Mixed material golf club head

Abstract

A golf club head includes a rear body having a crown member coupled to a sole member, and a front body coupled to the rear body to define a substantially hollow structure. The front body includes a strike face and a surrounding frame that extends rearward from a perimeter of the strike face. At least a portion of an outer wall of the club head comprises a thermoplastic composite having a plurality of lamina layers. The plurality of lamina layers include at least a fabric reinforced thermoplastic composite layer and a filled thermoplastic layer, and the fabric reinforced thermoplastic composite layer and the filled thermoplastic layer are directly bonded to each other without an intermediate adhesive.

1 . A golf club head comprising:
 a front body including a strike face and a surrounding frame that extends rearward from a perimeter of the strike face;   the front body comprising a thermoplastic composite having a plurality of lamina layers;   a rear body coupled to the front body to define a substantially hollow structure, the rear body including a crown and a sole wherein the rear body comprises a first rear body layer comprising a fabric reinforced thermoplastic composite and a second rear body layer comprising a filled thermoplastic composite.   
     
     
         2 . The golf club head of  claim 1 , wherein the plurality of lamina layers includes an outer front body layer comprising a fabric reinforced thermoplastic composite and an inner front body layer comprising a filled thermoplastic. 
     
     
         3 . The golf club head of  claim 2 , wherein the outer front body layer comprises a uniform thickness. 
     
     
         4 . The golf club head of  claim 2 , wherein the outer front body layer forms portions of the crown, the sole, and the strike face. 
     
     
         5 . The golf club head of  claim 2 , wherein the outer front body layer and the inner front body layer are directly bonded to each other without an intermediate adhesive. 
     
     
         6 . The golf club head of  claim 5 , wherein the fabric reinforced thermoplastic composite of the outer front body layer and the filled thermoplastic of the inner front body layer each comprise a common thermoplastic resin component. 
     
     
         7 . The golf club head of  claim 2 , wherein the inner front body layer has a variable thickness. 
     
     
         8 . The golf club head of  claim 2 , wherein the inner front body layer forms a rear surface of the strike face. 
     
     
         9 . The golf club head of  claim 8 , wherein the inner front body layer includes a channel extending around a perimeter of the rear surface of the strike face. 
     
     
         10 . The golf club head of  claim 9 , wherein the inner front body layer has a variable thickness. 
     
     
         11 . The golf club head of  claim 1 , wherein the first rear body layer forms at portion of the crown. 
     
     
         12 . The golf club head of  claim 1 , wherein the sole at least partially comprises the first rear body layer and the second rear body layer. 
     
     
         13 . The golf club head of  claim 1 , wherein the first rear body layer and the second rear body layer are directly bonded to each other without an intermediate adhesive. 
     
     
         14 . The golf club head of  claim 1 , wherein the second rear body layer forms an aerodynamic feature. 
     
     
         15 . The golf club head of  claim 1 , wherein the plurality of lamina layers includes an inner front body layer comprising a fabric reinforced thermoplastic composite and an outer front body layer comprising a filled thermoplastic outer front body layer. 
     
     
         16 . The golf club head of  claim 15 , wherein the outer front body layer forms an aerodynamic feature. 
     
     
         17 . The golf club head of  claim 15 , wherein the fabric reinforced thermoplastic composite of the inner front body layer and the filled thermoplastic of the outer front body layer each comprise a common thermoplastic resin component.