Golf Club Head Having a Face Insert and Method of Making Same

Abstract

A golf club includes a club head body having a front face with a cavity formed therein. The cavity has a bottom wall, a lower side wall, an upper side wall and a platform separating the lower and upper side walls. A first sub-cavity is defined between the bottom wall and the platform. A second sub-cavity is defined between the platform and the front face. A damping insert is disposed in the first sub-cavity, and a face insert is disposed in the second sub-cavity.

1 . A method of making a golf club comprising:
 providing a club head body having a front face with a cavity formed therein, the cavity being defined by a bottom wall, a lower side wall, an upper side wall and a platform separating said lower and upper side walls with the lower side wall being located below the platform and the upper side wall being located above the platform;   inserting a first insert formed of a first material in a lower portion of the cavity located between the bottom wall and the platform substantially covering the bottom wall and lying adjacent the lower side wall; and   inserting a second insert formed of a second material in an upper portion of the cavity located between the platform and the front face substantially covering the first insert and lying adjacent the upper side wall.   
   
   
       2 . The method of  claim 1 , wherein inserting the first insert comprises:
 preforming the first insert; and   attaching the first insert to the bottom wall.   
   
   
       3 . The method of  claim 2 , wherein the first insert is formed of a first polymer having a Shore A hardness. 
   
   
       4 . The method of  claim 2 , wherein inserting the second insert comprises:
 preforming the second insert; and   attaching the second insert to the first insert and the platform.   
   
   
       5 . The method of  claim 4 , wherein the second insert is formed of a second polymer having a Shore D hardness. 
   
   
       6 . The method of  claim 4 , wherein the first polymer is selected from a group of materials including elastomer, silicone, silicone dielectric gel, and silicone rubber. 
   
   
       7 . The method of  claim 2 , wherein attaching the first insert to the bottom wall comprises using adhesive. 
   
   
       8 . The method of  claim 4 , wherein attaching the second insert to the first insert and the platform comprises using adhesive. 
   
   
       9 . A golf club comprising:
 a club head body having a heel end, a toe end, and a front face with a cavity formed therein, said cavity being defined by a bottom wall, a lower side wall, an upper side wall, and a platform separating said lower and upper side walls, the lower side wall being located between the bottom wall and the platform, the upper side wall being located between the platform and the front face, the cavity having a lower portion circumscribed by the lower side wall and an upper portion circumscribed by the upper side wall;   a damping insert formed of a first material disposed in the lower portion of the cavity; and   a face insert formed of a second material disposed in the upper portion of the cavity.   
   
   
       10 . The golf club of  claim 9 , wherein said first material comprises an elastomer, and wherein said second material comprises polyurethane. 
   
   
       11 . The golf club of  claim 9 , wherein said first material comprises a material having a Shore A hardness, and wherein said second material comprises a material having a Shore D hardness. 
   
   
       12 . The golf club of  claim 9 , wherein said first material comprises a double-sided adhesive material. 
   
   
       13 . A golf club head comprising:
 a body having a heel end, a toe end and a front face with a cavity formed therein, said cavity including a bottom wall, a lower side wall, an upper side wall, and a platform separating said lower and upper side walls, said cavity comprising a first sub-cavity defined between the bottom wall and the platform, and a second sub-cavity defined between the platform and the front face;   a first insert formed of a first material disposed in the first sub-cavity; and   a second insert formed of a second material disposed in the second sub-cavity above the first insert.   
   
   
       14 . The golf club head of  claim 13 , wherein said lower side wall is located between the bottom wall and the platform, and wherein the upper side wall is located between the platform and the front face. 
   
   
       15 . The golf club head of  claim 13 , wherein said body is formed of a third material. 
   
   
       16 . The golf club head of  claim 13 , wherein said first material has a Shore A hardness, and wherein said second material has a Shore D hardness. 
   
   
       17 . The golf club head of  claim 13 , wherein said first material comprises an elastomer, and wherein said second material comprises a polymer. 
   
   
       18 . The golf club head of  claim 13 , wherein said first material comprises a double-sided adhesive material. 
   
   
       19 . The golf club head of  claim 13 , wherein said first material includes material selected from a group of materials including an elastomer, a dielectric gel, and a silicone rubber. 
   
   
       20 . The golf club head of  claim 15 , wherein the third material comprises metal.