surface energy for metal materials include vapor or solvent degreasing, increasing the effective bonding surface area by chemical or acid etching, use of a chemical coupler surface treatment such as a sol-gel process, and use of a corrosion inhibiting primer to preserve the freshly treated surface. By improving the efficiency of the bonding the overall bond width may be reduced, especially in the side joints. The coupling member is preferably constructed from a material that is the same as the body member or weldable to the body member.
• FIG. 96shows crown member1114 coupled tocoupling member1116 with a lap joint. The lap joint is created by aflange1118 included oncoupling member1116 and an overlapping portion ofcrown member1114 that is coupled thereto. For example, the two members may be coupled using abonding material1120, such as by adhesive bonding, brazing, or soldering the two components together. Where the materials ofcrown member1114 andcoupling member1116 permit welding, thebonding material1120 may be weld material.
• Referring toFIGS. 97-102, alternative coupling configurations between a crown member, a coupling member and a body member will be described.
• FIG. 97 illustrates a lap joint andFIG. 98 illustrates a tapered scarf joint that may be employed. For example, inFIG. 97, acrown member1122 and a coupling member1124 have complementary stepped flanges that are coupled withbonding material1120. The stepped flanges are formed by a plurality ofshoulders1126 andlandings1128 and althoughshoulders1126 andlandings1128 are shown perpendicular to each other, it should be appreciated that they may have any angle relative to each other. For example, shoulders1126 andlandings1128 may be oriented to generally form a saw tooth pattern.
• FIG. 98 illustrates another lap joint that includes an angled interface between acrown member1130 and acoupling member1132. The angle of the interface between the components may be selected so that a desired distribution of shear and normal forced may be placed onbonding material1120 for a predetermined force on the components.
• In other embodiments of coupling configurations, the components are configured so that a portion of one component is received in a portion of the other component. As a result, the components are coupled bybonding material1120 and a mechanical connection.
• FIG. 99 shows a coupling in which a portion of acrown member1134 is inserted into a recess of a coupling member1136 and a pair of parallel interfaces are coupled bybonding material1120.
• FIG. 100 shows another embodiment in which acrown member1138 includes a recess that receives a portion of acoupling member1140.Crown member1138 and coupling member also engage at a stepped interface that includes a plurality ofshoulders1142 andlandings1144.Bonding material1120 is disposed at the stepped interface to securely couple the components.
• FIG. 101 shows another embodiment, in which a portion of acrown member1146 is received in a recess of acoupling member1148 and the two components engage at a pair of angled interfaces that are also held together withbonding material1120. In such embodiments, the components may be coupled using thermal fitting techniques. For example, the coupling member may be heated and/or the crown member may be cooled so that clearance is provided between the components when the temperatures are different, then the components may be held in place until their temperatures are equalized. The materials may be selected, at least in part, by considering the required expansion based on the coefficient of thermal expansion of the material.
• FIG. 102 illustrates a strap lap joint that includes acrown member1150 that is attached to acoupling member1152 by a pair ofsupport members1154. In particular, end surfaces ofcrown member1150 andcoupling member1152 abut andsupport members1154 are coupled across the abutment to the side surfaces ofcrown member1150 andcoupling member1152.
• It should further be appreciated that the club head construction including a coupling member to couple the body member and another component may be applied in other portions of the golf club head. For example, a coupling member may be used to couple a crown member (as shown), a sole member, a face member, and/or a hosel member to a body member of the golf club head.
• The invention provides strong and lightweight coupling between members, components, or inserts in a golf club head. Using attachments at seams preferably with flanges (e.g., forsole member1016 inFIG. 87,crown member1066 inFIG. 91, orcrown member1114 inFIG. 96), the invention provides a mode of coupling that is extensible to body members generally, including face members or inserts as well as any other insert to optimize the utility or function of a club head.
• For example, attachment methods described above are provided for attaching panels, inserts, or components, for example, light weight inserts (e.g., optionally similar tosole member1016, above, or having any configuration).
• FIG. 103 showsclub head1605 havinginsert1609. Other exemplary inserts including, for example, light-weight inserts (for example, in the crown region) are discussed in Golf Club Head, U.S. Pat. No. 7,938,740; Golf Club Head with Concave Insert, U.S. Pat. No. 7,524,249; and Golf Club Head, U.S. Pub. 2011/0272846, the contents of each of which are incorporated by reference herein in their entirety.FIG. 103 shows insert1609 in a sole region.Insert1609 can be anywhere on a club head (e.g., face, skirt, crown, heel, or toe) as shown, for example, in the above-cited patents and publications.
• FIG. 104 is a cross-sectional view of the club head shown inFIG. 103. As shown inFIG. 104,insert1609 may optionally be of a different thickness than surrounding material ofclub head1605.Insert1609 is joined to head1605 at a seam, which may have any construction discussed herein (see, e.g.,FIGS. 96-102). A construction seam will generally include at least oneflange1601. As described here,flange1601 is generally a protruding tab of material monolithically formed with surrounding material ofclub head1605 and optionally recessed somewhat into the head so that ifinsert1609 is in place,flange1601 is not directly visible from the outside of the club head. However,flange1601 may also refer to the corresponding portion ofinsert1609. Further, the recessed side can be on the club head, on the insert, or on a mixture of both.
• FIG. 105 shows an embodiment in which both ofinsert1609 andhead1605 include an L-shaped flange (e.g., pointing into the club head) to present a mating surface for coupling the insert into the club head. In certain embodiments (not shown), onlyclub head1605 includes an L-shaped flange, andinsert1609 includes material that is as thick as the flange, thus not needing to be L-shaped, for example, to provide more weight or due to a light weight choice of material. In certain embodiments,insert1609 includes an L-shaped flange andclub head1605 does not.
• A flange or coupling seam according to the invention may be used to couple two components (e.g., substantially similar in size, i.e., neither one an “insert” in the other).
• FIG. 106 shows aclub head1505 having abody member1509 coupled to the club head at an attachment perimeter that includes aflange1501. Attachment of a body member via an attachment perimeter is discussed in Golf Club Head with Concave Insert, U.S. Pat. No. 7,658,686 and U.S. Pat. No. 7,980,964; Golf club Head with Concave Insert, U.S. Pub. 2011/0275455; Golf Club Head, U.S. Pub. 2011/0053706; and Golf Club Head U.S. Pub. 2007/0054751, the contents of each of which are hereby incorporated by reference in their entirety.Flange1501 can be disposed as shown inFIG. 106 or it can have any form (see, e.g.,FIGS. 96-102,105) in which at least one area of material is bound to another material.
• FIG. 107 shows a detail view of aclub head1605, similar to one shown inFIG. 95, including a coupling member to presentflange1601 tocrown member1609. In various embodiments (e.g., including a coupling member or not and in which the flange is on an insert, a body, or both, and in which a flange has any disposition or morphology) the invention provides optimization to a flange for better weight and construction strength. Flanges according to the invention allow a greater variety of types (e.g., bonding ledges, lap joints, butt joints, tongue-and-groove types, saw tooth conformations) to be used in more places in a club head, for example, by minimizing weight of flange material and increasing bonding surface area, as well as allowing for removal of excess adhesive.
• The invention generally provides aflange1601 for binding acomponent1609 to aclub head1605.Flange1601 may optionally include one or more void1613 in, through, on, or near a mating surface.
• FIG. 108 shows a series of substantiallycircular voids1613 arrayed alongflange1601 participating in aseam binding component1609. A void1613 may optionally pass all the way throughflange1601.
• In some embodiments, adhesive1607 bindscomponent1609 toclub head1605. Where void1613 presents a recess intoflange1601, void1613 may function as a cavity (see, e.g.,cavity1080 inFIG. 92) allowing adhesive1607 to flow away from the contact surfaces.
• Where void1613 presents a hole throughflange1601, void1613 further allows an adhesive1607 to pass throughflange1601. This allows a greater surface area offlange1601 to contact adhesive1607, providing a strong bond. This further allows excess adhesive1607 to be easily removed, creating a clean finish line and aclub head1605 with a minimum of unnecessary excess weight. Excess adhesive can be removed from withinclub head1605 in any manner. For example, it can be allowed to dry and globules of adhesive not substantially participating in bonding will be as pellets, capable of being shaken out through a construction hole or hosel. Excess adhesive can be sanded away. Ridges, protrusions, or flashings of excess adhesive can be broken off by sonication, a tool, chemical treatment, or other means known in the art. In certain embodiments, a solvent such as turpentine or acetone is introduced intoclub head1605 and swirled around to remove excess adhesive and then washed out ofclub head1605.
• Flange1601 can include asingle void1613 into the surface or through it. In a preferred embodiment, a plurality ofvoids1613 are provided throughflange1601 arrayed in a perforation-like pattern. A pattern ofvoids1613 can be described with reference to a number of features. A plurality of voids can be described with reference to an average aperture area A of opening (e.g., wherevoids1613 are round with a radius r, an individual aperture area Ai can be given by πr2). An area including a pattern ofvoids1613 can be described with reference to a ratio S of void space to total area. A void1613 can be described with reference to a geometric shape of a perimeter ofvoid1613. An aperture area ofvoids1613 can be described with reference to a pattern describing the arrangement ofvoids1613. Aflange1601 with voids can be described in terms of a number N of voids per cm in a linear direction along an attachment perimeter of component1609 (e.g., N can be between about 10 and about 5000 or between about 0.1 and about 9).
• FIGS. 108-113 each show aflange1601 including an area ofvoids1613 according to certain embodiments of the invention. As shown inFIG. 108,voids1613 may be generally substantially circular and arrayed in a linear repeating pattern. An average aperture area A ofvoids1613 may generally be between about 0.5 mm²and about 5 cm². A ratio S of void space to total area offlange1601 may generally be between about 0.001 and 0.9, preferably between about 0.01 and about 0.9, preferably between about 0.1 and about 0.75 (e.g., between about 0.2 and about 0.5).Voids1613 may be divots in a surface offlange1601 or holes throughflange1601.
• FIG. 109 shows a pattern ofvoids1613 presenting holes throughflange1601. As shown inFIG. 109,voids1613 can be arrayed in an offset, or zigzag, pattern.Voids1613 may be arrayed in a precise geometrical pattern, or with an irregular spacing or irregular offset. As shown inFIG. 109, a ratio S of void space to total area offlange1601 may generally between about 0.1 and about 0.5, e.g., between about 0.3 and about 0.4. A perimeter of a void1613 may be circular or substantially circular, as well as optionally oval, elliptical, ovoid, or oblong. A perimeter may be hexagonal, triangular, star shaped (e.g., if punched out by a punch tool) and need not be flush or planar with a surrounding area offlange1601. For example, if avoid1613 is made by punching with a punch tool, a perimeter may be a rough edge including a series of points furled back in a direction of a punch.
• FIG. 110 shows a pin-hole pattern ofvoids1613. Pin-hole voids may be arrayed in any density (e.g., tight cluster making a screen-like flange, or spaced apart). For example, a ratio S may be above about 0.5 (tight cluster or mesh) or lower (substantially solid flange). For pin-hole voids, an average aperture area A ofvoids613 may generally be less than about 0.5 mm²(e.g., between about 0.001 mm²and about 0.1 mm²). A pattern ofpinhole voids1613 may be square grid, rectangular grid, diamond grid, triangular grid, hexagonal grid, or irregular. In certain embodiments,pinhole voids1613 are arrayed in a pattern to represent an image or text (i.e., a brand or logo is “written” on the flange in pinhole voids).
• FIG. 111 illustrates aflange1601 have an irregular array of irregular shapedvoids1613. Withirregular voids1613, any average aperture area A or ratio S is possible. For example, an average aperture area A can be between about 0.1 mm²and about 5 mm²or between about 5 mm². and about 3 cm². Irregular voids provide a ratio S that can be anything, for example, between about 0.001 and about 0.95.
• FIG. 112 shows aflange1601 havingvoids1613 generally having a substantially rectangular perimeter and arrayed in a regular, repeating pattern.
• FIG. 113 shows aflange1701 according to certain embodiments of the invention. As shown inFIG. 113,flange1701 may be part of an area of material1705 in a club head.Flange1701 may generally have a honeycomb structure with substantiallyhexagonal voids1713.
• FIG. 114 is a reproduction of the drawing inFIG. 113 with idealized bounding lines extending around the honeycomb structure to help visualize a three-dimensional shape offlange1701. The honeycomb structure is not drawn or shown extending for the entire length ofmaterial1705. The honeycomb structure may optionally extend for a portion of, or an entirety of,flange1701 and may also extend any amount into surroundingmaterial1705.
• A honeycomb structure or any of the embodiments described herein including one or more void in a flange can be made by any method known in the art. For example, material can be etched away from metal by laser etching. Material can be formed by laser metal sintering. Making components via laser metal sintering is discussed in Method of Making Golf Clubs, U.S. Pat. No. 8,007,373 and Method of Making Golf Clubs, U.S. Pub. 2011/0277313, both herein incorporated by reference in their entirety. Methods of making components are discussed in Golf Club Head, U.S. Pat. No. 7,803,065; Method of Making Golf clubs, U.S. Pub. 2011/0277313; Golf Club Head with Multi-Component Construction, U.S. Pub. 2011/0152003; Method of Making Golf clubs, U.S. Pub. 2010/0298065; Golf Club Heads, U.S. Pub. 2011/0151989; Club head with Improved Inertia, U.S. Pub. 2010/0056297; and Metal Wood Golf Club Head, U.S. Pub. 2008/0227564, the contents of each of which are incorporated by reference in their entirety.
• An advantage of the invention includes the improvement to surface area, weight, joint strength, and appearance of coupled components when one or more void is provided on a mating surface or flange. For example, where a coupling seam is required in an area of a club head where weight is desired to be minimized (e.g., in a crown, above a center of gravity), voids can be provided. Voids do not need to be spaced evenly along a flange. For example, where a coupling seam extends across a crown and into a heel area and a toe area, a flange of the coupling seam may include more voids, or voids having a higher average aperture area A, or a higher ratio S near the crown, and a gradual or abrupt transition to minimum or no voids near a heel toe region.
• Voids in a flange may be provided in a variety of sizes or shapes (e.g., intermingled). For example, large voids can be provided side-by-side with pinhole voids or any intermediate sized void. Where a flange comprises a curved surface (e.g., a portion of a spheroid surface), voids can be arrayed, for example, as a combination of hexagons and pentagons (i.e., soccer-ball structure or geodesic dome structure) to give a substantially regular geometry over a flange surface. Such a combination of voids may be employed when honeycomb structure (as shown inFIG. 113) is included on a flange having a substantially curved surface area.
• FIG. 115A is a side view of a club head according to certain embodiments of the invention.FIG. 115B is a cross-sectional view of the club head shown inFIG. 115A. As shown inFIG. 115B,flange1601 may be included oncomponent1609. As shown inFIG. 115A,component1609 extends from a sole ofclub head1605 to a skirt ofclub head1605.Flange1601 may include voids in the form of perforations (e.g., array of substantially circular voids), pinhole perforations, honeycomb structure, or regular or irregular divots or holes according to any description herein. Voids may be: onflange1601 oncomponent1609 as shown inFIG. 115B; onflange1601 onclub head1605 as shown inFIG. 104; on both; on either or both of L-shaped flanges as shown inFIG. 105; or on any other mating surface morphology of the present invention, for example, as shown herein throughout. Any coupling member, flange, attachment perimeter, joint, or other mating morphology, for example, as shown at least inFIGS. 96-102, may include one ormore voids1613 according to descriptions herein or natural equivalents thereof.
• For example, in certain aspects, the invention provides golf club head that includes a crown, a sole, and a face defining a body, in which the body includes at least oneinsert component1609 connected to the body at an attachment perimeter. The attachment perimeter includes aflange1601, and the flange includes one or a plurality of avoid1613, each forming a hole in a surface of the flange. The hole can go through the surface of the flange.Flange1601 may be on the body and configured to be concealed from the outside of an assembled club head by the insert component, or it may be on the component. Theinsert component1609 may be anywhere on the club head. Typically, lightweight inserts may be favored for the crown. Sole inserts may include any distribution of weight or topologies according to a club designer. The flange can be L-shaped. In some embodiments, the holes are pinpoint holes with average aperture area between about 0.01 mm²and about 1 mm², or they may have a ratio of aperture space to total surface area between about 0.1 and about 0.75. In some embodiments, the plurality of holes are disposed to be visible from the exterior of an assembled club head.
• In certain aspects, the invention provides acomponent1609 for a golf club head including material shaped to matingly couple to another component to form a body of a club head and comprising aflange1601, wherein the flange comprises at least one hole through it.
• Voids according to the invention offer particular benefits for optimizing the performance of adhesives (such as epoxy, resins, products such as Scotch-Weld brand adhesive DP807 from 3M Company (St. Paul, Minn.)) and other bonding substances. For example, voids present a greater surface area for adhesives to contact and, more particularly, can be configured to offer a greater surface area with a lower total volume of material than other assembly mechanisms. By increasing surface area while minimizing volume, bonding strength can be increased while a mass of a bond can be minimized, thereby giving a club head designer more discretionary mass to place elsewhere.
• Voids1613 allow excess adhesive to flow away from mating surfaces, thereby giving assembled golf clubs stronger bonds as well as a more precise it among parts, creating a more attractive appearance and aerodynamic outside surface. A better fit among parts creates club heads with more consistent playing characteristics and makes club head sub-assemblies during manufacturing more consistently compatible with downstream equipment (e.g., finishing stations for adding more components or laser etchings) in assembly work flows.
• Voids1613 further allow novel visual features that aid a golfer in recognizing a particular model of club or understanding a physical aspect of a club. For example, in some embodiments, aflange1601 on an outside surface of a club includes one ormore void1613.Void1613 may be partially or entirely filled adhesive. A part of void1613 may optionally be filled with another material (e.g., urethane, water clear polyethylene or opaque materials, polycarbonate, acrylic, poly(methyl methacrylate), polystyrene, or polydimethylsiloxane). Any such material may be included in its default color, may be painted or colored on a surface, or may be impregnated with pigments or made translucent. For example, in some embodiments a flange includes voids to optimize a performance of adhesive, in which the voids are on an outside surface of the club and further filled to the surface with a translucent (or opaque or transparent) material, thereby allowing a golfer to understand why or how the club may exhibit certain playing properties or mass properties.
• The disclosure herein includes description and discussion of methods and mechanism for assembling components such as inserts, sole plates, crown plates, and components of club heads, and bodies, to one another. The invention includes the insight that one or more of any of any mechanism of the invention, any component of the invention, or any feature of the invention can be combined in any number and in any combination. For example, any given flange arrangement and any given fastening mechanism may be combined—even if not shown together in a figure of the present disclosure—to provide a multi-component club head or club head with separable component or insert. Thus a club head of the present invention may include, for example, barbed posts designed to be broken off to remove a component as well as magnets for fastening components together.
• It is an insight of the invention that a number of aspects of a club head can be uniquely selected with a variety of options and that this is well suited to customizing club heads to a customer's desires. It is a related insight that computer device technology provides a valuable tool for managing the complexity of manufacturing where customized orders are included. Accordingly, the invention provides systems and methods for providing a customized club head.
• Providing a customized head can include offering options for one or more features that are available with a club head and receiving a selection from a consumer of an option.
• FIG. 116 depicts a display that can be used to receive a consumer's selection of one or more options for a club head. As shown inFIG. 116, a consumer could be given a display (e.g., in a web browser as presented via a graphical user interface (GUI)) that includes elements such as pull-down menus for choosing options. Any method of offering options and receiving selections is included, such as, for example, point-and-click selection, keyboard entry, radio buttons, and confirmation of suggested options. A selection of an option can include selecting a given option from a set of possibilities and it can also include selecting whether or not to include a certain feature at all. For example, a consumer can be offered whether or not they would like a removable crown panel on their club head and, if they choose so, they can then be offered a list. Options can be offered and selections received for any aspect of a club head including all of those discussed herein. As indicated inFIG. 116, a consumer could choose a material for a crown panel and suitable choices could include, for example, clear plastic, translucent plastic, composite, carbon fiber, titanium, aluminum, alloy.
• A customer could be offered choices of bodies and body materials. Choices of certain bodies may govern the availability of certain other choices. For example, some bodies may have a forward member for supporting a strike face and a body skirt member upon which a crown panel and sole plate are to be installed. Where a customer chooses such a body, they may then be offered a choice of sole plate (e.g., with choice of style, material, color, etc.).
• Other features a customer could choose options for include overall finish of surface (e.g., anodized, painted, decal set), strike face, removable/interchangeable weight members, reconfigurable shaft, setting indicator window, customer-uploaded photo printed on surface (e.g., as uploaded digitally), number of club heads (e.g., customer orders entire set or matching clubs/sets for whole families), etc.
• FIG. 116 generally shows an exemplary display as could be shown on a screen, for example, of a computer or smartphone, discussed in more detail below. In certain embodiments,FIG. 116 represents a display rendered in a web browser (e.g., a web page being displayed by Internet Explorer or Google Chrome).
• As shown inFIG. 116, receiving customer options can be done via a series of related screens. For example, a customer can choose materials for parts in a first screen, choose optional accessories in another screen, and save their choices and pick colors in another screen. However, in other embodiments, all choices are made on a single screen or a different combination of screens. In certain embodiments, choices are suggested based on inferences made according to computer program rules about a customer's likely preference. For example, if a customer orders a shaft in a given color (e.g., orange), a club head can be shown and suggested with a given matching or complementary color (e.g., orange main material with blue contrast finish details, or all green panels).
• Given the variety of options a customer may choose and the variety of numbers a customer may order, the invention provides methods of receiving and preparing customized orders.
• FIG. 117 gives a high-level block diagram of steps of a method of providing a customized club head according to certain embodiments of the invention. A method of providing a customized club head according to certain embodiments of the invention can include receiving a customer's choice of a product (e.g., AMP-product line driver club head) and showing the customer a product example (e.g.,FIG. 116). A customer's selections of an option are received and saved in a memory. If the selection reflects a change from what was previously shown, the displayed product view can be updated to show what the customer has chosen. This can be repeated for as many features as are customizable or as many features as the customer chooses to select options for.
• If the customer ends up not placing an order, they can be returned to browsing (e.g., shown a web page home screen or another product screen). Their choices can be saved and displayed to them at a later web page visit.
• If the customer places an order, methods of the invention include capturing information from the customer about how they will pay for the product and how they will receive it. For example, a customer can provide a credit card number over a computer network (e.g., by typing into a payment web page), and then choose shipping by expedited mail and provide their home address. Or, alternatively, a customer can indicate that they wish to use a corporate account (e.g., they are purchasing a dozen club heads that are printed with a corporate logo which they have uploaded an image file such as a TIFF) and they can specify delivery to some site. A customer can also choose in-store pickup. In certain embodiments, a method of providing a customized club head is operable in conjunction with a special event, and methods include capturing delivery information about providing the club heads at the special event. For example, if Acme Golf Co is sponsoring and staffing a booth at Corporate Inc.'s charity fund-raiser, Acme Golf Co can collect information from a person at Corporate Inc. about a customized golf club (e.g., as a promotional item or prize) via methods of the invention, and Acme Golf Co can bring the golf club to the booth at the charity fund-raiser.
• After delivery information is captured, it is determined whether the ordered item is already in stock, as-ordered. If it is, the ordered item is shipped or prepared for delivery according to the customer's delivery information. If the ordered item is not in stock, the order is batched.
• Methods of the invention include organizing sets of orders for efficient production. A computer program, executed by a processor, can make reference to information about production facilities to organize a plurality of different orders and to coordinate production instructions so that production facilities include minimal down-time while components or parts are “switched out”. For example, if regular production is scheduled for ten gross of aluminum club head bodies and ten gross of titanium club head bodies, and customized orders have been placed for one composite body, one aluminum body, one titanium body, and one alloy body, then order batching can include listing the order, for example, in the following order: 1441 aluminum; 1441 titanium; 1 composite; 1 alloy.
• Order batching further includes scheduling production of individual batches, where a batch is a sub-set of all orders identified by a computer executing program instructions according to production criteria. Batches may be scheduled according to information about production times, steps, complexity, or interrelationships involved. For example, if a repositionable shaft connection is required to be added to a club head at an assembly workstation where a main body of a club head is painted, while a sole plate is added to a club head at a dedicated separate workstation and can only be added after a main body is painted, then a batch can be prepared that is all club heads with repositionable shaft connections batched with all club heads to be painted, while a separate batch is prepared that includes all club heads with a sole plate. Then, the second batch can be routed to the main assembly work station first, for example, to leave additional time for adding the repositionable shaft connection to that batch while the other batch is at the main assembly workstation so that the entire set of batches is completed at the same time.
• After order batching, order information (e.g., info regarding batches, production schedules, and individual orders of club heads) is transmitted to a production system or facility, and the ordered club heads are produced.
• After production, the club heads are sent. If a customer has ordered a club to be shipped to their home, the club is sent to the customer. If a customer has requested in-store pickup, the club is sent to the store. If a customer has requested another delivery option, it is so initiated.
• The invention provides systems suitable for implementing methods of providing a customized golf club including the foregoing methods.
• FIG. 118 shows components in an exemplary system for providing a customized golf club. As shown inFIG. 118,system200 generally includes one or more computer, communicably coupled vianetwork215. Systems and methods of the invention may generally be implemented through the use of one or more computer such as any combination of aprovider computer281, aproduction computer261, and aconsumer computer201 along with, for example, asales server241 and aproduction server221. A computer generally includes a processor (e.g.,209,289,269,249,229) operably coupled to a memory (e.g.,207,287,267,247,227) and configured to send or receive information via input-output device (e.g.,205,285,265,245,225).
• One of skill in the art will recognize that a processor may be provided by one or more processors including, for example, one or more of a single core or multi-core processor (e.g., AMD Phenom II X2, Intel Core Duo, AMD Phenom II X4, Intel Core i5, Intel Core i& Extreme Edition 980X, or Intel Xeon E7-2820). In certain embodiments, any ofconsumer computer201,provider computer281,production computer261 may be a notebook or desktop computer sold by Apple (Cupertino, Calif.) or a desktop, laptop, or similar PC-compatible computer such as a Dell Latitude E6520 PC laptop available from Dell Inc. (Round Rock, Tex.). Such a computer will typically include a suitable operating system such as, for example,Windows 7, Windows 8, Windows XP, all from Microsoft (Redmond, Wash.), OS X from Apple (Cupertino, Calif.), or Ubuntu Linux from Canonical Group Limited (London, UK). In some embodiments, any ofconsumer computer201,provider computer281,production computer261 may be a tablet or smart-phone form factor device andprocessor281 can be provided by, for example, an ARM-based system-on-a-chip (SoC) processor such as the 1.2 GHz dual-core Exynos SoC processor from Samsung Electronics, (Samsung Town, Seoul, South Korea).
• In some embodiments, either ofsales server241 orproduction server221 can be a Hitachi Compute Blade500 computer device sold by Hitachi Data Systems (Santa Clara, Calif.). Either ofprocessor249 orprocessor229 can be, for example, a E5-2600 processor sold under the trademark Xeon by Intel Corporation (Santa Clara, Calif.).
• Input-output devices generally includes one or a combination of monitor, keyboard, mouse, data jack (e.g., Ethernet port, modem jack, HDMI port, mini-HDMI port, USB port), Wi-Fi card, touchscreen (e.g., CRT, LCD, LED, AMOLED, Super AMOLED), pointing device, trackpad, microphone, speaker, light (e.g., LED), or light/image projection device.
• In certain embodiments, a consumer's selection of options is received via the consumer's use ofconsumer computer201 and the selection is received atsales server241 and stored inmemory247.Sales server241 uses a network card for input/output245 to received data.Sales server241 maintainsorder database243 which may includeaccounts244 where consumer information is stored (e.g., for payment and delivery information).
• After orders are received and ready for production, digital files can be transferred via input/output245 fromsales server241 toproduction server221 via input/output225, which may also be a network card or other data transfer mechanism. Order information (e.g., orders239) is stored inproduction database235 inmemory227.Processor229 executes computer program instructions stored inmemory229 to perform order batching and to initiate production.
• A production facility may be equipped with aproduction computer261 which either automatically coordinates the operation of machines or provides information to production employees, e.g., via input/output265, which could include, for example, a monitor or laser printer.
• Many of the steps and functions described herein can be planned or coordinated by a provider personnel usingprovider computer281. For example, engineers or sales personnel can prepare and upload information (e.g., digital files such as in a comma-separated values (CSV) format) that, for example, lists options for features for consumer selection. That is, in certain embodiments, provider personnel useprovider computer281 to “set up” what options are available, for example, within a display such as the one shown inFIG. 116. Such uploaded information may be saved inmemory247 onsales server241 and can be used, for example, byprocessor249 to cause a display to be rendered such as that shown in FIG. {44 on input/output205 onconsumer computer201. Input/output205 can include a monitor displaying a view of a web browser. A customer's selection of options can be stored in one ofaccounts244 inorder database243 by writing a file inmemory247.
• A memory generally refers to one or more storage devices for storing data or carrying information, e.g., semiconductor, magnetic, magneto-optical disks, or optical disks. Information carriers for a memory suitable for embodying computer program instructions and data include any suitable form of memory that is tangible, non-transitory, non-volatile, or a combination thereof. In certain embodiments, a device of the invention includes a tangible, non-transitory computer readable medium for memory. Exemplary devices for use as memory include semiconductor memory devices, (e.g., EPROM, EEPROM, solid state drive (SSD), and flash memory devices e.g., SD, micro SD, SDXC, SDIO, SDHC cards); magnetic disks, (e.g., internal hard disks or removable disks); magneto-optical disks; and optical disks (e.g., CD and DVD disks). The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
• The subject matter described herein can be implemented in a computing system that includes a back-end component (e.g.,sales server241 or production server221), a middleware component (e.g., an application server or sales sever241), or a front-end component (e.g.,consumer computer201 having a graphical user interface or a web browser through which a user can interact with an implementation of the subject matter described herein), or any combination of such back-end, middleware, and front-end components. The components of the system can be interconnected throughnetwork215 by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include cell network (e.g., 3G or 4G), a local area network (LAN), and a wide area network (WAN), e.g., the Internet.
• The subject matter described herein can be implemented as one or more computer program products, such as one or more computer programs tangibly embodied in an information carrier (e.g., in a non-transitory computer-readable medium) for execution by, or to control the operation of, data processing apparatus (e.g., a programmable processor, a computer, or multiple computers). A computer program (also known as a program, software, software application, app, macro, or code) can be written in any form of programming language, including compiled or interpreted languages (e.g., C, C++, Perl), and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. Systems and methods of the invention can include instructions written in any suitable programming language known in the art, including, without limitation, C, C++, Perl, Java, ActiveX, HTML5, Python, Ruby on Rails, Visual Basic, or JavaScript. In certain embodiments, systems and methods of the invention are implemented through the use of a mobile app. As used herein, mobile app generally refers to a standalone program capable of being installed or run on a smartphone platform such as Android, iOS, Blackberry OS, Windows 8, Windows Mobile, etc.
• Functionality of the invention can be implemented by a mobile app or a software application or computer program in other formats included scripts, shell scripts, and functional modules created in development environments.
• A computer program does not necessarily correspond to a file. A program can be stored in a portion of a file that holds other programs or data, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
• A file can be a digital file, for example, stored on a hard drive, SSD, CD, or other tangible, non-transitory medium. A file can be sent from one device to another over network215 (e.g., as packets being sent between a server and a client, for example, through a Network Interface Card, modem, wireless card, or similar).
• Writing a file according to the invention involves transforming a tangible, non-transitory computer-readable medium, for example, by adding, removing, or rearranging particles (e.g., with a net charge or dipole moment into patterns of magnetization by read/write heads), the patterns then representing new collocations of information about objective physical phenomena desired by, and useful to, the user (e.g., a physical arrangement of particles that indicates that a specific, new club head is to be constructed from a certain set of multiple components and sent to a customer). In some embodiments, writing involves a physical transformation of material in tangible, non-transitory computer readable media (e.g., with certain optical properties so that optical read/write devices can then read the new and useful collocation of information, e.g., burning a CD-ROM). In some embodiments, writing a file includes transforming a physical flash memory apparatus such as NAND flash memory device and storing information by transforming physical elements in an array of memory cells made from floating-gate transistors. Methods of writing a file can be invoked manually or automatically by a program or by a save command from software or a write command from a programming language.
• As used herein, the word “or” means “and or or”, sometimes seen or referred to as “and/or”, unless indicated otherwise. Any documents referenced in the disclosure are hereby incorporated herein by reference in their entirety for all purposes.
• Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.
• References and citations to other documents, such as patents, patent applications, patent publications, journals, books, papers, web contents, have been made throughout this disclosure. All such documents are hereby incorporated herein by reference in their entirety for all purposes.

Claims (21)

What is claimed is:

1. A golf club head comprising:

a first body member;

a second body member interchangeably coupleable to the first body member at an attachment perimeter to create a playable club.

2. The club head ofclaim 1, wherein the first body member further comprises a boss for receiving a releaseable shaft and the second body member includes a portion that is adapted so that the second body member is fastened in place by fastening the shaft to the first body member.

3. The club head ofclaim 1, further comprising a releasable functional component that fastens the second body member to the first body member.

4. The club head ofclaim 3, wherein the releasable component is a weight screw.

5. The club head ofclaim 4, wherein the weight screw comprises a threaded post dimensioned to pass through a hole in the second body member and be screwed into a threaded hole in the first body member.

6. The club head ofclaim 1, wherein the second body member comprises a majority of a crown of the club head, a majority of a heel-side skirt of the club head, and a majority of a toe-side skirt of the club head.

7. The club head ofclaim 6, wherein the first member comprises a face cup, a hosel, and at least a portion of a sole of the club head.

8. The club head ofclaim 7, wherein the first member comprises a majority of the sole.

9. The club head ofclaim 1, wherein the attachment perimeter intersects the assembled club head at an intersection through a crown, a sole, a toe-side skirt portion, and a heel-side skirt portion of the club head.

10. The club head ofclaim 9, wherein the intersection is substantially within a plane that is substantially vertical when the club head is at address.

11. The club head ofclaim 1, wherein the attachment perimeter comprises a wavy line.

12. The club head ofclaim 1, wherein the first and second bodies are coupled by mating a plurality of posts on one of the two bodies with a plurality of corresponding holes on the other of the two bodies.

13. A golf club head comprising:

a fore body member comprising a hosel, a portion of a sole, and at least a portion of a ball-striking face; and

an aft body member releasably coupled to the fore body member by a mechanism.

14. The club head ofclaim 13, in which the mechanism comprises a cantilever with a protruding tip on one body member and a recess dimensioned to receive the protruding tip on the other body member.

15. The club head ofclaim 14, wherein the recess comprises a hole through the body member, and the club head can be disassembled by pressing on the protruding tip to disengage the cantilever mechanism.

16. The club head ofclaim 14, wherein the cantilever mechanism comprises a protruding tab that can be operated from outside of the club head to release the aft body member from the fore body member.

17. The club head ofclaim 16, wherein the protruding tab is configured to be disengaged through the use of a tool.

18. The club head ofclaim 13, wherein the mechanism includes a cam.

19. The club head ofclaim 18, wherein operation of the cam causes one or more engagement hooks to engage with a receiving portion to fasten the aft body member to the fore body member.

20. The club head ofclaim 18, wherein the cam includes a tool engagement surface.

21. A kit for a golf club head comprising:

a fore body member comprising a hosel, at least a portion of a ball-striking face, and an attachment mechanism;

a first aft body member comprising at least a portion of a crown, a sole, a skirt, and the attachment mechanism, and adapted to be releasably coupled to the fore body member; and

a second aft body member also adapted to be releasably coupled to the fore body member, wherein coupling either aft body member to the fore body member provides a playable club head.

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