Golf club head with an insert on the striking surface

[0002] This application is a continuation in part of application Ser. No. 09/220,089, filed Dec. 23, 1998, and a continuation-in-part of application Ser. No. 08/711,337, filed Sep. 6, 1996, U.S. Pat. No. 5,944,619 the disclosure of which is incorporated by reference in its entirety.

[0003] The present invention relates to golf clubs and, more particularly, to a golf club that has an insert on the strike surface of the club.

[0004] Golf clubs have long been developed to improve the “touch and feel” of the club, most particularly with, but not limited to, the clubs used on and around the green. One approach to improve the touch and feel of a club is to modify either the grip, the shaft, or the strike face of the golf club. For example, modifications to the club head could include an insert that is placed on the club strike surface to affect the impact of the club with the golf ball and to improve the feedback to the golfer after impact.

[0005] It is desired that the present invention provided an improved golf club head with better touch and feel as a result of modifying the strike face of the golf club head.

[0006] An object of the present invention is to provide a golf club with an improved “touch and feel” on and around the green.

[0007] Another object of the present invention is to provide a golf club with an insert on the strike face that affects the rebound of the golf ball at impact with the strike face.

[0008] Another object of the present invention is to provide a golf club that dampens vibrations and improves the feedback to the golfer at impact of the golf club with the golf ball.

[0009] The present invention includes a golf club head having a toe and an opposite heel, a sole portion and an opposite top portion, a forwardly facing exposed strike face and an opposite rearwardly facing exposed back face portion. The club head includes a recess in the strike face, an insert disposed within the recess, and a vibration dampening material that extends continuously from the strike face to the back face portion. In one embodiment, the vibration dampening material extends through the insert.

[0010] According to another embodiment of the present invention, a golf club includes a strike surface and an opposite back face portion. The strike face includes a recess with a bottom surface and a side wall surface. The club head further includes an insert which is disposed in the recess. The insert has a first portion, a second portion, and a back face. The first portion includes a front surface spaced from the strike face, and a first passageway extending from the upper surface to the back face of the insert. The second portion forms a portion of the strike face. A vibration dampening material is located in the first passageway.

[0011] In one embodiment, the insert is configured so that it has a peripheral edge spaced from the side wall surface to form a peripheral groove on the strike face, and the vibration dampening material located in the groove.

[0012] In another embodiment the club head further includes first apertures that extend from the back face portion to the bottom surface, and the vibration dampening material is located in the first aperture.

[0013] In yet another embodiment, the first passageway further includes second apertures through the first portion of the flange and a cutout extending between the second apertures into at least partial alignment with the first apertures.

[0014] Thus, the present invention provides a club head with an insert and vibration dampening material that is continuous from the strike face to the back face portion.

[0015] The configuration of the insert and club head vary the amount of vibration dampening material within the club to vary the feel of the club.

[0016] FIG. 1 is a front perspective view of a golf club head of the present invention showing an insert located on a strike face with a vibration dampening material there around.

[0017] FIG. 2 is a rear view of the golf club head of FIG. 1 showing a plurality of apertures spaced apart on a back face of a club head with the vibration dampening material within the apertures.

[0018] FIG. 3 is an exploded front perspective view of the golf club head shown in FIG. 1 showing the club head before assembly.

[0019] FIG. 4 is a front view of the club head of FIG. 3, showing the club head after assembly but prior to injecting the vibration dampening material therein.

[0020] FIG. 4A is an enlarged partial front view of the portion of the club head within the circle 4A—4A of FIG. 4.

[0021] FIG. 5 is a cross-sectional view taken from line 5—5 of FIG. 4 showing the golf club head with the vibration dampening material therein.

[0022] FIG. 6 is an enlarged, front perspective view of another embodiment of the insert for use with the club head of the present invention.

[0023] FIG. 7 is a front view of the club head of FIG. 6, showing the club head after assembly but prior to injecting the vibration dampening material therein.

[0024] FIG. 6A is an enlarged, front perspective view of another embodiment of the insert for use with the club head of the present invention.

[0025] FIG. 7A is a front view of the club head of FIG. 6A, showing the club head after assembly but prior to injecting the vibration dampening material therein.

[0026] FIG. 8 is a cross-sectional view taken from line 8—8 of FIG. 7 showing the golf club head with the vibration dampening material therein.

[0027] FIG. 9 is an enlarged, front view of a golf club head with the insert removed.

[0028] FIG. 9ais an enlarged, front view of another embodiment of the insert for use with the club head shown in FIG. 9A.

[0029] FIG. 10 is an enlarged, back view of the insert shown in FIG. 9.

[0030] FIG. 11 is a cross-sectional view taken from line 11—11 of FIG. 9 showing the golf club head with the insert of FIGS. 9-10 and the vibration dampening material therein.

[0031] FIG. 12 is an enlarged, back view of another embodiment of the insert for use with the club head shown in FIG. 9A.

[0032] FIG. 13 is an enlarged perspective view of another embodiment of the insert for use with the club head shown in FIGS. 1-4.

[0033] FIG. 14 is a cross-sectional view along the line 14—14 of FIG. 13 showing the insert of FIG. 13 assembled in a club head and the vibration dampening material therein.

[0034] FIG. 15 is a cross-sectional view along the line 15—15 of FIG. 13 showing the insert of FIG. 13 assembled in a club head and the vibration dampening material therein.

[0035] FIG. 16 is an enlarged, front perspective view of another embodiment of the insert for use with the club head shown in FIGS. 1-4.

[0036] According to the present invention and referring to FIGS. 1 and 2, a golf club 10 has a shaft 12 (only partially shown) attached to a club head 14. A putter-type club head is shown in FIG. 1. The club head 14 has a hosel 16 that accepts the shaft 12 with a heel 18 at the hosel end of the club head 14 and a toe 20 opposite of the heel 18. The club head 14 also has a sole portion 26 and an opposite top portion 28. Extending between the heel 18 and the toe 20 is a strike face 22, which is the surface that contacts the golf ball (not shown) upon impact between the golf club 10 and the ball. The strike face 22 includes a “sweet spot,” or the center of gravity in the toe to heel direction, which is covered with an insert 24. The insert 24 is made of a material that is different than the rest of the club head. In the preferred embodiment, the insert is made of a tellurium copper alloy, which is a relatively soft alloy that improves the touch and feel of the club. In the preferred embodiment, the tellurium copper alloy includes a minimum of 99.4% copper, a maximum of 0.004-0.012 ppm of phosphorus and a maximum of 0.4-0.7 ppm of tellurium, and has a hardness of approximately 80 HB.

[0037] Referring to FIG. 3, the strike face 22 defines a recess 30 having a bottom surface 32 and a side wall surface 34 surrounding the bottom surface 32. The side wall surface 34 includes a plurality of portions 36-40. The pair of horizontal side wall portions 36 are substantially parallel to one another, and generally horizontal. The pair of vertical side wall portions 38 are substantially parallel to one another, and generally vertical. The four corner side wall portions 40 extend between adjacent horizontal and vertical side wall portions to form angled surfaces.

[0038] As shown in FIG. 2, the club head 14 has an essentially flat back face portion 42 that extends partially between the heel 18 and the toe 20 and partially between the top portion 28 and the sole portion 26. The back face portion 42 has a plurality of apertures 44 that are preferably evenly spaced apart in relation to each other. The apertures also follow the contour of the back face portion 42 and are essentially perpendicular to the strike face 22 (as shown in FIG. 1).

[0039] Turning to FIG. 3, the apertures 44 extend from the back face 42 toward the insert 24. Preferably more than five apertures are used, more preferably there are greater than 20 apertures, and most preferably there are 32 apertures. A vibration dampening material 46, such as an elastomeric material, that is deformable is located in each aperture 44. In the preferred embodiment, which will be described in detail below, the elastomeric material is a silicone material, Stock No. GE281, available from General Electric Company in Waterford, N.Y.

[0040] Referring to FIG. 3, the integrally formed insert 24 includes a first portion or projections 48 and a second or platform portion 50. The projections 48 are spaced apart and extend radially outwardly from the platform portion 50. The projections 48 define the spaces 51 there between. The insert 24 further includes a back face 52. Each projection 48 includes a front surface 53 spaced from the front surface 55 of the platform portion 50. The projections 48 are sized to fit within the recess 30. When the insert 24 is inserted in the recess 30, the back face 52 is in contact with the bottom surface 32 of the recess 30.

[0041] Furthermore, the projections 48 are disposed adjacent and in contact with the bottom surface 32 and the side wall surface portions 36-40. In the installed position, the platform portion 50 includes an outer peripheral edge, which is spaced from at least a portion of the side wall surface, to define a peripheral groove 54 (as shown in FIGS. 3-5) between the platform portion 50 and the side wall surfaces 36-40. The projections 48 center the insert within the recess. The peripheral groove 54 surrounds the platform portion 50 of the insert. The groove has a width, designated by the arrow w in FIG. 1.

[0042] Referring now to FIGS. 2-4, the apertures 44a-ereceive a fastening means 58a-e. The outermost apertures 44a-dhas complementary counterbores. The aperture 44eis a central aperture that receives a center fastener 44e. The insert back face 52 includes five threaded holes 60a-e(shown in phantom) that are complimentary to the apertures 44a-44ein the club head 10. The five fasteners 58a-58eare fastened into the insert holes 60a-e. The fasteners 58a-econnect the insert 24 to the club head.

[0043] During machining of the loft in the putter, the fasteners aid in maintaining the connection between the insert and the club head. After machining, the center fastener 58eis removed from the insert hole 44e. The purpose of the center fastener 44eis to aid in maintaining the connection between the insert and the club head during machining.

[0044] Referring to FIG. 4, the top row of apertures are designated 44f. When the insert 24 is disposed within the recess 30, the aperture or space 51 between the projections 48 is located so that it is partially aligned with the top row of apertures 44f. As a result, as best shown in FIG. 4A, a portion of the top row apertures 44fare visible from the front of the club head within the groove 54 before the vibration dampening material is disposed within the club head. The portion of the apertures (shown in phantom) are covered by the platform portion 50 of the insert.

[0045] As shown in FIGS. 4 and 5, once the vibration dampening material is disposed in the groove 54 and the apertures 44 and the space 51 provides a passageway for allowing the elastomeric material in the groove 54 to be in fluid communication with the elastomeric material in the apertures 44. Thus, the vibration dampening material is continuous from the strike face 22 to the back face portion 42.

[0046] Referring to FIGS. 3 and 5, also when the insert 24 is within the recess 30, the front surface 53 of the projections 48 is spaced from the strike face 22 and the front surface 55 of the platform portion 50 forms a portion of the strike face 22. As a result, the passageway in the insert is spaced from the strike face 22.

[0047] In this embodiment the top row of apertures are aligned with the spaces between the projections. In other embodiments, the insert can be configured so that, for example, the top row and the bottom row of apertures are partially or fully aligned with associated spaces between the projections.

[0048] The contact between the insert and the club head creates a metal-to-metal contact between the insert and the recess surfaces. The size of the apertures 44 and the volume of the elastomeric material 46 located in the apertures and the grooves and spaces combine to reduce the amount of metal-to-metal contact between the insert 24 and the recess surfaces. Therefore, the “touch and the feel” of the putter may be altered by varying the amount of metal-to-metal contact and by proportionately varying the amount of elastomeric material located around the insert.

[0049] Referring to FIG. 6, the insert 124 has been modified to include a first portion which is a flange 148. The flange 148 extends radially outwardly from the platform portion 150. The flange is sized to fit within the recess 30 of the club head 10 shown in FIG. 7. This club head is similar to the club head discussed above. The insert 124 is fastened within the club head as discussed previously.

[0050] Referring to FIG. 6, the flange 148 defines upper and lower notches or passageways 151aand b, respectively. Referring to FIG. 7, the notches 151aand bare sized so that when the insert 124 is disposed within the recess 30, a pair of the two center apertures 44fin the top and bottom rows of the apertures are completely aligned with the notches 151aand 51b.

[0051] Referring to FIG. 8, it is shown that by completely aligning the notches 151aand bwith the holes 44fthe vibration dampening material in the groove 54 is in fluid communication with the vibration dampening material in the apertures, and the vibration dampening material is continuous from the strike face 22 to the back face portion 42.

[0052] In this embodiment, the portion of the insert forming the apertures 151aand bis not in contact with the bottom surface 32 of the recess. The remaining portion of the back face 52 of the insert 124 is in contact with the bottom surface of the recess. The metal-to-metal contact of the insert and the recess surfaces is reduced by using the vibration dampening material.

[0053] In another embodiment, the flange can be configured so that the notches are partially aligned with various apertures in the club head. Furthermore, the shape, location, and number of the notches can be varied while still providing the passageway as desired.

[0054] Referring to FIG. 6A, the insert 124′ is similar to the insert 124 shown in FIG. 6, and similar features have the same reference numeral followed by a prime. The insert 124′ has been modified to include a flange 148′. The flange 148′ extends radially outwardly from the platform portion 150′. The flange is sized to fit within the recess 30 of the club head 10 shown in FIG. 7A. This club head is similar to the club head discussed above. The insert 124′ is fastened within the club head as discussed previously.

[0055] Referring to FIG. 6A, the flange 148′ defines a pair of upper and lower notches or passageways 151aand b, respectively. Referring to FIG. 7A, the notches 151aand bare sized so that when the insert 124 is disposed within the recess 30, a pair of the apertures 44f′ at the toe side 18 and a pair of the apertures 44f′ at the heel side are completely aligned with the respective notches 151aand 51b. This embodiment allows metal-to-metal contact of the insert 124′ with the bottom surface of the recess over the sweet spot and more vibration dampening toward the toe and heel. Thus, off-center hits should be provided more dampening.

[0056] Referring to FIG. 9, the insert 224 has been modified and includes a first portion which is a flange 248. The flange 248 extends radially outwardly from the platform portion 250. The flange is sized to fit within the recess 30 of the club head 10 shown in FIG. 9A. The flange 248 defines a pair of upper and lower apertures 251aand b, respectively.

[0057] Referring to FIGS. 10 and 11, the back face 52 of the insert 224 further includes a plurality of cavities 252. The cavities 252 are aligned to be complementary with the apertures 44 and 244. Some of the apertures 44 receive the fasteners as previously discussed to secure the insert 224 to the club head.

[0058] Referring to FIGS. 10 and 11, four of the cavities 252aare formed so that they include a counterbored portion 254 and a reduced diameter portion 256. The counterbored portion 254 extends from the insert back face 52 to the reduced diameter portion 256. The counterbored portion 254 is configured so that it forms the apertures 251aand band a cutout 258 extending between the apertures 251aand band the reduced portion of the cavities 256. The cavities and counterbores which form the apertures 251aare located so that the apertures 251aare notches extending to the periphery of the flange. The cavities and counterbores which form the apertures 251bare located so that the apertures 251bextend through the flange spaced from the periphery of the flange.

[0059] Referring to FIG. 9A, when the insert 224 is disposed within the recess 30, the cavities 252aare aligned with the apertures 244. As shown in FIG. 11, the passageway from the groove 54 to the apertures 244 is formed by each aperture 251aand band the associated the counterbores 254. The vibration dampening material 46 is disposed within the groove 54, the apertures 251aand b, the cavities 252a, and the apertures 44 and 244. The vibration dampening material 46 in the apertures 244, and the vibration dampening material 46 is continuous from the strike face 22 to the back face portion 42.

[0060] In this embodiment, the portion of the insert forming the counterbores and cavities is spaced from the bottom surface 32 of the recess. The remaining portion of the insert 224 is in metal-to-metal contact with the bottom surface of the recess. The insert cavities 252 and 252aprovide a more pronounced vibration dampening feature than the embodiment disclosed in FIGS. 3 and 6, since the amount of metal-to-metal contact will be decreased using the insert 224 versus the inserts 24 and 124. This results from the elastomeric material 46 extending into the back face 52 of the insert 224 due to the cavities. So the elastomeric material encompasses more area on the back face of the insert 224.

[0061] In another embodiment, the back face of the insert can be modified so that the cutouts have a different shape. Furthermore, the location and number of the apertures and cavities can be varied while still providing the passageway as desired.

[0062] Referring to FIG. 12, the insert 324 is similar to the insert 224 shown in FIGS. 9-11, and for use with the club head shown in FIG. 9A. Similar portions of the insert 324 to the insert 224 begin the reference with a number “3” instead of “2”. The back face 52 of the insert 324 further includes a continuous passageway 360 or a matrix. The passageway 360 connects each of the insert cavities 352 and 352a. The passageway is formed using conventional techniques so that the insert back face landings or areas 358 remain between portions of the passageway. In this embodiment, the depth of the passageway 360 does not equal the depth of the cavities 352 so the cavities 352 remain after the passageway is formed.

[0063] The front of the insert 324 is similar to that shown in FIG. 9 where the insert includes the flange and the platform portion. The counterbored portions 354 form apertures 351 and bin the flange. The insert 324 is fastened within the club head as discussed previously.

[0064] Once the insert 324 is disposed in a club head, the passageway from the groove 54 to the apertures 244 is formed by each aperture 351 in the flange and the associated cavities 352awith the counterbores. The vibration dampening material 46 is disposed within the groove 54, the apertures 351 in the flange, the cavities 352, and the apertures 44 and 244. The vibration dampening material 46 is continuous from the strike face 22 to the back face portion 42.

[0065] In this embodiment, the portion of the insert forming the counterbores and cavities is spaced from the bottom surface of the recess. The remaining portion of the insert 324 (i.e., the landings 358 and the remaining area of the back face 52) is in contact with the bottom surface of the recess. This is metal-to-metal contact. The continuous passageway 360 provides a more pronounced vibration dampening feature than the embodiment disclosed in FIG. 10 since the amount of metal-to-metal contact will be decreased using the insert 324 versus the insert 224.

[0066] In another embodiment, the back face of the insert can be modified so that the cavities have a different shape and/or the passageway connects the cavities in a different arrangement. Furthermore, the location and number of the apertures and cavities can be varied while still providing the passageway as desired. In addition, the passageway can be continuous through the cavities so that separate lines or shapes are formed by the back face passageway.

[0067] Referring to FIG. 13, the insert 424 is for use with a club head similar to that shown in FIG. 9A, and includes a flange 448 similar to that shown in FIG. 6. However, the flange 448 defines a plurality of circumferentially spaced notches 451. However, the back face 52 of the insert 424 further includes a plurality of projections 460 (shown in phantom) extending therefrom at spaced locations. The insert 424 is fastened within the club head as discussed previously.

[0068] Referring to FIGS. 14 and 15, when the insert 424 is disposed within the recess 30, the free ends 462 of the projections 460 are portions of the back face that are in contact with the bottom surface 32 of the recess 30. The remaining portion 464 of the back face is spaced from the bottom of the recess so that a gap 466 is defined there between. The vibration dampening material 46 within the gap 466 is in fluid communication with the vibration dampening 46 material within the apertures 44. Referring to FIG. 15, the notches or apertures 451 define passageways between the groove 54 and the gap 466 and the apertures 44. The vibration dampening material 46 is continuous from the strike face 22 to the back face portion 42.

[0069] In this embodiment, the projections 460 provide metal-to-metal contact between the insert and the recess 30. A club head with the insert 424 exhibits a different touch and feel than a club head with a similarly configured insert which does not have projections but defines a gap between the back face of the insert and the recess bottom. Co-pending application Ser. No. 09/220,083, filed Dec. 23, 1998 discloses such a club head in FIGS. 15, 16, 23-26 and the associated specification language. In addition, co-pending application Ser. No. 08/711,337, filed Sep. 6, 1996 discloses such a club head in FIGS. 15 and 16 and the associated specification language. The gap 466 may provide a more pronounced vibration dampening feature than the embodiment disclosed in FIGS. 1-12, since the amount of metal-to-metal contact will be decreased using the gap.

[0070] Referring to FIG. 16, the insert 524 is for use with a club head similar to that shown in FIG. 9A. The insert 524 is similar to the insert 24 shown in FIG. 3. However, the projections 548 have an increased thickness so that the portion 526 of the back face of each projection is spaced from the remaining portion 528 of the back face. Thus, the projection back face portion 526 is spaced a distance 530 from the remaining portion 528. When the insert 524 is disposed in a club head similar to that described in FIG. 3, the portions 526 are in contact with the bottom surface 32 of the recess 30. The remaining portion 528 of the back face is spaced from the bottom of the recess so that a gap similar to the gap 466 (shown in FIGS. 14 and 15) is defined there between. The vibration dampening material 46 within the gap is in fluid communication with the vibration dampening material within the apertures 44. Similarly to FIG. 15, the spaces 551 between the projections 548 define passageways between the groove 54 and the gap and the apertures 44. The vibration dampening material 46 is continuous from the strike face 22 to the back face portion 42.

[0071] In this embodiment, the projections 548 provide metal-to-metal contact between the insert and the recess 30. A club head with the insert 524 exhibits a different touch and feel than a club head with a similarly configured insert which does not have projections but defines a gap between the back face of the insert and the recess bottom, as discussed above.

[0072] In another embodiment, the back face of the inserts 424 and 524 can be modified to include notches of different sizes, locations, and shapes. Furthermore, the back faces can include cavities, counterbored portions and passageways as discussed above.

[0073] In another embodiment, the various portions of the golf club head can be filled with two or more different vibration dampening materials. For example, foam rubber or another elastomeric material can be used.

[0074] During manufacture, depending on the configuration of the insert and the apertures, in order to introduce the elastomeric material into the club head, it is injected into the apertures and it may flow from the back face portion to the strike face. The configuration may require that the material is injected in the groove and the apertures so that the material will be continuous from the back face portion to the strike face. A squeegee is scraped across the back face portion and the strike face to remove the excess silicone, leaving the silicone in each of the apertures and the groove.

[0075] The amount of vibration dampening material in the club head can be varied in a number of ways. For example, the number of apertures or number of apertures filled with the vibration dampening material can be varied. In addition, the geometry of the peripheral groove can be varied by changing the width w (as shown in FIG. 1), by changing the depth D (as shown in FIG. 5), by changing the geometry of the flange or projections, or by changing the size of the gap.

[0076] Varying the amount of vibration dampening material affects the feel of the club head and allows the club head to be custom fit to a particular player or group of players depending on their needs, preferences, and/or performance. If a player, such as a Tour player, prefers more metal-to-metal contact between the insert and recess bottom surface, the amount of vibration dampening material can be decreased. If as a group, ladies, seniors or juniors, for example, prefer less metal-to-metal contact the amount of vibration dampening material can be increased. Thus, the club head of the present invention allows the manufacturer to modify the club head to satisfy one player or a group of players, which is advantageous.