Hollow club head with deflecting insert face plate

Abstract

A head for a golf club includes a body shell, a face plate held on the body shell for striking the golf ball and an internal element mounted in the body shell for reinforcing the face plate. More specifically, the face plate is deflectable from a static position to a striking position as a result of stress produced when striking the golf ball. Further, a mechanism is provided for maintaining a gap between the reinforcing element and the face plate when the face plate is in a static position so as to provide a cushioning effect immediately upon striking the golf ball. .Iadd.The club head having a face plate mounting assembly in the form of a channel on the body shell, a cooperating lug on the face plate for receipt in the channel and a mounting flange on the body shell for capturing the lug within the channel..Iaddend.

I claim: 
     
       1. A head for a golf club, comprising: a body shell;   a face plate held on said body shell for striking a golf ball, said face plate being deflectable from a static position to a striking position as a result of stress produced when striking a golf ball;   an element mounted on said body shell defining a means for reinforcing said face plate by means of physical engagement with said face plate when said face plate is in said striking position; and   means for maintaining a gap between said reinforcing element and said face plate when said face plate is in said static position whereby a cushioning effect is provided immediately upon striking the golf ball.   
     
     
       2. The golf club head set forth in claim 1, wherein said body shell .Iadd.includes .Iaddend.a cast top, sole and sidewalls. 
     
     
       3. The golf club head set forth in claim . .2.!. .Iadd.1.Iaddend., wherein said face plate is constructed from a material selected from a group consisting of metals, nonmetals and composites having a tensile strength of between 40.0-250.0 ksi and a thickness of between 0.01-0.30 inches. 
     
     
       4. The golf club head set forth in claim . .3.!. .Iadd.1.Iaddend., wherein said reinforcing element includes: (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball.   
     
     
       5. The golf club head set forth in claim . .3.!. .Iadd.1.Iaddend., wherein said face plate has a minimum yield strength of 40.0 ksi and a modulus of elasticity of between 10×10 3  -20×10 3  ksi. 
     
     
       6. The golf club head set forth in claim . .5.!. .Iadd.1.Iaddend., wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug. . .   
     
     
       7.  The golf club head set forth in claim 5, wherein said reinforcing element includes: (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.   
     
     
       8. A golf club, comprising the head set forth in claim . .7.!. .Iadd.1.Iaddend., a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft. . .9. The golf club head set forth in claim 7, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped   
     
     
        channel and capturing said mounting lug..!.10. The golf club head set forth in claim . .7.!. .Iadd.1.Iaddend., wherein said gap is between 0.001-0.30 inches thick. . .11. The golf club head set forth in claim 10, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for face plate mounting said face plate to said body shell, said mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .12. A golf club, comprising the head set forth in claim 10, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft..!.. .13. The golf club head set forth in claim 2, wherein said reinforcing element includes:   (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.. .14. The golf club head set forth in claim 2, wherein said gap is between 0.001-0.30 inches thick..!.. .15. The golf club head set forth in claim 2, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including:   (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .16. A golf club, comprising the head set forth in claim 2, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said   
     
     
        shaft..!.. .17.  The golf club head set forth in claim 1, wherein said face plate is constructed from a material selected from a group consisting of metals, nonmetals and composites having a tensile strength of between 40.0-250.0 ksi and a thickness of between 0.01-0.30 inches..!.. .18. The golf club head set forth in claim 17, wherein said gap is between 0.001-0.30 inches thick..!.. .19. The golf club head set forth in claim 17, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .20. A golf club, comprising the head set forth in claim 17, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said   
     
     
        shaft..!.. .21.  The golf club head set forth in claim 17, wherein said face plate has a minimum yield strength of 40.0 ksi and a modulus of elasticity of 10×10 3  14 20×10 3  ksi..!.. .22. The golf club head set forth in claim 21, wherein said reinforcing element includes: (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.. .23. The golf club head set forth in claim 21, wherein said gap is between 0.001-0.30 inches thick..!.. .24. The golf club head set forth in claim 21, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including:   (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .25. A golf club, comprising the head set forth in claim 21, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft..!.. .26. The golf club head set forth in claim 17, wherein said reinforcing element includes:   (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing plate; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.. .27. The golf club head set forth in claim 1, wherein said face plate has a minimum yield strength of between 40 ksi and a modulus of elasticity of between 10×10 3  -20×10 3  ksi..!.. .28. The golf club head set forth in claim 27, wherein said reinforcing element includes:   (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member; and   (3) spaced ribs for connecting said arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.. .29. The golf club head set forth in claim 27, wherein said gap is between 0.001-0.30 inches..!.. .30. The golf club head set forth in claim 27, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including:   (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .31. A golf club, comprising the head set forth in claim 27, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said   
     
     
        shaft..!.. .32.  The golf club head set forth in claim 1, wherein said reinforcing element includes: (1) a support plate for engaging said face plate when said face plate is in said striking position;   (2) an arched backing member to said support plate, said arched backing member and ribs serving to distribute load placed upon said support plate when striking a golf ball..!.. .33. The golf club head set forth in claim 32, wherein said gap is between 0.001-0.30 inches thick..!.. .34. The golf club head set forth in claim 32, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including:   (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped   
     
     
        channel and capturing said mounting lug..!.. .35.  A golf club, comprising the head set forth in claim 32, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft..!.. .36. The golf club head set forth in claim 1, wherein said gap is between 0.001-0.30 inches thick..!.. .37. The golf club head set forth in claim 36, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .38. A golf club, comprising the head set forth in claim 37, a flexible shaft having a proximal end an a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said   
     
     
        shaft..!.. .39.  A golf club, comprising the head set forth in claim 36, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft..!.. .40. The golf club head set forth in claim 1, wherein said gap maintaining means includes means for mounting said reinforcing element to said body shell and means for mounting said face plate to said body shell, said face plate mounting means including: (1) an z-shaped channel on said body shell;   (2) a cooperating z-shaped lug on said face plate for receipt in said z-shaped channel; and   (3) a bendable mounting flange on said body shell for closing said z-shaped channel and capturing said mounting lug..!.. .41. A golf club, comprising the head set forth in claim 1, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said   
     
     
        shaft..!..Iadd.42.  A head for a golf club including a top wall, a sole, side walls, and a striking face extending between said top wall and said sole, comprising: a body shell having a front face;   a face plate held on said body shell for striking a golf ball, said face plate including a ball striking surface which is deflectable from a static position to a striking position as a result of stress produced when striking a golf ball;   a mounting flange about a periphery of said front face of said body shell including a channel formed therein; and   a cooperating lug extending from a periphery of said ball striking surface of said face plate for receipt in said channel of said mounting flange for securing said face plate to said body shell, such that said mounting flange and said striking surface of said face plate form said striking face of said head of said golf club..Iaddend..Iadd.43. The golf club head set forth in claim 42, wherein said channel and cooperating lug are z-shaped..Iaddend..Iadd.44. The golf club head set forth in claim 42, wherein a portion of said mounting flange is bendable..Iaddend..Iadd.45. A golf club, comprising the head set forth in claim 42, a flexible shaft having a proximal end and a distal end, and a grip, said head being connected to said distal end of said shaft and said grip being connected to said proximal end of said shaft..Iaddend..Iadd.46. The golf club head set forth in claim 42, wherein said body shell includes a cast top, sole   
     
     
        and sidewalls..Iaddend..Iadd.47.  A method for manufacturing a head for a golf club including a top wall, a sole, a side wall, and a striking face extending between said top wall and said sole, wherein said golf club comprises: a body shell having a front face; a face plate held on said body shell for striking a golf ball; a mounting flange about a periphery of said front face of said body shell including a channel formed therein; and a cooperating lug extending from a periphery of a ball striking surface of said face plate, comprising the following steps: inserting said cooperating lug within said channel of said mounting flange such that a striking surface of said face plate is substantially aligned with said front face of said body shell; and   folding said mounting flange over said cooperating lug to securely retain   
     
     
        said face plate to said front face of said body shell..Iaddend..Iadd.48. The method according to claim 47, wherein said mounting flange is folded over said cooperating lug such that said mounting flange and said striking surface of said face plate form said striking face of said head of said golf club..Iaddend.