Multi-component golf club head

Abstract

To provide means for maximizing discretionary weight to maximize club head moment of inertia (MO I) and lower / back center of gravity (CG).SOLUTION: Embodiments of a golf club head comprising a first component and a second component that are coupled together to enclose a hollow interior are disclosed herein. The first component comprises at least a striking face, a striking face return, and a rear extension 3500. In some embodiments, the first component also comprises a weight channel at a rear end and one or more braces that attach to the striking face return and the rear extension. The second component comprises a crown portion, a sole toe portion 3150, and a sole heel portion 3160. The density of the second component is less than the density of the first component. In some embodiments, the first component mass is 85% to 96% of a mass of the golf club head.SELECTED DRAWING: Figure 37

Description

Technical Field

[0001] The present disclosure generally relates to golf equipment, and more particularly, to a multi-element golf club head and a method of manufacturing a multi-element golf club head.

Background Art

[0002] Generally, club head mass is the sum of structural mass and discretionary mass. In an ideal club design with a constant total swing weight, the structural mass is minimized (without sacrificing elasticity), thereby providing the designer with sufficient discretionary mass for any configuration to customize and maximize club performance. Structural mass generally refers to the mass of the material required to provide the club head with the structural elasticity to withstand repeated impacts. Structural mass is highly design-dependent, and the amount that a designer can control for a particular mass distribution is relatively small. Conversely, discretionary mass is any additional mass (above the minimum structural requirements) that can be added to the club head design only to customize the performance and / or forgiveness of the club. In the art, there is a need for alternative designs for all metal golf club heads to provide means for maximizing discretionary weight to maximize the club head moment of inertia (MOI) and the lower / rear center of gravity (CG), and to provide options for golf ball flight operation.

Brief Description of the Drawings

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Mode for Carrying Out the Invention

[0081] A hollow golf club head including two main components is described herein. The first component is metal. The second component is non-metal. The second component may comprise a single part or multiple parts. The first component made of metal includes a striking portion and a sole extension. The non-metal second component includes the rear portion of the crown and wraps around to also include a portion of the sole. The first component includes the load-bearing region or structural region of the golf club head and also includes most of the mass of the golf club head. The first component includes a sole portion that extends rearward, and most of the golf club mass is at the rearmost portion of the extension, and the first portion forms a "T" shape when viewed from above. The first component may further comprise a bridge or crown brace that extends to the rear portion of the golf club head. This configuration provides discretionary mass that can be redistributed to improve the position of the center of gravity (CG) and the moment of inertia (MOI). The improved CG and MOI provide a more accurate ball flight compared to all traditional all-metal golf club heads. The golf club heads discussed herein can include driver-type golf club heads, fairway-type golf club heads, or hybrid-type golf club heads.

[0082] The higher density "T" shaped sole of the first component is joined to the lower density wrapped crown of the second component, reducing the mass of the crown and shifting the center of gravity (CG) of the golf club head lower, thereby optimizing the mass characteristics. The weight saved from the second component can be redistributed to other locations on the golf club head to further optimize the CG and increase the MOI. The CG of the golf club head can move downward and rearward of the golf club head including the first and second components, and the second component includes a second material having a second density lower than the density of the first material compared to an alternative golf club head including only the first material having a constant density.

[0083] In one or more embodiments, the club head may be a hollow wood-type golf club head formed by joining a first component to a second component to form a closed internal volume therebetween. The first component may include both the striking face and a portion of the sole, and may further be formed from metal or a metal alloy. The second and third components may form at least a portion of the crown, and may further wrap around to form both the heel portion and the toe portion of the sole. In this design, the metallic first component extends between the polymeric heel portion of the sole and the polymeric toe portion of the sole.

[0084] "A", "an", "the", "at least one", and "one or more" are used interchangeably to indicate that at least one of the items is present and that more than one such item may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., amounts or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term "about" whether or not the term "about" actually appears before the numerical value. "About" indicates that the recited numerical value allows for some degree of imprecision (with a degree of approach to the exact value, near or reasonably close to the value; approximately). Where the imprecision provided by "about" is not understood in the ordinary sense in the art, "about" as used herein indicates at least the variability that may arise from the normal methods of measuring and using such parameters. Also, the disclosure of a range includes all values and further includes subranges within the entire range. Each value within the range and the endpoints of the range are disclosed herein as all separate embodiments. The terms "comprising", "comprises", "including", and "having" are inclusive and thus specify the presence of the recited items but do not preclude the presence of other items. As used herein, the term "or" includes any and all combinations of one or more of the recited items. When terms such as first, second, third, etc. are used to distinguish various items from one another, these names are for convenience only and do not limit the items.

[0085] If so, the terms "first", "second", "third", "fourth", "fifth", etc. in this specification and the claims are used to distinguish similar elements and are not necessarily used to describe a particular order or chronological order. Terms so used are interchangeable in appropriate circumstances. For example, it should be understood that the embodiments described herein can operate in a sequence other than the sequence illustrated or otherwise described herein. Further, the terms "comprising", "having", and any variations thereof are intended to encompass non-exclusive inclusions such that a process, method, system, article, device, or apparatus comprising a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed in such process, method, system, article, device, or apparatus.

[0086] If so, the terms "left", "right", "front", "back", "up", "down", "above", "below", etc. in this specification and the claims are used for illustrative purposes and are not necessarily for describing a permanent relative position. Terms so used are replaceable in appropriate circumstances so that the embodiments of the manufacturing apparatus, manufacturing method, and / or manufactured article described herein can operate in an orientation other than, for example, that illustrated or otherwise described herein. For the sake of consistency and accuracy, all references to directions used in this application are based on the premise that the golf club head being referred to is resting on a horizontal and flat ground such that the pre-defined loft angle and lie angle of the head are achieved. The "front" or "front portion" of a golf club head generally refers to the side of the golf club head (when viewed perpendicular to the ground) that includes the striking face of the golf club. Conversely, the rear portion of the club head can include the area behind the striking face and / or the portion of the club that follows the striking face at impact.

[0087] Other features and aspects will become apparent by considering the following detailed description and the accompanying drawings. Before any particular embodiment of the present disclosure is described in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction or the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure can support other embodiments and can be practiced or carried out in various ways. It is to be understood that the description of specific embodiments is not intended to limit the present disclosure from covering all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure. Also, it is to be understood that the terminology and phraseology used herein is for the purpose of description and should not be regarded as limiting. I) First Embodiment of a Golf Club Head

[0088] An embodiment of a golf club head (100) is described herein that includes two components, a first component (300) and a second component (200). As shown in FIGS. 1A - 1E, the golf club head includes a striking face (170), a return portion (177), a hosel (140), a crown (110), a sole (120), a heel end (160), a toe end (150), a trailing edge (130) at the rearmost portion of the rear end (180), a hosel (140), and a hosel adapter mounting recess (195) in the sole portion.

[0089] The golf club head (100) further defines a loft plane (198) that contacts the striking face center (175) of the striking face (170). A face height parallel to the loft plane can be measured between the upper end of the peripheral portion of the striking face near the crown (110) and the lower end of the peripheral portion of the striking face near the sole (120). In these embodiments, the peripheral portion of the striking face can be arranged along the outer edge of the striking face (170), where the curvature deviates from the bulge and / or roll of the striking face (170).

[0090] Referring to FIGS. 1D and 1E, the center of the hitting face (175) defines a coordinate system having an origin at the center of the hitting face (175) of the hitting face (170). The coordinate system has an X-axis, a Y-axis, and a Z-axis. The X-axis (190) is a horizontal axis that extends through the center of the hitting face (175) of the hitting face (170) in the direction from the heel end (160) to the toe end (150) of the golf club head (100) and is parallel to the ground plane (105) when the club head (100) is in the address position. The Y-axis (192) is a vertical axis that extends through the center of the hitting face (175) of the hitting face (170) in the direction from the crown (110) to the sole (120) of the golf club head (100) and is perpendicular to the X-axis (190). The Z-axis (196) is a vertical axis that extends through the center of the hitting face (175) of the hitting face (170) in the direction from the hitting face (170) to the rear end (180) of the golf club head (100) and is perpendicular to the X-axis (190) and the Y-axis (192).

[0091] The coordinate system defines an XY plane that extends through the X-axis (190) and the Y-axis (192), an XZ plane that extends through the X-axis (190) and the Z-axis (196), and a YZ plane that extends through the Y-axis (192) and the Z-axis (196). Here, the XY plane, the XZ plane, and the YZ plane are all perpendicular to each other and intersect at the origin of the coordinate system at the center of the hitting face (175) of the hitting face (170). The XY plane extends parallel to the hosel axis (199) and is positioned at an angle corresponding to the loft angle of the golf club head (100) from the loft plane. The hosel axis (199) is inclined with respect to the X-axis (190) at a predetermined angle called the lie angle. The hosel axis (199) can be inclined with respect to the X-axis (190) by a lie angle between 58 degrees and 65 degrees. In some embodiments, the hosel axis (199) is positioned at a lie angle of 60 degrees with respect to the X-axis (190) as viewed from a direction perpendicular to the XY plane.

[0092] The sole (120) is the lower hemisphere of the golf club head (100). In some embodiments, the sole (120) can be defined as a part of the golf club head that is visible when viewed from the bottom surface when the club is at address. The skirt of the golf club head (100) can be defined as the junction between the sole (120) and the crown (110), and in particular, forms the perimeter of the club head behind the striking face (170).

[0093] The golf club head (100) can have a hollow body structure that forms a closed internal cavity (185). The outer shell of the golf club head (100) can comprise a first component (300) and a second component (200), which cooperate and / or are joined to at least partially define the outer boundary of the internal cavity (185) (i.e., each component (200, 300) defines at least a part of the outer boundary of the internal cavity (185)).

[0094] Referring to FIG. 1F, the first component (300) is generally T-shaped when viewed from the sole. The sole of the first component (300) has a sole rear extension (500) with a mass portion (510), and the mass portion (510) houses at least one weight at the rearmost end of the sole extension (500). The second component (200) forms the remaining majority of the golf club head not formed by the first component (300). This configuration lowers the CG of the assembled golf club head and moves the CG towards the rear of the assembled golf club head.

[0095] The first component (300) includes a first material having a first density. The first material includes a metallic material. The second component (200) includes a second material having a second density. The second component (200) includes a non-metallic material. The first and second components (300, 200) each include a first component mass and a second component mass. In some embodiments, the first component (300) may be integrally formed as a single component, and thus, the first component includes a single material. In some embodiments, the first component (300) may be integrally formed with a portion excluding a detachable and / or repositionable mass portion. Alternatively, the first component (300) may include a separately formed impact face insert that includes a material different from the remainder of the first component (300) (i.e., a third material).

[0096] The second non-metallic component (200) attaches to, wraps around, or surrounds the first metallic component (300) to form a hollow golf club head (100). A trailing edge portion (230) of the second component connects a second component crown portion (205) and second component sole portions (212, 214) such that they wrap around the first component (300).

[0097] The material density of the first component (300) (i.e., the first density) is greater than the material density of the second component (200) (i.e., the second density). The mass percentage of the first component (300) can range from 85% to 96% of the total mass of the golf club head (100). For example, the percentage of the first component of the mass of the golf club head can be 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, or 96%. The mass percentage of the second component (200) can range from 4% to 15% of the total mass of the golf club head (100). The first component (300) includes a rear extension (500) on the sole, and the rear extension (500) has a mass portion (510). The mass portion (510) is at the rear end of the rear extension (500), starting at the front end of the weight port and ending at the trailing edge (130). The mass portion (510) can constitute 20% to 35% of the mass of the hollow multi-element golf club head (100). Placing most of the mass of the golf club head at the rearmost position of the golf club head provides functionally desirable mass characteristics. For example, the rearmost position of the mass portion (510) can lower the CG of the golf club head, thereby improving the launch characteristics.

[0098] A) The first component

[0099] As shown in FIGS. 1A - 1F and FIGS. 4 - 8, the first component (300) can include a striking face (170) having a return portion (177) and a rear extension (500). The return portion (177) can form at least a part of the crown (400), a part of the sole (120), the hosel (140), a part of the heel end (160), a part of the toe end (150), and a recessed lip (450) (also called a coupling extension surface). The rear extension (500) is connected to the return portion (177) and extends rearward from the return portion (177). The rear extension (500) forms at least a part of the sole and is disposed substantially perpendicular to the striking face (170). The rear extension (500) extends from the rear end of the return portion (177) toward the trailing edge (130) of the club head (100). The striking face return portion (177) forms a rear profile in the direction from the heel end to the toe end. In other embodiments, the rear profile of the first component (300) can extend in a linear profile, a positive parabolic profile, a bell-shaped profile, or any other profile with respect to the striking face (170) from the heel end (160) to the toe end (150).

[0100] Referring to FIGS. 1E and 4, the first component (300) includes a hosel bore (145) defining a hosel axis (199), a striking face center (175), a front crown portion (400) having a front crown portion width (405), and a first component trailing edge (130). Some embodiments can further include a crown portion turbulator (430) of the first component having a crown portion turbulator toe portion (432) and a crown portion turbulator heel portion (434) of the first component.

[0101] The first component can include a recessed lip (450, also referred to as the first component lip or joining extension surface) that overlaps a portion of the second component (200) and is configured to together form a golf club head (100). The first component lip (450) can bound a first component peripheral edge (462) having a first component crown lip (455) and a first component tab (457). The first component tab (457), and the mating groove within the second component, align the first component (300) with the second component (200) during assembly and provide mechanical support to prevent lateral movement between the first component (300) and the second component (200). In some embodiments, the second component does not include a groove for receiving the first component tab (457). In these embodiments, the first component tab (457) provides a predetermined space (i.e., an adhesive gap) between the first and second components. This predetermined space allows the adhesive to provide a uniform and consistent joint across the overlap joint.

[0102] The first component lip (450) is recessed from the outer surface of the golf club head (100) so as to conform to the combined thickness of the overlapping lip of the second component (200) and any adhesive that secures the two components together. Referring to FIGS. 5, 9, and 10, the first component (300) includes a first component lip recess offset (459), a first component sole lip (460), a first component sole rear extension (500), a first component sole rear extension mass portion (510) having a mass portion internal front boundary (corresponding to 1050, the front extension boundary 918 shown in FIG. 9), one or more mass portion internal ribs (520), and a removable weight recess (540) having a threaded fastener receiving boss (542). Referring also to FIG. 1F, the first component lip (455) is configured to be covered by a portion of the second component (200) when the first component (300) is coupled to the second component (200) to form the golf club (100). The first component (300) may preferably be coupled to the second component (200) using an adhesive disposed between the overlapping surfaces of the first and second components.

[0103] Referring to FIG. 7A, the lip of the first component has a width (730), which can range from 0.125 inches to 0.275 inches. For example, the lip width (730) of the first component can be 0.125 inches, 0.150 inches, 0.175 inches, 0.200 inches, 0.222 inches, 0.225 inches, 0.250 inches, or 0.275 inches.

[0104] The first component recess offset (459) is the offset distance of the lip (455) from the outer surface of the first component (300) toward the interior of the golf club head. The recess offset (459) can range from 0.060 inches to 0.160 inches toward the interior of the golf club head (100). In other embodiments, the recess offset (459) can range from 0.060 inches to 0.150 inches, from 0.060 inches to 0.140 inches, from 0.080 inches to 0.160 inches, from 0.090 inches to 0.150 inches, or from 0.090 inches to 0.160 inches. For example, the recess offset (459) can be 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, 0.100 inches, 0.110 inches, 0.120 inches, 0.130 inches, 0.140 inches, 0.150 inches, or 0.160 inches.

[0105] The first component lip (450) can include a thickness. The thickness of the first component lip (450) can range from 0.007 inches to 0.030 inches. In some embodiments, the thickness of the first component lip (450) can be from about 0.007 inches to 0.009 inches, from 0.009 inches to 0.011 inches, from 0.011 inches to 0.013 inches, from 0.013 inches to 0.015 inches, from 0.015 inches to 0.017 inches, from 0.017 inches to 0.019 inches, from 0.019 inches to 0.021 inches, from 0.021 inches to 0.023 inches, from 0.023 inches to 0.025 inches, from 0.025 inches to 0.027 inches, or from 0.027 inches to 0.030 inches.

[0106] Referring further to FIG. 5, the first component has a rear extension on the sole, which allows a majority of the mass of the assembled golf club head to be lowered to the sole of the assembled golf club and moved rearward. The rear extension (500) extends from the return portion (177), is integral with the return portion (177), allows impact stress to propagate all the way to the rear of the sole, and helps balance the distribution of impact stress in the golf club head.

[0107] Referring further to FIG. 5, the first component lip (450) includes a first component crown lip (455) and a first component sole lip (460). The first component lip (450) may have other parts.

[0108] Referring to FIG. 6, a plane (610) parallel to the ground plane (105) and intersecting the center of the striking face (175) defines a view of the lower portion of the first component (300) shown in FIG. 7A. Referring to FIGS. 7A and 8, the rear extension (500) extends from the rear periphery of the striking face return sole portion (810) toward the rear end (180) of the golf club head (100).

[0109] Referring to FIG. 7A, the first component (300) includes a first component sole heel extension (710), a first component sole toe extension (720), a first component lip (460) having a first component lip width (730), a first component trailing edge (740), a vertical lip (750), and a first component sole rear extension mass portion (510) having a mass portion trailing edge shelf (760).

[0110] The rear extension (500) has a greater mass at the most rearward position of the extension. Positioning the mass at the most rearward position allows manipulation of the rear sole extension position to significantly affect the mass characteristics of the assembled golf club head. Referring to FIGS. 57 - 60, in some embodiments, the rear extension (500) of the first component may comprise a sole hole (555). The sole hole functions to further shift the mass closer to the rearmost end of the rear extension (500). As described above, positioning the mass at the rearmost end allows the CG to be moved rearward, thereby allowing an increase in the moment of inertia of the club head. Adding the sole hole (555) creates more discretionary mass disposed at the rearmost end of the rear extension (500).

[0111] Referring to FIG. 8, the first component (300) includes a striking face return sole rear extension (500) having a first component sole rear extension length (505) and a first component sole rear extension width (507). The first component (300) includes a striking face return sole (810) having a striking face return sole width (815), a first component sole toe extension (820) having a first component sole toe extension length (825), and a first component sole heel extension (830) having a first component sole heel extension length (835). The rear extension length (505) is measured from the rear periphery of the striking face sole return portion (810) towards the rear end (180). The rear extension length (505) can range from 2.5 inches to 4.5 inches. The width (815) of the return sole portion is measured from the loft face (198) rearward to the rear periphery of the striking face return portion (177), which is the sole portion of the first component peripheral edge (462). Both the rear extension length (505) and the width (815) of the striking face return sole portion constitute the total sole length of the golf club head (100) measured from the loft plane (198) along the sole (120) to the rear end (180). The width (507) of the rear extension is the width of the rear extension (500). The width (507) of the rear extension is measured in the heel-to-toe direction from the rear periphery of the striking face return sole portion (810), which is the sole portion of the first component peripheral edge (462). The width (507) of the rear extension is less than the total width of the sole (120) of the golf club (100). The width (507) of the rear extension can range from 25% to 85% of the total width of the sole (120). The width (507) of the rear extension can range from 25% to 85% of the total width of the sole (120). In some embodiments, the width (507) of the rear extension can range from 0.4 inches to 2.5 inches.

[0112] Referring to FIGS. 7A and 8, the first component sole portion rear extension (500), the toe extension (720), and the heel extension (710) together form a T-shaped configuration. The first component sole portion rear extension (500) forms a toe direction angle (850) with respect to the toe extension (720) and a heel direction angle (855) with respect to the heel extension (710). The first component (300) further includes a detachable weight receptacle (540) having a plurality of detachable weight receptacle tabs (546).

[0113] Referring to FIGS. 5, 7A, and 8, the hitting face return (177) extends rearward from around the hitting face (170) substantially perpendicular to the hitting face. The hitting face (170) and the hitting face return (177) constitute the front portion of the assembled golf club head. The hitting face return (177) includes a hitting face return crown portion (400) having a hitting face return crown portion width (405) and a return sole portion (810) having a hitting face return sole portion width (815). The hitting face return crown portion (400) has a rear perimeter that forms a profile on the crown (110) from the heel end (160) of the crown (110) to the toe end (150) of the crown (110). The hitting face return crown portion width measured from the hitting face (170) toward the rear end (180) may vary. The maximum width (405) of the hitting face return crown portion may be located at the toe end (150) or the heel end (160). In other embodiments, the maximum width (405) of the hitting face return crown portion may be located in an intermediate region between the toe end (150) and the heel end (160). The width (405) of the hitting return crown portion can be at least 0.8 inches, at least 1.0 inches, at least 1.2 inches, or at least 1.4 inches. In some embodiments, the maximum width (405) of the hitting face return crown portion can be in the range of 1.0 inches to 1.5 inches. For example, the maximum width (405) of the hitting face return crown portion may be 1.0 inches, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, or 1.5 inches. The width (405) of the crown portion of the second component can be similar to the crown portion as described in U.S. Patent Application No. 11 / 693,490, now U.S. Patent No. 7,601,078.

[0114] The hitting face return (177) of the first component (300) can have a thickness extending between the outer and inner surfaces of the hitting face return (177). The thickness of the first component (300) can range from 0.015 inches to 0.040 inches. In other embodiments, the thickness of the first component (300) can range from 0.010 inches to 0.040 inches, from 0.010 inches to 0.020 inches, from 0.015 inches to 0.025 inches, from 0.020 inches to 0.030 inches, from 0.025 inches to 0.035 inches, from 0.030 inches to 0.040 inches, from 0.040 inches to 0.10 inches, or from 0.10 inches to 0.25 inches. For example, the thickness of the first component (300) can be 0.010 inches, 0.015 inches, 0.020 inches, 0.025 inches, 0.030 inches, 0.035 inches, or 0.040 inches. In some embodiments, the thickness of the first component (300) can vary at the hitting face (170), at the return crown portion (400), at the sole portion (310) of the first component, at the sole portion heel extension (710) of the first component, at the sole portion toe extension (720) of the first component, and at the sole portion rear extension mass portion (510) of the first component.

[0115] Referring to FIG. 5, the crown portion turbulator (430) located in the return crown portion (400) is a protrusion that affects the aerodynamics of the golf club head (100). In some embodiments, the return crown portion (400) can have indentations on its inner surface. The indentations correspond to the crown portion turbulator (430) and impart the same thickness (wall thickness measured between the inner and outer surfaces) to the turbulator (430) as the rest of the return crown portion (400). However, in other embodiments, one or more crown portion turbulators (430) can be filled so as to have a greater thickness than the rest of the return crown portion (400). The increased thickness of the return crown portion (400) in one or more filled crown portion turbulators (430) can increase the durability of the golf club head (100) by increasing the rigidity of at least the portion of the return crown portion (400).

[0116] Referring to FIGS. 5, 7B and 7C, the crown portion turbulator (430) can be classified into toe portion turbulators (432) and heel portion turbulators (434). In some embodiments, one or more of the crown portion turbulators (430) can be filled with a material (solid) such that there are no indentations corresponding to the inner surface of the return crown portion (400). In some embodiments, one or more of the toe portion turbulators (432) can be filled. In some embodiments, one or more of the heel portion turbulators (434) can be filled. The region of the crown return portion (400) with one or more filled turbulators can be stiffer or harder than the region of the crown return portion (400) with unfilled turbulators. The solid turbulator has a greater thickness than the thickness of the rest of the return crown portion (400).

[0117] Referring to FIGS. 7B and 7C, in some embodiments, the thick region (436) of the crown return portion (400) has a thickness greater than the thickness of the remaining portion of the crown return portion (400). Generally, the crown return portion (400) can have the thickness of the impact face return (177) as described above. However, in some embodiments, the thickness of the return crown portion (400) can increase up to 0.002 inches, 0.003 inches, 0.004 inches, 0.005 inches, 0.006 inches, 0.007 inches, 0.008 inches, 0.009 inches, or 0.010 inches within the thick region (436). The thick region (436) can be in the form of a patch, a rectangular region, a defined region, and / or a shape that at least partially covers one or more of the crown portion turbulators (430). In the embodiment shown in FIG. 7B, the bounded region covers two of the heel portion turbulators (434). The turbulator is filled (solid) within the bounded region (436). FIG. 7C shows a cross-sectional view representing the filled crown portion turbulator (430).

[0118] When the golf ball impacts the golf club (100), the first component (300) including the crown return portion (400) flexes. The flexing of the crown return portion (400) of this first component (300) can induce stress within a second component that joins the first component lip (450). The second component (200) can be placed in a portion where there is a risk of material failure if the crown return portion (400) of the first component (300) repeatedly flexes beyond a threshold. Adding the thick region (436) can locally increase the cross-sectional area of the crown return portion (400) adjacent to the portion of the second component that may be at risk of material failure after repeated impacts. The increase in the cross-sectional area of the crown return portion (400) in the thick region (436) reduces the stress, thereby increasing the durability of the club head (100).

[0119] Manipulating the position of the rear sole extension (500) provides a means of manipulating the mass characteristics of the assembled golf club head. Referring to FIGS. 4, 5, 7A, and 8, the sole portion of the first component extends from a center near the striking face, toward the toe end forming the toe end extension (720) of the sole portion of the first component, toward the heel end forming the heel end extension (710) of the sole portion of the first component, and toward the rear end forming the rear extension (500) of the sole portion of the first component. The first component sole portion toe extension (720), the first component sole portion heel extension (710), and the first component sole portion rear extension (500) can form a "T" shaped profile. In some embodiments, the toe extension can have a first component sole portion toe end extension length (825) in the range of 1.50 inches to 2.00 inches from the YZ plane toward the toe end (150). For example, the first component sole portion toe extension (720) can have a first component sole portion toe end extension length (825) of 1.50 inches, 1.60 inches, 1.70 inches, 1.80 inches, 1.90 inches, or 2.00 inches toward the toe end (150). In some embodiments, the first component sole portion heel end extension (710) can have a first component sole portion heel extension length (835) in the range of 0.90 inches to 1.40 inches from the YZ plane toward the heel end (160). For example, the first component sole portion heel end extension (710) can extend 0.90 inches, 1.10 inches, 1.20 inches, 1.30 inches, or 1.40 inches. The first component sole portion rear extension (500) can extend from 2.30 inches to 2.90 inches rearward of the striking face return portion (177). For example, the first component sole portion rear extension (500) can extend from the striking face return portion (177) by a distance of 2.30 inches, 2.40 inches, 2.50 inches, 2.60 inches, 2.70 inches, 2.80 inches, or 2.90 inches.

[0120] Shifting the first component sole portion rear extension (500) (or simply referred to as the "rear extension") near the toe end (150) or the heel end (160) of the golf club head (100) provides a means to manipulate the mass characteristics of the assembled golf club head and change the ball flight. When manufacturing the first component (300), moving the rear extension (500) towards the toe end (150) or the heel end (160) of the golf club (100) changes the mass characteristics of the assembled golf club head. When the rear extension (500) is moved towards the toe end (150) by reducing the first component sole portion toe end extension (825), the center of gravity of the golf club head (100) will also move towards the toe end (150). When the first component sole portion rear extension (500) is moved towards the heel end (160) of the golf club head (100), the center of gravity of the golf club head (100) will also move towards the heel end (160).

[0121] The first component (300) includes a surface area in the range of 27 square inches to 41 square inches of the total surface area of the golf club head (100). In some embodiments, the surface area of the first component (300) can be in the range of 25 square inches to 43 square inches, 25 square inches to 28 square inches, 28 square inches to 31 square inches, 31 square inches to 34 square inches, 34 square inches to 37 square inches, 37 square inches to 40 square inches, or 40 square inches to 43 square inches. For example, 25 square inches, 27 square inches, 29 square inches, 31 square inches, 33 square inches, 35 square inches, 37 square inches, 39 square inches, 41 square inches, 43 square inches, etc.

[0122] The first component (300) can include materials such as steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the first component (300) can include a Ti-8Al-1Mo-1V alloy. In many embodiments where the golf club head (100) is a driver-type club head, the first component (300) can include a titanium material. In many embodiments where the golf club head (100) is a fairway wood-type club head, the first component (300) can include a steel material.

[0123] In many embodiments, the first component (300) can be cast. In other embodiments, the first component (300) can be forged, pressed, rolled, extruded, machined, electroformed, 3-D printed, or any suitable forming technique. Referring to FIG. 15, in embodiments where the first component (300) is cast, the first component (300) can further include a plurality of casting support bars including one or more heel-end casting support bars (1510) and one or more toe-end casting support bars (1512). 1) First component rear sole extension

[0124] As described above, the first component includes a striking face and a striking face return (177). These portions of the golf club head (100) receive and distribute impact forces when the golf club strikes the ball. The rear extension (500) is formed integrally with the remainder of the first component (300) and extends from the striking face return sole portion (810). Further, the mass of the rear extension (500) resists torque forces caused by impacts off-center of the striking face. In many embodiments, the first component sole toe end extension (720) and the first component sole heel end extension (710) can be parallel to the striking face (170) and have a constant width from front to back. In other embodiments, the toe end extension (720) and the heel end extension (710) can increase and / or decrease in width toward the toe end (150) and the heel end (160), including various widths. In some embodiments, the first component sole toe end extension (720) and the heel end extension (710) can include widths in the range of 1.0 inch to 1.5 inches. For example, the toe end extension (720) and the heel end extension (710) can be 1.00 inches, 1.10 inches, 1.20 inches, 1.30 inches, 1.40 inches, or 1.50 inches.

[0125] In many embodiments, the first component sole portion rear extension (500) can increase in width, decrease in width, and / or include a width (507) of a boat from the rear boundary of the hitting face return sole portion (810) toward the rear end (180). In some embodiments, the rear extension (500) can include a width (507) in the range of 1.0 inch to 3.5 inches. For example, the rear extension can be 1.0 inch, 1.25 inches, 1.50 inches, 1.75 inches, 2.00 inches, 2.25 inches, 2.50 inches, 2.75 inches, 3.0 inches, 3.25 inches, or 3.50 inches. In some embodiments, the rear extension (500) has a width that varies in the front-to-back direction. Specifically, the rear extension (500) can include a width that increases in the front-to-back direction. In these embodiments, the width of the rear extension (500) has a minimum value adjacent to the hitting face return sole portion (810) and a maximum value adjacent to the rear portion of the club head. Spreading the width of the rear extension (500) toward the rear portion of the club head allows the rear extension (500) to support a weight or weight system. Varying the width of the rear extension (500) such that the minimum width is adjacent to the hitting face return sole portion (810) reduces the mass adjacent to the face return portion and allows this saved weight to be redistributed around the club head. In other embodiments, the rear extension (500) can include a width that decreases in the front-to-back direction. Narrowing the width of the rear extension toward the rear portion of the club head can provide additional structural support for a weight or weight system attached to the rear extension (500).

[0126] In some embodiments, such as those shown in FIG. 2, the first component sole portion rear extension (500) can extend in a direction perpendicular to the striking face (170) and be located at the center between the toe end (150) and the heel end (160). In other embodiments, the rear extension (500) can extend closer to the toe end (150) or closer to the heel end (160). The rear extension (500) can be offset from 0.05 inches to 1.0 inches toward the heel end (160). For example, the rear extension (500) can be offset 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, or 1.0 inches toward the heel end (160). The first component sole portion rear extension (500) can be offset from 0.05 inches to 1.0 inches toward the toe end (150). For example, the rear extension (500) can be offset 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, or 1.0 inches toward the toe end (160).

[0127] When the first component sole portion rear extension (500) is offset toward the toe end (150), the center of gravity of the golf club head (100) can be offset up to 0.150 inches toward the toe portion (150) compared to a similar golf club head with the sole portion rear extension (500) centered. For example, the center of gravity can be offset 0.010 inches, 0.020 inches, 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, 0.100 inches, 0.110 inches, 0.120 inches, 0.130 inches, 0.140 inches, or 0.150 inches toward the toe end (150). When the first component sole portion rear extension (500) is offset toward the heel end (160), the center of gravity of the golf club head (100) can be offset up to 0.150 inches toward the heel end (160). For example, the center of gravity can be offset 0.010 inches, 0.020 inches, 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, 0.100 inches, 0.110 inches, 0.120 inches, 0.130 inches, 0.140 inches, or 0.150 inches toward the heel end (160). The offset of the center of gravity affects the flight characteristics of the ball by biasing the golf club head at impact to a position where the fade is mitigated or the draw is mitigated.

[0128] Referring to FIGS. 31 and 32, another means of manipulating the mass characteristics of the golf club head is to vary the angle of the rear sole extension relative to the striking face of the first component. The rear sole extension of the first component can comprise a rear extension axis (504). The rear extension axis (504) can extend through the center of the sole extension as viewed from the sole. The rear extension axis (504) can be positioned such that, in a sole view, it is approximately equidistant from both sides of the sole rear extension (500) at any point along the axis (504). As shown in FIGS. 35 and 36, the rear extension (500) itself can be arranged such that the rear extension axis intersects the YZ plane (193) at a rear extension angle (508). In some embodiments, the rear extension axis (504) can intersect the YZ plane (193) at a point proximate to the rear end of the return portion (177). The rear extension angle (508) can range from 0 degrees to 45 degrees. In some embodiments, the rear extension angle (508) can range from 0 degrees to 10 degrees, 0 degrees to 20 degrees, 0 degrees to 30 degrees, 0 degrees to 40 degrees, 10 degrees to 20 degrees, 10 degrees to 30 degrees, 10 degrees to 40 degrees, 10 degrees to 45 degrees, 20 degrees to 30 degrees, 20 degrees to 40 degrees, 20 degrees to 45 degrees, 30 degrees to 40 degrees, or 30 degrees to 45 degrees. FIGS. 25-28, 33 and 34 show other embodiments with angled sole extensions as described below.

[0129] Since the weight is fixed within the removable weight recess (540), adjusting the angle of the rear extension is a matter of positioning the removable weight on the club head (100) in a heel or toe direction. By angling the rear extension (500), when the extension (500) is angled in the heel direction of the club head (100), the club (100) can be biased to have a draw bias. In other embodiments, angling the rear extension (500) in the toe direction of the club head (100) results in a fade bias for the club head.

[0130] Referring to FIG. 8, the angulation of the rear extension (500) can also be understood as the angle between the end of the sole rear extension (500) and the return portion (177). The first component sole portion rear extension toe direction angle (850) and the first component sole portion rear extension heel direction angle (855) are supplementary angles (i.e., the two angles add up to 180 degrees). In one embodiment, the toe direction angle (850) and the heel direction angle (855) are each 90 degrees, and thus the rear extension (500) is essentially perpendicular to the striking face (170). In another embodiment, the toe direction angle (850) and the heel direction angle (855) can each vary between 45 degrees and 135 degrees as long as the two angles continue to be supplementary. For example, the toe direction angle (850) can be 100 degrees while the heel direction angle (855) is the supplementary 80 degrees. In this example, the mass portion (510) is angled offset toward the heel end (180) of the golf club head (100).

[0131] Other combinations of the toe direction angle (850) and the heel direction angle (855) may be 110 degrees and 70 degrees, 120 degrees and 60 degrees, 130 degrees and 50 degrees, or 135 degrees and 45 degrees. The center of gravity of the golf club head will be offset towards the position of the rear mass portion (510). For example, the center of gravity may be offset by 0.010 inches, 0.020 inches, 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, 0.100 inches, 0.110 inches, 0.120 inches, 0.130 inches, 0.140 inches, or 0.150 inches towards the heel end (160). Similarly, the toe direction angle decreases and the heel direction angle increases. For example, the combination of the toe direction angle (850) and the heel direction angle may be 80 degrees and 100 degrees, 70 degrees and 110 degrees, 60 degrees and 120 degrees, 50 degrees and 130 degrees, or 45 degrees and 135 degrees. For example, the center of gravity may be offset by 0.010 inches, 0.020 inches, 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, 0.100 inches, 0.110 inches, 0.120 inches, 0.130 inches, 0.140 inches, or 0.150 inches towards the toe end (160). This angular offset may desirably position the club head center of gravity in that direction by placing more of the rear mass towards the heel direction portion or the toe direction portion at the rear in order to affect the ball flight characteristics. The angular offset in other embodiments can generate different club head center of gravity positions and different ball flight characteristics by combining the first component sole portion rear extension toe direction angle (850) and the first component sole portion rear extension heel direction angle (855) differently. 2) Mass of the rear sole extension of the first component

[0132] As described above, the first component includes most of the mass of the assembled golf club head. The rear extension (500) allows a portion of the mass of the golf club to be disposed away within the sole of the club head toward the rear of the club head. The rear extension (500) includes a mass portion at the rear of the golf club head, where the mass can further affect the CG and MOI of the golf club head. The sole portion rear extension mass portion (510) of the first component can, alone, include from 20% to 35% of the total mass of the golf club head (100). Placing this mass at the rearmost portion of the rear extension (500) is an important aspect for controlling the mass characteristics of the golf club head (100) during the manufacture of the first component (300).

[0133] Referring to FIG. 9, the sole portion rear extension mass portion (510) of the first component includes a threaded receiving portion (545), one or more weight receiving tabs (546), and a mass portion (510) having a heel side outer boundary (910), a toe side outer boundary (915), and a front outer boundary (918).

[0134] Referring to FIG. 10, the mass portion (510) further includes a plurality of internal ribs (520) having an internal rib width (523). The plurality of internal ribs (520) can include two ribs, three ribs, four ribs, five ribs, or more than five ribs. The plurality of internal ribs (520) engage or are attached to the inner surface of the detachable weight receptacle (540) of the rear extension mass portion. The internal ribs (520) can reduce unwanted vibrations in the mass portion (510), which is desirable since most of the mass of the golf club head (100) is disposed toward the rear of the golf club head. The mass portion (510) further includes a vertical lip (750) having a vertical lip height (1150) and a mass portion trailing edge shelf (1042) having a shelf length (1048), a shelf height (1044), and a shelf width (1046). The shelf length (1048) is substantially the same as the width (507) of the rear extension and varies as the width of the mass portion (510) varies.

[0135] The shelf (1042) provides a mating surface for a portion of the second component when the first and second components are joined and assembled to form a golf club head. The mass portion (510) further includes an internal front boundary (1050) and a vertical lip length (1052).

[0136] Referring to FIG. 8, a view of the rear mass body (510) is bisected by the YZ plane (193). As shown in FIG. 11, the mass portion includes an internal length (1110), a maximum height (1112) of the mass portion, and a vertical lip height (1150). The internal rib further includes a rib height (1120) and a rib length (1122).

[0137] The internal rib width (523) can range from 0.025 inches to 0.100 inches. For example, the internal rib width (523) may be 0.025 inches, 0.050 inches, 0.075 inches, or 0.100 inches. The internal rib height (1120) ranges from 25% to 100% of the removable weight recess depth (1216). The internal rib length (1122) can range from 0.100 inches to 1.500 inches. For example, the internal rib length (1122) may be 0.100 inches, 0.200 inches, 0.300 inches, 0.400 inches, 0.500 inches, 0.600 inches, 0.700 inches, 0.800 inches, 0.900 inches, 1.000 inches, 1.100 inches, 1.200 inches, 1.300 inches, 1.400 inches, or 1.500 inches.

[0138] The mass portion (510) has a maximum height (1112) of the mass portion located along substantially the upper part of the mass portion vertical lip (750). The mass section (510) decreases in thickness as it approaches the heel side outer boundary (910), the toe side outer boundary (915), and the front outer boundary (918). The maximum height (1112) of the mass portion includes the maximum thickness of the mass portion (510). The maximum thickness of the mass section (510) can range from 0.40 inches to 0.70 inches. For example, the maximum thickness of the mass portion (510) may be 0.40 inches, 0.50 inches, 0.60 inches, or 0.70 inches. 3) Removable Weight and Embedded Weight of the First Component

[0139] To enable further control of the mass characteristics of the assembled golf club head, a removable weight recess and a removable weight are provided, and the mass of the removable weight can finely adjust the mass characteristics of the golf club head when assembled. The removable weight recess (540) further includes a plurality of removable weight recess tabs. The plurality of removable weight recess tabs may be two tabs, three tabs, four tabs, five tabs, or more than five tabs.

[0140] Referring to FIG. 12, it is desirable to further increase the mass disposed at the rearmost part of the golf club head. The mass portion (510) may further include an embedded weight recess (1220). Accordingly, an embedded weight recess (1220) and an embedded weight (1600) including an embedded weight material having a density higher than the first density of the first material of the first component (300) (configured to be received in the embedded weight recess (1220)) can be provided.

[0141] Referring to FIG. 13, the removable weight (1300) can include materials such as steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, metal alloys, composite polymer materials, or any combination thereof. In many embodiments, the sole weight can be tungsten. The removable weight (1300) has a mass.

[0142] The mass of the removable weight (1300) can range from 1.0 gram to 35.0 grams. For example, the mass of the removable weight (1300) can be 1.0 gram, 1.5 grams, 2.0 grams, 3.0 grams, 4.0 grams, 5.0 grams, 6.0 grams, 7.0 grams, 8.0 grams, 9.0 grams, 10.0 grams, 11.0 grams, 12.0 grams, 13.0 grams, 14.0 grams, 15.0 grams, 16.0 grams, 17.0 grams, 18.0 grams, 19.0 grams, 20.0 grams, 21 grams, 22 grams, 23 grams, 24 grams, 25 grams, 26 grams, 27 grams, 28 grams, 29 grams, 30 grams, 31 grams, 32 grams, 33 grams, 34 grams, or 35 grams.

[0143] Referring to FIGS. 8 and 13, the removable weight (1300) is configured to be received within the removable weight recess (540). The removable weight (1300) further includes a through hole substantially at the center of the removable weight (1300). The through hole is configured to receive a threaded fastener for the removable weight (1320), and the threaded fastener (1320) can be threadedly received within a threaded receiving boss (542) to enable the removable weight (1300) to be fixed within the removable weight recess (540).

[0144] Referring to FIG. 14, the detachable weight (1300) further includes a thickness (1430), a plurality of detachable weight offsets (1434), and a plurality of detachable weight side grooves (1438). The plurality of detachable weight offsets (1434) may be two offsets, three offsets, four offsets, five offsets, or more than five offsets. The plurality of detachable weight side grooves (1438) may be two grooves, three grooves, four grooves, five grooves, or more than five grooves. The offset (1434) is configured to slightly offset the detachable weight (1300) from the wall of the detachable weight recess (540) when the detachable weight (1300) is received within the detachable weight recess (540). The detachable weight side groove (1438) is configured to receive the detachable weight recess tab when the detachable weight (1300) is received within the detachable weight recess (540).

[0145] Referring to FIGS. 16A and 16B, the embedded weight (1600) has a mass. The mass of the embedded weight (1600) can range from 1.0 gram to 20.0 grams. For example, the mass of the embedded weight (1600) may be 1.0 g, 2.0 g, 3.0 g, 4.0 g, 5.0 g, 6.0 g, 7.0 g, 8.0 g, 9.0 g, 10.0 g, 11.0 g, 12.0 g, 13.0 g, 14.0 g, 15.0 g, 16.0 g, 17.0 g, 18.0 g, 19.0 g, or 20.0 g.

[0146] The embedded weight (1600) includes a tungsten material, a tungsten alloy material, a polymer matrix embedded with tungsten particles, or any other suitable material having a density greater than the first material density. The embedded weight (1600) is configured to fit within the embedded weight recess (1220) and be permanently fixed within the embedded weight recess. The embedded weight (1600) may be permanently fixed using an adhesive, by swaging or other press-fitting methods, or by using suitable mechanical attachment means. B) The second component

[0147] The golf club head (100) includes a first component (300) and a non-metallic lightweight second component (200) configured to be joined together to form the hollow golf club head (100). As shown in FIGS. 1F, 2, and 3, the second component (200) can include at least a portion of the crown (110), the sole (120), the trailing edge (130), and the rear notch (240). With particular reference to FIGS. 1F and 2, the second component (200) includes a second component crown portion (205), a second component sole portion heel portion (214), a second component sole portion toe portion (212), a second component peripheral end portion (220), a second component sole portion rear notch width (242) and a second component sole portion rear notch height (244) of the second component sole portion rear notch (240), and a second component sole portion trailing edge (230). In some embodiments, although not shown, the second component can include only a portion of the crown. In these embodiments, the sole portion rear notch (240) can surround the crown (205).

[0148] As shown in FIGS. 1-4, the second component crown portion (205) wraps over the trailing edge (130) and integrally forms a part of the sole that is complementary to the first component. The heel and toe sole portions (214)(212) of the second component (200) formed by the second component can include a triangular shape disposed between the toe end extension and the rear end extension of the first component, and a triangular shape disposed between the rear end extension and the heel end extension. In other embodiments, the sole portion formed by the second component (200) can include a circular, square, oval, any other polygon, or a shape having at least one curved surface that is complementary to the sole portion of the first component (100). The second component (200) may include a single monolithic component formed entirely together without the need for further joining. For example, the second component (200) can be formed by injection molding a single monolithic component that includes a single material.

[0149] Alternatively, the second component (200) may comprise a plurality of separately formed parts that are subsequently permanently joined by an adhesive, sonic welding, fusing, or any other permanent joining method appropriate for the materials used in forming the plurality of separately formed parts. For example, the crown portion (205), toe portion (212), and heel portion (214) of the second component may be separately formed from the same or different materials. Next, the second component parts can be adhesively joined to form the complete second component (200). Such formation of separately joined parts can be advantageous when using materials such as bidirectional carbon fiber prepreg materials. Bidirectional carbon fiber prepregs cannot be easily applied to specific small curvatures and cannot be easily formed as a single piece to achieve the desired second component (200) shape. Using such materials requires the formation of separate sole portions (212) and (214), which are later joined to the remaining part of the second component (200) by an adhesive or other means.

[0150] Alternatively, the plurality of second components may be coupled to the first component remotely without being coupled to each other.

[0151] The second component of the golf club head (100) can include a thickness. The thickness of the second component can range from 0.030 inches to 0.500 inches. In some embodiments, the thickness of the second component is from 0.030 inches to 0.040 inches, from 0.030 inches to 0.045 inches, from 0.030 inches to 0.055 inches, from 0.045 inches to 0.055 inches, from 0.050 inches to 0.060 inches, from 0.055 inches to 0.065 inches, from 0.060 inches to 0.070 inches, from 0.065 inches to 0.075 inches, from 0.070 inches to 0.080 inches, from 0.075 inches to 0.085 inches, from 0.080 inches to 0.090 inches, from 0.085 inches to 0.095 inches, from 0.090 inches to 0.100 inches, from 0.100 inches to 0.200 inches, from 0.200 inches to 0.300 inches, from 0.300 inches to 0.400 inches, or from 0.400 inches to 0.500 inches. For example, the thickness of the second component can be 0.008 inches, 0.010 inches, 0.015 inches, 0.020 inches, 0.025 inches, 0.030 inches, 0.035 inches, 0.040 inches, 0.045 inches, 0.050 inches, 0.055 inches, 0.060 inches, or 0.065 inches. The thickness of the second component can be further varied from the crown, sole, heel end, toe end, and trailing edge. For example, in one embodiment, the thickness of the second component may vary across the crown, sole, heel end, toe end, and trailing edge of the second component.

[0152] In some embodiments, the second component further comprises internal ribs or internal thickened sections. When referring to internal ribs or internal thickened sections, this disclosure intends to refer to a portion of the club body having a varying inner surface contour presenting a relatively greater thickness (measured orthogonal to the outer surface of the component) than the non-thickened areas of the second component. In each instance, the term "internal" is intended to mean a feature not readily perceptible from the outside of the club head. Stated differently, the outer surface retains a distinct or substantially distinct contour across the feature and adjacent to the structure.

[0153] The internal ribs or internal thickened sections may provide additional strength and / or rigidity to the club head through various mechanisms. First, the thickened ribs / sections may function as struts / gussets providing a structural framework for the component. As such, the design of the structure itself can promote strength. Further, the presence of the thickened section can assist in controlling the direction, velocity, and uniformity of polymer flow during casting. In that way, the orientation of the embedded fibers can be controlled such that any anisotropic parameters of the material itself are directed to support the purpose of the club head. In this regard, the thickened section can provide both the designed structure and the designed material. Finally, in some embodiments, the first component may include a reinforcing feature such as an upright strut configured to be fixed to the second component. In such a design, the thickened section can provide an appropriate bonding location such that the thickened material can disperse any transmitted load without risk of fatiguing or breaking the relatively thinner sections.

[0154] In some embodiments, such as the embodiment of FIG. 3, the second component (200) further comprises a plurality of second component thin sections (250) having one or more crown section thin sections (255) and one or more sole section thin sections (257). The second component (200) further comprises a plurality of second component internal ribs (260) having one or more crown section internal ribs (262) and one or more sole section internal ribs (264). The plurality of internal ribs (260) may be two ribs, three ribs, four ribs, five ribs, or more than five ribs. The internal ribs of the crown section (262) and the sole section (264) are between the second component thin sections (250). The internal ribs of the crown section (262) and the sole section (264) can include the maximum thickness of the second component (200). In some embodiments, the internal ribs (260) of the second component can be similar to the ribs described in U.S. Patent Application No. 15 / 076,511 (currently U.S. Patent No. 9,700,768), which is hereby incorporated by reference in its entirety. The internal ribs (260) of the second component can reduce stress on the golf club head (100) and improve the sound during impact.

[0155] The plurality of second component thin sections (250) have a thickness. The thickness of the plurality of second component thin sections (250) can range from 0.008 inches to 0.035 inches. In other embodiments, the thickness of the thin section (250) can range from 0.008 inches to 0.015 inches, 0.010 inches to 0.020 inches, 0.015 inches to 0.025 inches, 0.020 inches to 0.030 inches, or 0.025 inches to 0.035 inches. For example, the thickness of the thin section (250) can be 0.008 inches, 0.010 inches, 0.015 inches, 0.020 inches, 0.025 inches, 0.030 inches, or 0.035 inches. The thickness of the internal rib or thick section can be up to 0.010 inches thicker than other parts of the second component (200). In some embodiments, the second component lacks internal ribs and thin sections.

[0156] Generally as shown in FIG. 3B, in still other embodiments, the second component includes a central thick section (270) surrounded by a relatively thin crown section thin section (255). In one configuration, this central thick section (270) has a total area of from about 1.5 square inches to about 3.0 square inches. In other configurations, this central thick section (270) has a total area of from about 2.0 square inches to about 2.5 square inches. In some embodiments, the central thick section (270) is slightly trapezoidal, and at least a portion (272) of the thick section (270) near the face and / or front end (274) is wider than a portion of the thick section (270) farther from the face. Such width dimensions are preferably obtained parallel to the horizontal centerline of the face extending between the heel and toe of the club head. As further shown, the central thick section (270) may be separated from the front end (274) by a distance (d) greater than about 0.8 inches, or a distance between 0.8 inches and 1.0 inches, 1.0 inches and 1.2 inches, 1.2 and 1.4 inches. In some embodiments, the distance (d) is about 1.25 inches.

[0157] In some embodiments (not shown), the second component can further include a front thickness strip that runs along the perimeter or front edge (274) of the second component (200). This thickness strip can have a thickness equivalent to the trailing edge (230) and / or the central thickness section (270). The front thickness strip imparts structural strength to the front edge (274). A thickness transition region exists between the front thickness strip and the crown thin-wall section (255), which can mitigate the transmission of stress across the crown. The second component includes a mass percentage of the total mass of the golf club head (100). The mass percentage of the second component can range from 4% to 15% of the total mass of the golf club head (100), or can be from about 10 grams to 25 grams. In other embodiments, the mass percentage of the second component can range from 4% to 15%. For example, the mass percentage of the second component can be 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, or 15% of the total mass of the golf club head (100).

[0158] The second component includes an outer surface area in the range of 17 square inches to 25 square inches. In some embodiments, the surface area of the second component can range from 15 square inches to 27 square inches, from 15 square inches to 18 square inches, from 18 square inches to 21 square inches, or from 21 square inches to 25 square inches. For example, the surface area of the second component can be 15 square inches, 17 square inches, 19 square inches, 21 square inches, 23 square inches, or 25 square inches. 1) Second Component Material

[0159] The second component (200) comprises a material having a lower density than the material of the first component. In some embodiments, the second component can comprise a composite formed from a polymer resin and reinforcing fibers. The polymer resin can comprise a thermosetting resin or a thermoplastic resin. The composite of the second component (200) can be either a filled thermoplastic (FT) or a fiber-reinforced composite (FRC). In some embodiments, the second component (200) can comprise an FT combined with an FRC. The filled thermoplastic (FT) is typically shaped into a desired form by injection molding. As the name implies, the filled thermoplastic (FT) can comprise a thermoplastic resin and randomly oriented discontinuous fibers. Conversely, the fiber-reinforced composites (FRCs) are formed from a resin impregnated (prepreg) sheet of continuous fibers. The fiber-reinforced composites (FRCs) can comprise a thermoplastic material or a thermosetting resin.

[0160] In embodiments having a thermoplastic resin, the resin can comprise a thermoplastic polyurethane (TPU) or a thermoplastic elastomer (TPE). For example, the resin can comprise polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyimide, polyamides such as PA6 or PA66, polyamideimide, polyphenylene sulfide (PPS), polycarbonate, engineering polyurethane, and / or other similar materials. Strength and weight are two primary properties considered for composite materials, but suitable composite materials can also exhibit secondary advantages such as acoustic properties. In some embodiments, PPS and PEEK are desirable because they generally emit a metallic-sounding acoustic response when impacted.

[0161] The reinforcing fibers can comprise carbon fibers (or chopped carbon fibers), glass fibers (or chopped glass fibers), graphite fibers (or chopped graphite fibers), or any other suitable filler material. In other embodiments, the composite material can comprise any reinforcing filler that adds strength, durability, and / or weight.

[0162] The density of the composite material (a composite of resin and fiber) forming the second component (200) can range from about 1.15 g / cc to about 2.02 g / cc. In some embodiments, the composite material density ranges from about 1.20 g / cc to about 1.90 g / cc, from about 1.25 g / cc to about 1.85 g / cc, from about 1.30 g / cc to about 1.80 g / cc, from about 1.40 g / cc to about 1.70 g / cc, from about 1.30 g / cc to about 1.40 g / cc, or from about 1.40 g / cc to about 1.45 g / cc. Filled thermoplastic material (FT)

[0163] For the FT material, the polymeric resin should preferably incorporate one or more polymers having material strength and / or strength / weight ratio characteristics high enough to withstand typical use while providing the benefit of weight savings in the design. Specifically, it is important for the design and materials to efficiently withstand the stresses imparted during impact between the striking face and the golf ball without substantially contributing to the overall weight of the golf club head. Generally, the polymer can be characterized by a yield point tensile strength exceeding about 60 MPa (neat). When the polymeric resin is combined with reinforcing fibers, the resulting composite material can have a yield tensile strength exceeding about 110 MPa, exceeding about 180 MPa, exceeding about 220 MPa, exceeding about 260 MPa, exceeding about 280 MPa, or exceeding about 290 MPa. In some embodiments, a suitable composite material may have a yield point tensile strength of about 60 MPa to about 350 MPa.

[0164] In some embodiments, the reinforcing fibers include a plurality of discontinuous dispersed fibers (i.e., "chopped fibers"). In some embodiments, the reinforcing fibers include discontinuous "long fibers" having a designed fiber length of about 3 mm to 25 mm. In some embodiments, the discontinuous "long fibers" have a designed fiber length of about 3 mm to 14 mm. For example, in some embodiments, the fiber length is about 12.7 mm (0.5 inches) prior to the molding process. In another embodiment, the reinforcing fibers include discontinuous "short fibers" having a designed fiber length of about 0.01 mm to 3 mm. In either case (short fibers or long fibers), note that a given length is a pre-mixed length and, due to breakage during the molding process, some fibers may actually be shorter than the range described in the final component. In some configurations, the discontinuous chopped fibers may be characterized by an aspect ratio (e.g., fiber length / diameter) of greater than about 10, or more preferably greater than about 50 and less than about 1500. Regardless of the type of discontinuous chopped fibers used, in certain configurations, the composite material may have a fiber length of from about 0.01 mm to about 25 mm or from about 0.01 mm to about 14 mm.

[0165] The composite material may have a polymer resin content of from about 40 wt% to about 90 wt%, or from about 55 wt% to about 70 wt%. The composite material of the second component can have a fiber content of from about 10 wt% to about 60 wt%. In some embodiments, the composite material has a fiber content of from about 20 wt% to about 50 wt%, from 30 wt% to 40 wt%. In some embodiments, the composite material has a fiber content of from about 10 wt% to about 15 wt%, from about 15 wt% to about 20 wt%, from about 20 wt% to about 25 wt%, from about 25 wt% to about 30 wt%, from about 30 wt% to about 35 wt%, from about 35 wt% to about 40 wt%, from about 40 wt% to about 45 wt%, from about 45 wt% to about 50 wt%, from about 50 wt% to about 55 wt%, or from about 55 wt% to about 60 wt%.

[0166] In embodiments where the second component (200) comprises a filled thermoplastic (FT) material, the second component (200) can be injection molded from a single composite material pellet that includes both a polymer resin and reinforcing fibers. The reinforcing fibers can be embedded within the resin prior to injection molding the second component. The pellet can be melted and injected into an empty mold to form the second component (200). The FT composite material can have a melting point from about 210°C to about 280°C. In some embodiments, the composite material can have a melting point from about 250°C to about 270°C.

[0167] In embodiments of the second component (200) with an FT material, at least 50% of the fibers can be aligned generally along the longitudinal direction in the central region of the crown (110). In other words, the fibers can be aligned generally perpendicular to the striking face (170). The FT material exhibits maximum strength in the fiber direction. Thus, the generally longitudinally aligned fibers in the crown (110) can improve the durability of the club head in the longitudinal direction. The fiber alignment can correspond to the direction of material flow during the injection molding process.

[0168] When the golf club head (100) strikes a golf ball, the position of the mass at the rear end (180) of the rear extension (500) can move in the vertical direction, the Y-axis (192) direction, due to the impact. During impact, the sole rear extension (500) bends upward, applying stress on the crown portion (205) of the second component. The crown portion is compressed between the rear extension (500) of the first component and the front portion of the first component (300). Thus, in embodiments of the second component (200) with FT, aligning the fibers in the direction of the compressive stress expected during impact reduces the likelihood of damage to the composite of the second component (200).

[0169] In some embodiments, the second component (200) can be formed from a long fiber reinforced TPU material (an example of an FT material). The long fiber TPU can include about 40 weight percent long carbon fibers. The long fiber TPU can exhibit a high modulus of elasticity that is greater than that of a short carbon fiber compound. The long fiber TPU can withstand high temperatures and be suitable for use in a golf club head that is used and / or stored in a high temperature environment. The long fiber TPU exhibits even higher toughness and can serve as an alternative to conventional metal components. In some embodiments, the long fiber TPU includes a tensile modulus of elasticity between about 26,000 MPa and about 30,000 MPa, or between about 27,000 MPa and about 29,000 MPa. In some embodiments, the long fiber TPU includes a flexural modulus of elasticity between about 21,000 MPa and about 26,000 MPa, or between about 22,000 MPa and 25,000 MPa. The long fiber TPU material can exhibit a tensile elongation (at the break point) of about 0.5% to about 2.5%. In some embodiments, the tensile elongation of the composite TPU material can be about 1.0% to about 2.0%, about 1.2% to about 1.4%, about 1.4% to about 1.6%, about 1.6% to about 1.8%, about 1.8% to about 2.0%. Fiber reinforced composite (FRC)

[0170] In some embodiments, the second component (200) can include a fiber reinforced composite (FRC) material. The FRC material generally includes one or more layers of a unidirectional or multi-directional fiber fabric that extends across a larger portion of the polymer. Unlike the reinforcing fibers used in filled thermoplastic (FT) materials, the maximum dimension of the fibers used in FRC can be substantially larger / longer than those used in FT materials and can have sufficient size and properties to be provided as a continuous fabric separate from the polymer. When formed from a thermoplastic polymer, the continuous fibers included are generally not fluid even when the polymer is molten and free to flow. The reinforcing fibers can have a surface weight (the ratio of weight to the product of length and width) of from 75 g / m 2 to 150 g / m 2 .

[0171] FRC materials are generally formed by placing fibers in desired positions and then impregnating the fiber material with a sufficient amount of polymer material to provide rigidity. In this way, FT materials can have a resin content exceeding about 45% by volume, or more preferably exceeding about 55% by volume, while FRC materials desirably have a resin content of less than about 45% by volume, or more preferably less than about 35% by volume. In some embodiments, the resin content of the FRC material can range from 25% to 45% by volume.

[0172] FRC materials traditionally use a two - part thermosetting epoxy as the polymer matrix, but it is also possible to use a thermoplastic polymer as the matrix. In many cases, FRC materials are pre - prepared before final manufacturing, and such intermediate materials are often called prepregs. When a thermosetting polymer is used, the prepreg is partially cured in an intermediate form, and final curing occurs when the prepreg is formed into its final shape. When a thermoplastic polymer is used, the prepreg can contain a cooled thermoplastic matrix, which can subsequently be heated and formed into its final shape.

[0173] The second component (200) of the FRC can comprise a plurality of layers (also referred to as a plurality of thin films). Each layer can have the same thickness as the prepreg and / or be the same thickness as the prepreg. Each of the plurality of layers can comprise a unidirectional fiber cloth (UD) or a multi-directional fiber cloth (also called a fabric). In some embodiments, the plurality of layers can comprise at least three UD layers. The second and third layers can be angled with respect to the base layer. With respect to the base layer oriented at 0 degrees, the second and third layers can be oriented at ±45 degrees from the base layer. In some embodiments, in any suitable order, the layers can be oriented at 0 degrees, +45 degrees, -45 degrees, +90 degrees, -90 degrees. In some embodiments, the plurality of layers can comprise at least one multi-directional fabric layer typically disposed as a top layer to improve the appearance of the second component (200) of the FRC. Composite material

[0174] The second component (200) can have a hybrid material structure that includes both a fiber-reinforced composite elastic layer and a molded thermoplastic structural layer. In some preferred embodiments, the molded thermoplastic structural layer may be formed from a filled thermoplastic material (FT). As described above, the FT can be discontinuous glass, carbon, or aramid polymer fiber fillers embedded throughout the thermoplastic material. The thermoplastic resin can be, for example, a TPU such as polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or a polyamide such as PA6 or PA66. The fiber-reinforced composite elastic layer can be a woven glass, carbon fiber, or aramid polymer fiber-reinforced layer embedded in a polymer resin (or matrix). The polymer resin of the elastic layer can be thermoplastic or thermosetting.

[0175] In some embodiments, the fiber-reinforced composite elastic layer is a thermoplastic material similar to the resin of the molded thermoplastic structural layer. In other words, the fiber-reinforced elastic layer and the molded thermoplastic structural layer can comprise a common fiber thermoplastic resin. When forming the elastic layer and the structural layer using the common fiber thermoplastic resin, a strong chemical bond can be formed between these layers. In these embodiments, the elastic layer and the structural layer can be joined without using an intermediate adhesive. In certain embodiments, the elastic layer of the second component can comprise a carbon fiber cloth embedded in sulfonated polyphenylene (PPS), and the structural layer of the second component can comprise a filled sulfonated polyphenylene (PPS) polymer. In other embodiments, the second component can be an extrusion molding, an injection blow molding, a 3-D printing, or any other suitable molding means. Cross-connecting member

[0176] In an alternative embodiment, the second component (200) can have one or more internal cross-connecting members (not shown). The cross-connecting members can provide additional structural rigidity or acoustic control. The internal cross-connecting members can include members that connect non-adjacent portions inside the second component (200). For example, the cross-connecting member can connect the inner surface of the crown portion (205) of the second component to one of the sole portion heel portion (214) or the sole portion toe portion (212) of the second component. The internal cross-connecting member can include a length that extends completely from the inner surface of the frontmost end of the second component (200) to the inner surface of the trailing edge portion (230) of the second component, or the internal cross-connecting member can include a length that does not extend completely from the inner surface of the frontmost end of the second component (200) to the inner surface of the trailing edge portion (230) of the second component. The internal cross-connecting member has a thickness. The thickness of the internal cross-connecting member can range from 0.01 inches to 0.25 inches. For example, the thickness of the internal cross-connecting member can be 0.01 inches, 0.05 inches, 0.10 inches, 0.15 inches, 0.20 inches, or 0.25 inches. II) Second Embodiment of a Golf Club Head (Including a Weight Channel)

[0177] The golf club head (2100) of the second embodiment shown in FIG. 17 includes a first component (2300) having a weight channel and a second component (2200) joined onto the first component (2300). The first component (2300) of the golf club head (2100) can be the same as the first component (300) of the golf club head (100) except for the weight system. The second component (2200) of the golf club head (2100) can be the same as the second component of the golf club head (100) described above. The golf club head (2100) forms a striking face (2170), a striking face return (2177), a hosel (2140), a crown (2110), a sole (2120), a heel end (2160), a toe end (2150), and a skirt (2125) having a trailing edge (2130) at the rearmost part of the rear end (2180), and a sole portion hosel adapter mounting recess (2195). The skirt (2125) can extend between the crown (2110) and the sole (2120) along the periphery of the club head behind the hosel (2140).

[0178] As shown in FIG. 18, the first component (2300) can include a rear extension (2500). The rear extension (2500) can include a part of the sole (2120). The rear extension (2500) includes a weight channel (2540). The weight channel (2540) is exposed at the rear end (2180) and the sole (2120) of the club head (2300).

[0179] The weight channel (2540) is configured to receive the movable weight (2350) at one of three positions. The weight (2350) can be fixed to the weight channel (2540) by a threaded fastener (2320). The weight (2350) can be disposed at the toe side position, the central position, or the heel side position. The weight channel (2540) comprises an attachment wall (2542) and a sole wall (2550). The attachment wall (2542) can be oriented substantially perpendicular to the sole (2120). The sole wall (2550) can be oriented substantially parallel to the main sole (2120), but can enter inward by a distance equal to the height of the attachment wall (2542). The movable weight (2350) can comprise an elongate, trapezoidal shape, or any other suitable weight. The movable weight () (2350) can comprise an inner wall and a connecting wall. The movable weight (2350) can comprise an inner wall and a connecting wall. The inner wall is in the same plane as the sole wall (2550) of the weight channel (2540). The connecting wall is in the same plane as the attachment wall (2542) when the weight (2350) is attached at one of the three positions.

[0180] The mass of the movable weight (2350) can range from 1.0 gram to 35.0 grams. For example, the mass of the movable weight (2350) can be 1.0 gram, 2.0 grams, 3.0 grams, 4.0 grams, 5.0 grams, 6.0 grams, 7.0 grams, 8.0 grams, 9.0 grams, 10.0 grams, 11.0 grams, 12.0 grams, 13.0 grams, 14.0 grams, 15.0 grams, 16.0 grams, 17.0 grams, 18.0 grams, 19.0 grams, 20.0 grams, 21.0 grams, 22.0 grams, 23.0 grams, 24.0 grams, 25.0 grams, 26.0 grams, 27.0 grams, 28.0 grams, 29.0 grams, 30.0 grams, 31.0 grams, 32.0 grams, 33.0 grams, 34.0 grams, or 35.0 grams. The concentration of mass within the weight channel (2540) at the rear end (2180) of the clubhead can strategically position the head's center of gravity and improve the launch characteristics of the golf club.

[0181] The mounting wall (2542) of the weight channel (2540) has three screw holes corresponding to three weight positions. The mounting wall (2542) includes a toe-side screw hole (2544), a center screw hole (2546), and a heel-side screw hole (2548). The movable weight (2350) is positioned at the toe-side position by aligning the connecting wall of the weight (2350) with the mounting wall (2542) of the channel (2540) and fixing the fastener (2320) to the toe-side screw hole (2544). The movable weight (2350) is positioned at the center position by aligning the connecting wall of the weight (2350) with the mounting wall (2542) of the channel (2540) and fixing the fastener (2320) within the center screw hole (2546). The movable weight (2350) is positioned at the heel-side position by aligning the connecting wall of the weight (2350) with the mounting wall (2542) of the channel (2540) and fixing the fastener (2320) within the heel-side screw hole (2548).

[0182] As illustrated in the sole view of FIG. 19A, when the movable weight (2350) is disposed at the central position, the golf club (2100) is configured not to impart a draw or fade bias. As shown in FIG. 19B, when the weight (2350) is disposed at the toe-side position, the weight (2350) imparts a fade bias to the club head. As shown in FIG. 19C, when the weight (2350) is disposed at the heel-side position, the weight (2350) imparts a draw bias to the club head. If the weight (2350) has a greater mass, the weight (2350) produces a greater fade or draw bias when disposed at the toe side or the heel side, respectively. A greater separation distance between each of the toe-side position, the central position, and the heel-side position can also increase the fade or draw bias. Thus, in some embodiments, the mass of the movable weight (2350) can be balanced with the separation distance of the weight position to achieve a desired shot bias.

[0183] Referring to FIGS. 20 and 21, when the movable weight (2350) is received in the weight channel (2540), the movable weight (2350) is offset from the sole wall (2550) of the weight channel (2540) with a gap therebetween. The gap or offset distance (2557) can be measured as the minimum distance between the movable weight (2350) and the sole wall (2550). The offset distance (2557) can be between about 0.004 inches and 0.050 inches. In some embodiments, the offset distance (2557) can be between about 0.004 inches and 0.010 inches, 0.006 inches and 0.010 inches, 0.008 inches and 0.012 inches, 0.010 inches and 0.014 inches, about 0.012 inches and 0.016 inches, 0.014 inches and 0.018 inches, 0.016 inches and 0.020 inches, 0.020 inches and 0.030 inches, 0.030 inches and 0.040 inches, or 0.040 inches and 0.050 inches. As the offset distance (2557) increases, after the golf club head impacts the golf ball, the movable weight (2350) can oscillate or vibrate up and down. This vibration can transmit stress to the fasteners (2320), screw holes (2544, 2546, 2548) and / or the weight channel (2540) that can cause aging deterioration.

[0184] Reducing the vertical swing of the movable weight (2350) can relieve stress by more than 10%, more than 20%, more than 30%, or more than 40% compared to a similar design that allows the movable weight (2350) to swing vertically. In some embodiments, reducing the vertical swing of the weight (2350) results in a stress of less than about 40% according to finite element analysis (FEA) simulations. The vertical swing (towards the crown or sole) of the movable weight (2350) is related to the vibration amplitude of the movable weight (2350). The vertical swing of the movable weight (2350) can be limited by the offset distance (gap size) described above between the movable weight (2350) and the sole wall (2550). In some embodiments, to maintain durability by reducing the vertical swing of the movable weight (2350), the offset distance must be less than 0.04 inches, less than 0.03 inches, less than 0.02 inches, less than 0.01 inches, less than 0.009 inches, less than 0.008 inches, less than 0.007 inches, less than 0.006 inches, or less than 0.005 inches.

[0185] The vertical swing and vibration of the weight (2350) can also be controlled by inserting a strong tape (2558), such as a very high bond (VHB) tape, between the movable weight (2350) and the sole wall (2550). The VHB tape (2558) fills most of the gap. In some embodiments, the VHB tape (2558) fills the gap completely. The VHB tape (2558) can reduce or eliminate the vibration of the movable weight (2350).

[0186] The first component (2300) includes a sole portion rear extension (2500), a striking face return crown portion (2400), and a striking face return sole portion (2810). The striking face return sole portion (2810) includes a heel extension (2830) and a toe extension (2820). The heel extension (2830) includes a rear wall (2832). The toe extension (2820) includes a rear wall (2822).

[0187] The first component rear extension part (2500) includes a toe side wall (2522) and a heel side wall (2532) that connect the weight channel (2540) to the strike face sole return (2810). The rear extension part toe side wall (2522) and the toe extension part rear wall (2822) can form a toe side wall angle (2850). The toe side wall angle (2850) can range from 45 degrees to 180 degrees. The rear extension part heel side wall (2532) and the heel extension part rear wall (2832) can form a heel side wall angle (2855). The heel side wall angle (2855) can range from 45 degrees to 180 degrees. In some embodiments, the toe side wall angle (2850) is approximately equal to the heel side wall angle (2855). In other embodiments, the toe side wall angle (2850) and the heel side wall angle (2855) are different. In some embodiments, the toe side wall angle (2850) and the heel side wall angle (2855) are supplementary angles (their sum is approximately equal to 180 degrees). In these embodiments, the toe extension part rear wall (2822) and the heel extension part rear wall (2832) are located in substantially the same plane (the toe rear wall (2822) and the heel rear wall (2832) are substantially parallel when viewed from the sole). For example, the toe side wall angle (2850) can be an acute angle, while the heel side wall angle (2855) can be a supplementary angle.

[0188] Referring to FIGS. 19 and 22, some embodiments comprise obtuse toe sidewall angles and heel sidewall angles (2850 and 2855). Referring to FIG. 23, some embodiments comprise toe sidewall angles and heel sidewall angles (2850 and 2855) of approximately 90°. Referring to FIG. 24, some embodiments comprise acute toe sidewall angles and heel sidewall angles (2850 and 2855). Embodiments having obtuse toe sidewall angles and heel sidewall angles (2850 and 2855) can smoothly disperse stress rearwardly within the sole (2120). The obtuse angles can increase the strength of the sole (2120) and support the sole rear extension (2500). However, embodiments having acute angles can include first components having a smaller mass than embodiments having obtuse or 90-degree angles. Thus, embodiments having acute toe sidewall angles and heel sidewall angles (2850 and 2855) can enable improved weight characteristics such as a high MOI.

[0189] As shown in the embodiments of FIGS. 19-21, the weight channel (2540) can fan out laterally beyond the main portion of the rear extension (2500). In these embodiments, where the weight channel (2540) extends in the toe and heel directions, the rear extension toe sidewall (2522) and the heel sidewall (2532) each have a bend adjacent to the weight channel (2540). In other embodiments, such as shown in FIG. 22, the rear extension toe sidewall (2522) and the heel sidewall (2532) may be straight. In some embodiments, the rear extension toe sidewall (2522) can be parallel to the rear extension heel sidewall (2532). In some embodiments, the rear extension toe sidewall (2522) can be non-parallel to the rear extension heel sidewall (2532). The rear extension (2500) can extend from the return portion (2810) at different positions. This movement of the position of the rear extension (2500) can affect how the rear extension (2500) is angled with respect to the return portion (2810). The rear extension axis (2504) approximates the center of the rear extension (2500). The rear extension axis (2504) extends between the front midpoint (2502) of the rear extension and the central screw hole (2546) of the weight channel (2540). The front midpoint (2502) is located midway between the toe-side intersection point (2824) and the heel-side intersection point (2834). The toe-side intersection point (2824) is the point where the toe extension rear wall (2822) intersects and connects with the rear extension toe sidewall (2522). Similarly, the heel-side intersection point (2834) is the point where the heel extension rear wall (2832) intersects and connects with the rear extension heel sidewall (2532). The toe-side and heel-side intersection points (2824 and 2834) can be located anywhere along the rear end of the front sole portion (2810). In some embodiments, the connection portions between the toe / heel extension rear walls (2822 / 2832) and the rear extension sole / heel sidewalls (2522 / 2532) are each filled, sloped, or chamfered.

[0190] The sole rear extension (2500) of the first component (2300) can be angled with respect to the intersection plane (2840). As shown in FIGS. 19 and 22 - 28, the intersection plane (2840) coincides with the toe - side intersection (2824) and the heel - side intersection (2834). In some embodiments, the intersection plane (2840) extends parallel to the XY plane (191). In some embodiments such as FIGS. 19 - 24, the rear extension (2500) extends linearly rearward, and as a result, the intersection plane (2840) and the rear extension axis (2504) form an angle of approximately 90 degrees as viewed from the sole. In some embodiments such as those of FIGS. 25 - 28, the intersection plane (2840) and the rear extension axis (2504) intersect at an angle other than 90 degrees.

[0191] The toe - side axis angle (2860) is measured (in the sole view) from the intersection plane (2840) to the rear extension axis (2504) on the toe - side of the rear extension axis (2504). The heel - side axis angle (2865) is measured (in the sole view) from the intersection plane (2840) to the rear extension axis (2504) on the heel - side of the rear extension axis (2504). The toe - side axis angle (2860) and the heel - side axis angle (2865) are supplementary angles (added to 180 degrees).

[0192] Referring to FIG. 25, in some embodiments, the rear extension is attached to the hitting face sole return (2810) closer to the toe end (2150) of the club head (2100) than to the heel end (2160) of the club head (2100). In these embodiments, the toe - side axis angle (2860) is greater than 90 degrees and the heel - side axis angle (2865) is less than 90 degrees. The weight channel (2540) remains located at the center of the rear end (2180) of the golf club head (2100). Due to the position of the rear extension (2500) of the first component, the second component (2200) can occupy a larger portion on the heel - side of the sole (2120). More specifically, the heel sole portion (2214) of the second component can be made larger than the toe sole portion (2212) of the second component.

[0193] Referring to FIG. 26, in some embodiments, the rear extension is attached to the sole return (2810) of the club head (2100) closer to the heel end (2160) of the club head (2100) than to the toe end (2150) of the club head (2100). In this embodiment, the toe-side shaft angle (2860) is greater than 90 degrees and the heel-side shaft angle (2865) is less than 90 degrees. The weight channel (2540) remains located at the center of the rear end (2180) of the golf club head (2100). Due to the position of the rear extension (2500) of the first component (2300), the second component (2200) can occupy a larger portion on the toe side of the sole (2120). More specifically, the toe sole portion (2212) of the second component can be made larger than the heel sole portion (2214) of the second component. The joining position of the rear extension can change the weight characteristics and launch characteristics of the golf club head (2100).

[0194] Referring to FIGS. 27 and 28, in some embodiments, the rear extension can have various widths. In these embodiments, the toe-side wall angle (2850) and the heel-side wall angle (2855) do not have to be supplementary angles (they do not have to sum to 180 degrees). In some embodiments, both the toe-side wall angle and the heel-side wall angle (2850 and 2855) can be acute angles, reducing the weight of the first component and allowing for a greater peripheral weight in the club head. In other embodiments, both the toe-side wall angle and the heel-side wall angle (2850 and 2855) can be obtuse angles, enhancing the durability of the sole and simplifying the manufacturing assembly of the golf club head (2100).

[0195] The rear extension width (2507) is measured in the heel-to-toe direction behind the rear circumference of the front sole portion (2810). The rear extension width (2507) is less than the full width of the sole (2120) of the golf club (2100). The rear extension width (2507) can be in the range of 25% to 85% of the full width of the sole (2120). The rear extension width (2507) can be 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80% or 85% of the full width of the sole (2120). The width of the rear extension portion adjacent to the weight channel (2540) can be in the range of 1 inch to 2.5 inches. The rear extension width (8507) between the toe-side intersection point (2824) and the heel-side intersection point (2834) can be in the range of 1 inch to 5 inches. The rear extension width (2507) can be increased adjacent to the weight channel (2540) as shown in FIGS. 27 and 28, or can be increased adjacent to the return portion (2810).

[0196] Referring to FIGS. 37 and 38, the position of the sole extension portion (2500) of the first component (2300) can also be understood in relation to the striking face (2170) and the XYZ coordinate system. The rear extension angle (2508) can be measured between the rear extension axis (2504) and the YZ plane (193) in a sole view. In some embodiments, the rear extension axis (2504) can intersect the YZ plane adjacent to the rear end (2180) of the club head (2100). In other embodiments, the rear extension axis (2504) can intersect the YZ plane at a point between the return portion (2177) of the club head (2100) and the rear end (2180) of the club head (2100). The rear extension angle (2508) can be in the range of 0 degrees to 45 degrees. In some embodiments, the rear extension angle (2508) can be in the range of 0 degrees to 10 degrees, 0 degrees to 20 degrees, 0 degrees to 30 degrees, 0 degrees to 40 degrees, 10 degrees to 20 degrees, 10 degrees to 30 degrees, 10 degrees to 40 degrees, 10 degrees to 45 degrees, 20 degrees to 30 degrees, 20 degrees to 40 degrees, 20 degrees to 45 degrees, 30 degrees to 40 degrees, or 30 degrees to 45 degrees.

[0197] In the embodiment of FIG. 37, the rear extension axis (2504) intersects the YZ plane adjacent to or at the rear end (2180) of the club head (2100). The front end of the rear extension (2500) is located closer to the heel end (2160) than the toe end (2150). By moving the front end of the rear extension (2500), since the first component (2300) is denser than the second component, the CG and MOI of the club head (2100) are affected. The greater placement of the first component (2300) within the heel end (2160) of the club head (2100) increases the mass within the heel end (2160) of the club head (2100).

[0198] In the embodiment of FIG. 38, the rear extension axis (2504) intersects the YZ plane adjacent to or at the rear end (2180) of the club head (2100). The front end of the rear extension (2500) is located closer to the toe end (2150) than the heel end (2160). The greater placement of the first component (2300) within the toe end (2150) of the club head (2100) increases the mass within the toe end (2150) of the club head (2100).

[0199] Referring to FIG. 39, in some embodiments, the rear end (2410) of the return portion (2177) can be angled with respect to the XY plane (191). In some embodiments, the rear end (2410) can be aligned with respect to the intersection plane (2840). In other embodiments, the rear end (2410) is at least partially curved or angled and is not perfectly aligned with respect to the intersection plane (2840). In some embodiments, as shown in FIG. 40, a portion of the rear end (2410) can be parallel to the XY plane (191) while the intersection plane (2840) is angled with respect to the XY plane (191). The rear end angle (2411) can be defined between the intersection plane (2840) and the XY plane (191). The rear end angle (2411) can range from 0 degrees to 45 degrees. In some embodiments, the rear end angle (2411) can range from 0 degrees to 10 degrees, 10 degrees to 20 degrees, 20 degrees to 30 degrees, or 30 degrees to 45 degrees. The angling of the rear end (2410) places more mass at the heel end (2160) or toe end (2150) of the club head (2100).

[0200] Referring to FIG. 40, in some embodiments, a portion of the rear end (2410) is offset from the remainder of the rear end (2410). For example, a portion of the rear end (2410) on the toe side of the rear extension (2500) (hereinafter, "rear end toe side portion (2412)") can be further forward than a portion of the rear end (2410) on the heel side of the rear extension (2500) (hereinafter, "rear end heel side portion (2413)"). The rear end toe side portion (2412) can be offset by a distance (2414) from the rear end heel side portion (2410). In the embodiment shown in FIG. 40, the rear end heel side portion (2413) is offset rearward by a distance (2414) from the rear end toe side portion (2412). In other embodiments, the rear end toe side portion (2412) can be offset rearward from the heel side portion (2413). In still other embodiments, the rear end (2410) of the return portion (2177) can be arcuate, parabolic, tapered, or shaped to contribute to the specific mass characteristics and / or impact durability of the first component (2300). Second component

[0201] As shown in FIGS. 29 and 30, the second component can include a crown portion (2205), a trailing edge portion (2230), a sole toe portion (2212), and a sole heel portion (2214). The crown portion (2205) connects the sole toe portion (2212) and the sole heel portion (2214). The trailing edge portion (2230) connects the crown portion (2205) to the sole toe portion and the heel portion (2212 and 2214). The crown portion (2205), the sole toe portion (2212), and the sole heel portion (2214) define a rear notch (2240) on the sole side of the second component (2200). In some embodiments as shown in FIG. 29, the rear notch 2240 is cut only into the sole. In some other embodiments as shown in FIG. 30, the rear notch 2240 is cut into both the sole portion and the crown portion (2205). Embodiments that cut into both the sole and the crown portion (2205) allow for more space for the weight channel (2540) of the first component (2300) at the rear end (2180) of the club head (2100).

[0202] The sole toe portion (2212) and the sole heel portion (2214) of the second component can be dimensioned to correspond to the dimensions of the first component (2300) as shown in FIGS. 22 - 28. For example, the sole toe portion (2212) of the second component can be approximately the same size as the sole heel portion (2214) when the rear extension (2500) is centered as in the embodiments of FIGS. 22 - 24. In embodiments where the rear rearward extension axis (2504) is angled with respect to the intersection plane (2840), the sole toe portion (2212) can be smaller or larger than the sole heel portion (2214) as shown in the embodiments of FIGS. 25 and 26.

[0203] In some embodiments, the second component (2200) can be fixed to the first component (2300) in a manner similar to that described above for the embodiment of the first golf club head (100). In some embodiments, the materials of the first component (2300) and the second component (2200) can also be the same as those described above for the embodiment of the first golf club head (100). III) Third Embodiment of a Golf Club Head (Including a Crown Brace and a Separated Second Component)

[0204] The third embodiment (3100) of the golf club head shown in FIGS. 37 - 41 and FIG. 53 includes a first component (3300) and a second component (3200) joined onto the first component (3300). The first component (3300) includes a sole rear extension (3500) and a crown brace (3560). The first component (3300) of the golf club head of the third embodiment can be similar to the first components (300 and 1300) of the golf club heads (100 and 2100), except that a crown brace (3560) is added. The second component (3200) can include a toe portion (3212) and a heel portion (3214). The toe and heel portions (3212 and 3214) can be separate components. Except for the two-component design, the second component (3200) of the golf club head can be similar to the second components (200 and 2200) of the golf club heads (100 and 2100). The golf club head forms a striking face (3170), a return portion (3177), a hosel (3140), a crown (3110), a sole (3120), a heel end (3160), a toe end (3150), and a skirt (3125) having a trailing edge (3130) at the rearmost part of the rear end (3180). The skirt (3125) can extend along the perimeter of the club head between the crown (3110) and the sole (3120) behind the hosel (3140).

[0205] Referring to FIGS. 40 and 41, the toe portion (3212) of the second component may include a toe center edge (3220) configured to be located along the center of the crown (3110) when the golf club head is fully assembled, a maximum crown width of the toe portion (3222) measured from the toe center edge (3220) to the toe end (3150), and a maximum crown length of the toe portion (3224) measured from the front end to the rear end. The heel portion (3214) of the second component may include a heel center edge (3216) configured to be located along the center of the crown (3110) when the golf club head is fully assembled, a maximum crown width of the heel portion (3217) measured from the heel center edge (3216) to the heel end (3160), and a maximum crown length of the heel portion (3218) measured from the front end to the rear end.

[0206] The toe portion (3212) and the heel portion (3214) may have the same maximum length (3224 and 3218). Alternatively, the toe portion (3212) and the heel portion (3214) may have maximum lengths (3224 and 3218) that vary such that one is larger than the other. The toe portion (3212) and the heel portion (3214) may have the same maximum width (3222 and 3217). Alternatively, the toe portion (3212) and the heel portion (3214) may have maximum widths (3222 and 3217) that vary such that one is larger than the other. The maximum length may be from 3.0 inches to 6.0 inches. The maximum length may be 3.0 inches, 3.1 inches, 3.2 inches, 3.3 inches, 3.4 inches, 3.5 inches, 3.6 inches, 3.7 inches, 3.8 inches, 3.9 inches, 4.0 inches, 4.1 inches, 4.2 inches, 4.3 inches, 4.4 inches, 4.5 inches, 4.6 inches, 4.7 inches, 4.8 inches, 4.9 inches, 5.0 inches, 5.1 inches, 5.2 inches, 5.3 inches, 5.4 inches, 5.5 inches, 5.6 inches, 5.7 inches, 5.8 inches, 5.9 inches, or 6.0 inches.

[0207] As shown in FIGS. 37-39, the first component (3300) of the third embodiment may include both a sole rear extension (3500) and a crown brace (3560). The sole rear extension (3500) houses a weight channel (3540) at its rear end (3180). The crown brace (3560) is attached to the front crown portion (3400) and the sole rear extension (3500). The crown brace (3560) is attached to the sole rear extension (3500) adjacent to the weight channel (3540) at the rear end (3180) of the club head. As shown in FIG. 39, the weight channels (3540) of the crown brace (3560) and the rear extension (3500) may form a hammer head shape. In other embodiments, the shape of the connection between the crown brace (3560) and the rear extension (3500) may be a fillet, round, or other shape.

[0208] The crown brace (3560) may provide support to prevent the sole rear extension (3500) from bending too far upward when the golf club head impacts the golf ball. Since the weight channel (3540) houses a movable weight (3350), the weight channel (3540) holds a significant amount of mass. The mass of the weight channel (3540) and the weight (3350) is supported by the sole rear extension (3500). However, the impact with the golf ball can cause the weight channel (3540) portion of the rear extension (3500) to bend upward. This upward bending of the rear extension (3500) can create compressive stresses within the crown (3110). In some embodiments, these stresses can cause fractures or cracks within the second component (3200) that forms most of the crown (3110). The crown brace (3560) may provide support to prevent the stress-generating bending (or clam shell effect) of the sole rear extension (3500). In other words, the crown brace (3560) may reduce the vibration and oscillation of the weight channel (3540).

[0209] In some embodiments, similar to the sole rear extensions (500 and 2500) of the golf club heads (100 and 2100) being angled, both the sole rear extension (3500) and the crown brace (3560) may be angled. In some embodiments, the crown brace (3560) is positioned at an angle different from the angle of the sole rear extension (3500).

[0210] Referring to FIG. 39, the crown brace (3560) includes a crown brace longitudinal axis (3565). The crown brace longitudinal axis (3565) bisects the crown brace (3560) along its maximum length. In some embodiments, the crown brace longitudinal axis (3565) may be offset toward the heel end or toe end of the golf club head parallel to the rear extension axis (2504), or alternatively, non - parallel to the rear extension axis (2504) such that the crown brace longitudinal axis (3565) forms an acute angle with the rear extension axis (2504).

[0211] The crown brace (3560) can comprise a toe side edge (3562) and a heel side edge (3564). The crown brace (3560) can have a width (3561) measured from the toe side edge (3562) to the heel side edge (3564). The crown brace width (3561) can be in the range of 0.05 inches to 0.8 inches. In some embodiments, the crown brace width (3561) can be in the range of 0.05 inches to 0.1 inches, 0.1 inches to 0.2 inches, 0.2 inches to 0.4 inches, 0.3 inches to 0.5 inches, 0.3 inches to 0.6 inches, or 0.4 inches to 0.7 inches. In some embodiments, the crown brace width can be approximately 0.2 inches, 0.25 inches, 0.3 inches, 0.35 inches, 0.4 inches, 0.45 inches, 0.5 inches, 0.55 inches, 0.6 inches, 0.65 inches, 0.7 inches, 0.75 inches, or 0.8 inches. The crown brace width (3561) can affect or determine the mass of the crown brace (3560). To maintain a discretionary mass, the crown brace (3560) can be designed to have a weight of less than 0.6 g, less than 0.5 g, less than 0.4 g, less than 0.3 g, less than 0.2 g, or less than 0.1 g.

[0212] Referring to FIGS. 40 and 41, two parts of the second component (3200) can each comprise parts of the crown (3110), the sole (3120), and the trailing edge (3130). The toe portion (3212) can be configured to fit and be fixed to an outer peripheral lip or ledge (not shown) of the first component (3300). In particular, the toe portion (3212) can be configured to engage the rear extension toe side wall (3522) and overlap the crown brace toe side wall (3562). The heel portion (3214) can be configured to engage the rear extension heel side wall (3532) and overlap the crown brace heel side wall (3564).

[0213] Because the second component (3200) comprises two separate parts (3212 and 3214), the second component (3200) can be assembled onto the first component (3300) in two steps. For example, first, the toe portion (3212) can be slid onto the first component (3300) in a direction from the toe to the heel. The heel portion (3214) can be separately slid onto the first component (3300) in a direction from the heel to the toe. As described in more detail below, because the second component (3200) can be assembled onto the first component from the heel and toe sides, the first component (3300) can have a more complex outer shape. The materials of the first (3300) and second (3200) components can be the same as those described above for the first golf club head (100) embodiment.

[0214] When the two second component parts (3212 and 3214) are assembled onto the first component, the two parts (3212 and 3214) can be positioned so as to completely cover the crown brace (3560). By completely covering the crown brace (3560), a strong coupling joint between the two parts (3212 and 3214) and the first component (2300) can be ensured. The two parts (3212 and 3214) can be positioned such that there is no portion of the crown brace (3560) that is exposed outside the golf club head.

[0215] In an alternative embodiment, the club head (3100) may be formed without a crown brace (3560), but still includes two second component parts (3212 and 3214). The two second component parts (3212 and 3214) may include central edge internal extensions, whereby the component parts (3212 and 3214) are connected. The internal extensions may extend along the entire central edge of each part or may extend only along a portion of the central edge of each part. The internal extensions may extend inwardly into the golf club head parallel to each other and substantially parallel to the Y-axis. The heel portion (3214) may have a heel portion internal extension (3234). The toe portion (3212) may have a toe portion internal extension (3232). Each internal extension may have an internal extension length of from 0.1 inches to 1.0 inches. The internal extension length may be 0.1 inches, 0.2 inches, 0.3 inches, 0.4 inches, 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, or 1.0 inches.

[0216] Referring to FIG. 42, in some embodiments, the internal extensions (3232 and 3234) may be positioned to abut each other when the golf club head is assembled. The internal extensions (3232 and 3234) may be mechanically fixed to each other with mechanical fasteners or press fit fasteners, or they may be adhesively fixed via epoxy or other suitable adhesive.

[0217] In another alternative embodiment, the golf club head (3100) may be formed of a single, integral second component similar to the second components (200 and 2200) described above for the first and second embodiments (100 and 2100), rather than two separate second component parts. This alternative embodiment may include a crown brace (3560), which serves to support the weight channel (3540) and the single second component. IV) Fourth Embodiment of a Golf Club Head (Including Two or More Braces)

[0218] The fourth embodiment (4100) of the golf club head includes a first component (4300) and a second component (not shown) joined onto the first component (4300). In this fourth embodiment, the first component (4300) may have more than one brace, support, bridge, or span extending between the front crown portion (4400) and the sole rear extension (4500). The brace may reduce the vibration and oscillation at the rear end of the club head and increase durability. The second component (not shown) of the fourth embodiment may be a single, integral second component similar to the second component (200 or 2200), or a separated (divided) second component similar to the second component (3200).

[0219] The golf club head (4100) may be similar to the golf club heads (100, 2100, and 3100) described above. Although the complete golf club head (4100) is not shown in FIGS. 43 - 56, the golf club head (4100) may form the same components as the golf club heads (100, 2100, and 3100) described above. The golf club head (4100) forms a striking face (4170 similar to 170, 2170, 3170), a return portion (similar to 177, 2177, 3177), a hosel (4140 similar to 140, 2140, 3140), a crown (similar to 110, 2110, 3110), a sole (similar to 120, 2120, 3120), a heel end (similar to 160, 2160, 3160), a toe end (similar to 150, 2150, 3150), and a skirt (similar to 125, 2125, 3125) having a trailing edge (similar to 130, 2130, 3130) at the rearmost part of the rear end (4180 similar to 180, 2180, 3180).

[0220] As shown in FIGS. 43 to 56, the golf club head (4100) may include a first component (4300) having various brace configurations. All variations of the first component (4300) include a striking face (4170), a front crown portion (4400), a front sole portion (4810), and a sole rear extension (4500) connected to the front sole portion (4810). The rear extension (4500) may include a toe side edge (4522), a heel side edge (4532), and a weight channel (4540) configured to allow attachment of a movable weight (4350) at the trailing edge (4130) of the golf club head (4100). The weight channel (4540) and the movable weight (4350) may be similar to the weight channels (2540, 3540) and the movable weights (2350, 3350) of the golf club heads (2100, 3100) as described above with reference mainly to FIGS. 17 to 21 and FIG. 41. The first component (4300) may also include an outer peripheral lip (4450), which is offset inwardly around the edges of the front crown portion (4400), the front sole portion (4810), and the sole rear extension (4500). The outer peripheral lip (4450) may be similar to a shelf and may function as a lap joint when the second component (4200) is attached to the first component (4300). The brace may reduce impact-induced vibration or oscillation of the weight channel (4540) at the rear end (4180), thereby reducing the stress received by the entire lap joint. Reducing the stress at the lap joint helps increase the durability of the lap joint connection and prevent delamination.

[0221] All variations of the first component (4300) may also include two or more braces (also referred to as supports, bridges, spans, or connecting members). The two or more braces provide stability to the weight channel (4540) and may reduce oscillation and vertical displacement of the rear weight channel after the golf club head (4100) impacts a golf ball. The two or more braces may also increase the lateral rigidity of the rear extension (4500) of the first component (4300).

[0222] In the modification examples shown in FIGS. 43 and 44, the first component (4300) includes a toe skirt brace (4566) and a heel skirt brace (4568). The toe skirt brace (4566) may extend from the return portion to the rear end of the club head. More specifically, the toe skirt brace (4566) may extend from the front crown and sole portions (4400 and 4810) to the rear extension (4500) at the trailing edge of the club head (4100). The toe skirt brace (4566) and the heel skirt brace (4568) are configured to be located at the same height as the outer peripheral lip (4450) of the first component (4300). In other words, the toe and heel skirt braces (4566 and 4568) may be flush with the outer peripheral lip (4450). The second component (4200) may fit into and completely cover the toe and skirt braces (4566 and 4568) when the club head (4100) is assembled.

[0223] In the modification examples shown in FIGS. 45 and 46, the first component (4300) includes a toe skirt brace (4566), a heel skirt brace (4568), and a center crown brace (4560). The toe skirt brace (4566) and the heel skirt brace (4568) may be the same as the toe and skirt braces (4566 and 4568) described above for the modification examples of FIGS. 43 and 44. The crown brace (4560) may be the same as the crown brace (3560) described above for the golf club head (3100) shown in FIGS. 37 to 42. The center crown brace (4560) may extend from the front crown portion (4400) to the rear extension (4500) at the trailing edge of the club head (4100). The center crown brace (4560) may be located approximately in the middle between the toe end (4150) and the heel end (4160) of the club head (4100). From a top view such as FIG. 46, the center crown brace (4560) may be substantially perpendicular to the XY plane (191). The orientation of the center crown brace (4560) may substantially bisect the sole rear extension (4500).

[0224] The modified examples shown in FIGS. 47 and 48 include a toe-side brace (4557) and a heel-side brace (4559), both of which are connected to the outer edge of the rear extension (4500). The toe-side brace (4557) extends rearward from the front crown portion (4400) and can be attached to the toe-side edge (4522) of the rear extension (4500) at the trailing edge (4532) of the club head (4100). Similarly, the heel-side brace (4557) extends rearward from the front crown portion (4400) and can be attached to the heel-side edge (4532) of the rear extension (4500) at the trailing edge (4130) of the club head (4100). The toe-side and heel-side braces (4557 and 4559) can be attached to the front crown portion (4400) at a position that divides the front crown portion (4400) into approximately one-third from the top view. In other words, from the top view, the toe-side and heel-side braces (4557 and 4559) are attached to the front crown portion (4400) such that when measured along the trailing edge of the front crown portion (4400), the distance between the toe end (4150) of the club head (4100) and the toe-side brace (4557) is approximately equal to the distance between the toe-side brace (4557) and the heel-side brace (4559), which is also approximately equal to the distance between the heel-side brace (4559) and the heel end (4160) of the club head (4100).

[0225] As shown in the top view of FIG. 48, the toe and heel-side braces (4557 and 4559) can be separated by a greater distance toward the trailing edge (4130) at the rear end (4180) of the golf club head (4100). From the top view, the toe and heel-side braces (4557 and 4559) can be within the footprint of the sole rear extension (4500).

[0226] The modified examples shown in FIGS. 49 and 50 include a toe-side brace (4557) and a heel-side brace (4559), both of which are connected to the center of the rear extension (4500). As described above for the modified examples of FIGS. 47 and 48, the toe-side and heel-side braces (4557 and 4559) can be attached to the front crown portion (4400) at a position that divides the front crown portion (4400) into approximately one-third from a top view. However, in the modified examples of FIGS. 49 and 50, the toe-side and heel-side braces (4557 and 4559) are separated by a smaller distance rearward (4130) at the rear end (4180) of the golf club head (4100). The toe-side brace (4557) can join with the heel-side brace (4559) before or at the connection with the rear extension (4500) at the rear end (4180). As shown in FIG. 50, the toe-side and heel-side braces (4557 and 4559) can form a V-shaped pattern from a top view.

[0227] The modified examples shown in FIGS. 51 and 52 include four braces, namely, a toe-side brace (4557), a heel-side brace (4559), a toe skirt brace (4566), and a heel skirt brace (4568). The toe and heel-side braces (4557 and 4559) of the modified examples of FIGS. 51 and 52 can be the same as the toe and heel-side braces of the modified examples of FIGS. 47 and 48 described above. The toe and heel skirt braces (4566 and 4568) of the modified examples of FIGS. 51 and 52 can be the same as the toe and heel skirt braces of the modified examples of FIGS. 43 and 44 described above.

[0228] The modified examples shown in FIGS. 53 and 54 include four braces, namely, a toe-side brace (4557), a heel-side brace (4559), a toe skirt brace (4566), and a heel skirt brace (4568). The toe and heel-side braces (4557 and 4559) of the modified examples in FIGS. 53 and 54 can extend from the front crown portion (4400) to the rear extension portion (4500) at the trailing edge (4130) of the club head rear end (4180). From the top view, the toe-side brace (4557) and the heel-side brace (4559) can be oriented substantially perpendicular to the XY plane (191). In some embodiments, the toe-side and heel-side braces (4557 and 4559) can be aligned such that their top view footprints generally follow the edges (4522 and 4532) of the sole rear extension portion (4500).

[0229] Referring to FIGS. 53 and 54, in some embodiments, when measured along the trailing edge of the front crown portion (4400), the distance between the toe end (4150) and the toe-side brace (4557) may be less than the distance between the heel-side brace (4559) and the heel end (4160). In other embodiments, when measured along the trailing edge of the front crown portion (4400), the distance between the toe end (4150) and the toe-side brace (4557) may be approximately equal to the distance between the heel-side brace (4559) and the heel end (4160). Both the distance between the toe end (4150) and the toe-side brace (4557) and the distance between the heel end (4160) and the heel-side brace (4559) can be less than the distance between the toe-side brace (4557) and the heel-side brace (4559).

[0230] The modified examples shown in FIGS. 55 and 56 include two braces that cross each other, namely, a first brace (4570) and a second brace (4572). The first brace (4570) extends from the heel-side half of the front crown portion (4400) to the toe-side half of the rear extension portion (4500) at the trailing edge (4130) of the rear end (4180). The second brace (4572) extends from the toe-side half of the front crown portion (4400) to the heel-side half of the rear extension portion (4500) at the trailing edge (4130) of the rear end (4180). The first and second braces (4570 and 4572) intersect each other and cross in a cross shape. In the embodiment shown in FIG. 56, the first and second braces (4570 and 4572) cross in a cross shape approximately in the middle between the front crown portion (4400) and the rear extension portion (4500) adjacent to the trailing edge (4130). The braces (4570 and 4572) that cross in a cross shape may form an X shape or an hourglass shape when viewed from above. In some embodiments, the braces (4570 and 4572) that cross in a cross shape are shifted toward the toe end (4150) or the heel end (4160) to achieve a desired structural support.

[0231] Any of the aforementioned braces may have a thickness. The brace thickness measured from the outer surface of the brace to the inner surface of the brace may be approximately 0.015 inches to 0.035 inches. In some embodiments, the brace thickness may be 0.015 inches, 0.016 inches, 0.017 inches, 0.018 inches, 0.019 inches, 0.020 inches, 0.021 inches, 0.022 inches, 0.023 inches, 0.024 inches, 0.025 inches, 0.026 inches, 0.027 inches, 0.028 inches, 0.029 inches, 0.030 inches, 0.031 inches, 0.032 inches, 0.033 inches, 0.034 inches, or 0.035 inches. A brace disposed on the crown (not a skirt brace) may have a width similar to the crown brace width (3561) described above for the club head (3100).

[0232] Any of the braces described above may have a brace width similar to the crown brace width (3561) described above. The width of each brace may affect or determine the mass of the brace. To maintain a discretionary mass, the braces within the club head (4100) may be designed to have a combined total weight of less than 0.6 g, less than 0.5 g, less than 0.4 g, less than 0.3 g, less than 0.2 g, or less than 0.1 g. In some embodiments, the total weight of the braces is equal to 0.6 g, 0.5 g, 0.4 g, 0.3 g, 0.2 g, or 0.1 g. Thus, in some cases, in embodiments having more braces, the brace width may be smaller than the brace width within embodiments having fewer braces.

[0233] Two or more of the braces described above may increase the durability of the golf club head. More specifically, the braces may reduce possible vertical oscillations of the weight channel (4540) of the sole rear extension (4500). The braces may also reduce lateral movement of the weight channel (4540). In a club head lacking the braces described herein, the impact force received when the golf club head (4100) strikes a golf ball may induce vibrations and oscillations in the rear extension due to the high concentration of weights in the weight channel and the movable weight. The vertical displacement of the trailing edge (4130) of the rear extension (4500) may be measured in a simulation to quantify the possible oscillations. Since larger amplitude oscillations can cause material fatigue, a larger vertical displacement upon impact corresponds to lower durability. The braces described above reduce the vertical displacement of the trailing edge (4130) upon impact and thus increase the durability of the club head (4100).

[0234] The above two or more braces may define or form the boundaries of the openings in the first component (4300). The openings may also be referred to as voids, areas without material, or empty regions. The two or more braces may define three, four, five, six, or more openings in the first component (4300). In the variations of FIGS. 43 and 44, the toe and heel skirt braces (4566 and 4568) form part of the boundary of the crown opening, part of the boundary of the toe sole opening, and part of the boundary of the heel sole opening. The rear extension (4500) and the strike face return also form part of the boundary of the toe and heel sole openings. In the variations of FIGS. 45 and 46, the toe and heel skirt braces (4566 and 4568) and the front crown portion (4400) surround and define two crown openings separated by the center crown brace (4560). The variations of FIGS. 45 and 46 may have toe and heel sole openings similar to those of the variations of FIGS. 43 and 44.

[0235] In the variations of FIGS. 47 and 48, the toe and heel side braces (4557 and 4559) define a center crown opening and two side openings. The crown opening intersects the skirt and extends to a part of the crown and a part of the sole respectively. The variations of FIGS. 49 and 50 are similar except that the center crown opening has a substantially triangular shape. In the variations of FIGS. 51 - 54, the braces define five openings. The skirt braces (4566 and 4568), the crown braces (4557 and 4559), the rear extension (4500), and the front crown portion (4400) define three crown openings. The skirt braces (4566 and 4568), the strike face return, and the sole extension (4500) define the toe sole opening and the heel sole opening.

[0236] In the variations of FIGS. 55 and 56, the brace defines six openings. The cross-bracing braces (4570 and 4572) define a front triangular opening and a rear triangular opening. The front crown portion (4400) and the cross-bracing brace configuration (4570 and 4572) form the edge of the front triangular opening. The rear extension (4500) and the cross-bracing brace configuration (4570 and 4572) form the edge of the rear triangular opening. The toe-side crown opening and the heel-side crown opening are formed between the centrally cross-bracing braces (4570 and 4572) and the toe and heel skirt braces (4566 and 4568). Further, the skirt braces (4566 and 4568), the impact face return, and the sole extension (4500) define the toe sole opening and the heel sole opening.

[0237] During impact with a golf ball and immediately after such impact, the rear weight (4350) and the weight channel (4540) of the first component (4300) can swing perpendicular to the remainder of the golf club head (4100). For a first component without any braces, a rear weight (4350) of 30 grams to 35 grams can swing more than 0.3 inches without additional support from the second component (4200). For a first component (4300) having two or more braces, a rear weight (4350) of 30 grams to 35 grams can swing from a maximum of 0.03 inches to 0.20 inches without additional support from the second component (4200). In some embodiments, the rear weight (4350) can swing from a maximum of 0.03 inches to 0.06 inches, 0.04 inches to 0.07 inches, 0.05 inches to 0.08 inches, 0.05 inches to 0.10 inches, 0.10 inches to 0.15 inches, or 0.15 inches to 0.20 inches. In some embodiments, the rear weight (4350) can swing from a maximum of about less than 0.3 inches, less than 0.2 inches, less than 0.18 inches, less than 0.16 inches, less than 0.14 inches, less than 0.12 inches, less than 0.10 inches, less than 0.08 inches, less than 0.06 inches, less than 0.04 inches, or less than 0.02 inches.

[0238] In some embodiments having two crown braces and no skirt brace, a rear weight (4350) of 30 grams to 35 grams can deflect up to 0.09 inches to 0.18 inches or 0.10 inches to 0.15 inches (perpendicular to the remainder of the club head) even without additional support of the second component (4200). In some embodiments having two skirt braces and no crown brace, the rear weight (4350) can deflect up to 0.10 inches to 0.20 inches. In some embodiments having two skirt braces and at least one crown brace, the rear weight (4350) can deflect up to 0.03 inches to 0.10 inches, or less than 0.10 inches, less than 0.08 inches, less than 0.07 inches, or less than 0.06 inches. In some embodiments, variants having parallel toe and heel side braces provide greater support (less deflection) than variants having crossed or angled (non-parallel) braces. V) Fifth Embodiment of the Golf Club Head

[0239] The fifth embodiment of the golf club head (5100) shown in FIGS. 53 to 56 includes a first component (5300) having a weight channel (5540) and a sole opening (5555), a second component (5200) joined on the first component (5300), and a sole panel (5556) covering the sole cavity (5555) in the first component (5300). The first component (5300) of the golf club head (5100) of the fifth embodiment can be the same as the first components (300 and 1300) of the golf club heads (100 and 2100) except for the sole opening (5555). The second component (5200) of the golf club head (5100) can be the same as the second component of the above-described golf club head (100). The second component (5200) of the golf club head (5100) can be the same as the second component of the above-described golf club head (100). The golf club head (5100) forms a striking face (5170), a return portion (5177), a hosel (5140), a crown (5110), a sole (5120), a heel end (5160), a toe end (5150), a trailing edge (5130) at the rearmost part of the rear end (5180), a hosel (5140), and a sole portion hosel adapter mounting recess (5195).

[0240] As shown in FIG. 57, the first component (5300) may include a rear extension (5500). The rear extension (5500) further includes a toe side span (5557) and a heel side span (5559). The toe side span (5557) extends toward the rear end (5180) and is connected to the rear end (5180). The heel side span (5559) extends toward the rear end (5180) opposite to the toe side span (5557) and is connected to the rear end (5180). The toe side span (5557), the heel side span (5559), the rear end (5180), and the return portion (5177) form a sole opening (5555). The sole opening (5555) functions to remove the high-density material of the first component (5300) toward the rear end (5180) of the first component (5300). The sole opening (5555) further enables a sole panel (5556) of a different material to cover and seal the sole opening (5555) to produce a multi-material sole (5120), leading to an increase in MOI and an improvement in acoustic properties.

[0241] The sole opening (5555) can be of any shape, but in most embodiments, the sole opening (5555) is substantially rectangular. The sole opening (5555) bends with the general shape of the sole (5120). In some embodiments, the sole opening (5555) can be square, rectangular, circular, oval, elliptical, triangular, polygonal, pentagonal, hexagonal, trapezoidal, or any other desired shape.

[0242] The sole opening (5555) has a width (5574) that is measured from the toe side span (5557) to the heel side span (5559). In most embodiments, the sole opening (5555) has a greater width closer to the return portion (5177) than the opening width closer to the rear end (5180). This feature helps to remove as much high-density mass as possible from the center of the club head (5100), allowing the mass to be redistributed to the rear end (5180) of the club head (5100). However, in some embodiments, the sole opening (5555) width can be equal or uniform from the return portion (5177) to the rear end (5180). Additionally, in some embodiments, the sole opening (5555) width can be greater closer to the rear end (5180) than the opening width near the return portion (5177).

[0243] The sole opening width (5574) can be from 0.5 inches to 6.0 inches. The width (5574) can be 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, 1.0 inches, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, 1.5 inches, 1.6 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, 2.5 inches, 2.6 inches, 2.7 inches, 2.8 inches, 2.9 inches, 3.0 inches, 3.1 inches, 3.2 inches, 3.0 inches, 3.4 inches, 3.5 inches, 3.6 inches, 3.7 inches, 3.8 inches, 3.9 inches, 4.0 inches, 4.1 inches, 4.2 inches, 4.3 inches, 4.4 inches, 4.5 inches, 4.6 inches, 4.7 inches, 4.8 inches, 4.9 inches, 5.0 inches, 5.1 inches, 5.2 inches, 5.3 inches, 5.4 inches, 5.5 inches, 5.6 inches, 5.7 inches, 5.8 inches, 5.9 inches, or 6.0 inches.

[0244] Furthermore, the sole opening (5555) has a length (5576) that is measured from the return portion (5177) to the trailing edge (5180). In most embodiments, the sole opening (5555) has a length that is equal to the length near the toe side span (5557) near the heel side span (5559). This feature helps maintain the balance of the club head in the direction from heel to toe. In some embodiments, the length near the heel side span (5559) may be less than the length near the toe side span (5557) by removing mass from the toe to influence a draw or hook shot and placing more at the heel. In contrast, in some embodiments, the length near the toe side span (5557) may be less than the length near the heel side span (5559) by removing mass from the heel to influence a slice or fade shot and placing more near the toe.

[0245] The sole opening length (5576) can be from 0.5 inches to 6.0 inches. The length (5576) can be 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, 1.0 inches, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, 1.5 inches, 1.6 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, 2.5 inches, 2.6 inches, 2.7 inches, 2.8 inches, 2.9 inches, 3.0 inches, 3.1 inches, 3.2 inches, 3.0 inches, 3.4 inches, 3.5 inches, 3.6 inches, 3.7 inches, 3.8 inches, 3.9 inches, 4.0 inches, 4.1 inches, 4.2 inches, 4.3 inches, 4.4 inches, 4.5 inches, 4.6 inches, 4.7 inches, 4.8 inches, 4.9 inches, 5.0 inches, 5.1 inches, 5.2 inches, 5.3 inches, 5.4 inches, 5.5 inches, 5.6 inches, 5.7 inches, 5.8 inches, 5.9 inches, or 6.0 inches.

[0246] The toe side span (5557) and the heel side span (5559) connect the return portion (5177) to the rear end (5180). The toe side span (5557) and the heel side span (5559) of the rear extension (5500) may comprise a part of the sole (5120). The rear extension (5500) comprises a weight channel (5540). The weight channel (5540) is exposed at the rear end (5180) of the club head (5300) and at least a part of the sole (5120).

[0247] The weight channel (5540) is configured to receive the movable weight (5350) at one of three positions. The weight (5350) may be fixed to the weight channel (5540) by a screw fastener (5320). The weight (5350) may be disposed at a toe side position, a center position, or a heel side position. The weight channel (5540) comprises an attachment wall (5542) and a sole wall (5550). The attachment wall (5542) may be oriented substantially perpendicular to the sole (5120). The sole wall (5550) may be oriented substantially parallel to the main sole (5120), but can enter inward by a distance equal to the height of the attachment wall (5542). The movable weight (5350) may comprise an elongated trapezoidal shape or any other suitable weight. The movable weight (5350) may comprise an inner wall and a connecting wall. The inner wall is flush with the sole wall (5550) of the weight channel (5540). The connecting wall is flush with the attachment wall (5542) when the weight (5350) is attached at one of the three positions.

[0248] The mounting wall (5542) of the weight channel (5540) has three screw openings corresponding to three weight positions. The mounting wall (5542) includes a toe-side screw opening (5544), a center screw opening (5546), and a heel-side screw opening (5548). The movable weight (5350) is located at the toe-side position by arranging the connecting wall of the weight (5350) flush with the mounting wall (5542) of the channel (5540) and fixing the fastener (5320) within the toe-side screw opening (5544). The movable weight (5350) is located at the center position by arranging the connecting wall of the weight (5350) flush with the mounting wall (5542) of the channel (5540) and fixing the fastener (5320) within the center screw opening (5546). The movable weight (5350) is located at the heel-side position by arranging the connecting wall of the weight (5350) flush with the mounting wall (5542) of the channel (5540) and fixing the fastener (5320) within the heel-side screw opening (5548).

[0249] When the movable weight (5350) is located at the center position (similar to the golf club (2100) as shown in the sole diagram of FIG. 19), the golf club (5100) is configured not to impart a draw or fade bias. When the weight (2350) is located at the toe-side position (similar to the golf club (2100) as shown in FIG. 20), the weight (2350) imparts a fade bias to the club head. When the weight (5350) is located at the heel-side position (similar to the golf club head (2100) as shown in FIG. 21), the weight (5350) imparts a draw bias to the club head.

[0250] The first component (5300) includes a sole portion rear extension (5500), a front crown portion (5400), and a front sole portion (5810). The front sole portion (5810) includes a heel extension (5830) and a toe extension (5820). The heel extension (5830) includes a rear wall (5832). The toe extension (5820) includes a rear wall (5822).

[0251] The first component rear extension (5500) includes a toe side wall (5522) and a heel side wall (5532) that connect a weight channel (5540) to a face sole return (5810). The toe side wall (5522) is formed by a toe side span (5557) opposite the sole opening (5555). Similarly, the heel side wall (5532) is formed by a heel side span (5559) opposite the sole opening (5555). The rear extension toe side wall (5522) and the toe extension rear wall (5822) may form a toe side wall angle (5850). The toe side wall angle (5850) can be in the range of 45 degrees to 180 degrees. The rear extension heel side wall (5532) and the heel extension rear wall (5832) may form a heel side wall angle (5855). The heel side wall angle (5855) can be in the range of 45 degrees to 180 degrees. In some embodiments, the toe side wall angle (5850) is approximately equal to the heel side wall angle (5855). In other embodiments, the toe side wall angle (5850) and the heel side wall angle (5855) are different. In some embodiments, the toe side wall angle (5850) and the heel side wall angle (5855) are supplementary angles (their sum is approximately equal to 180 degrees). In such embodiments, the toe extension rear wall (5822) and the heel extension rear wall (5832) are disposed in substantially the same plane (the toe rear wall (5822) and the heel rear wall (5832) are substantially parallel when viewed from the sole). For example, the toe side wall angle (5850) can be an acute angle, while the heel side wall angle (5855) is a supplementary obtuse angle.

[0252] A second component (5200) similar to the second component (2200) as shown in FIGS. 29 and 30 may include a crown portion (5205), a trailing edge portion (5230), a sole toe portion (5212), and a sole heel portion (5214). The crown portion (5205) connects the sole toe portion (5212) and the sole heel portion (5214). The trailing edge portion (5230) connects the crown portion (5205) to the sole toe and heel portions (5212 and 5214). The crown portion (5205), the sole toe portion (5212), and the sole heel portion (5214) define a rear notch on the sole side of the second component (5200). The rear notch may be similar to the rear notch (2240) described for the second embodiment with reference to FIGS. 29 and 30. In some embodiments, such as that shown in FIG. 29, the rear notch (2240) cuts only into the sole. In other embodiments, such as that shown in FIG. 30, the rear notch (2240) cuts into both the sole portion and the crown portion (5205). Embodiments that cut into both the sole and the crown portion (5205) allow for more space at the rear end (5180) of the club head (5100) for the weight channel (5540) of the first component (5300).

[0253] In some embodiments, the second component (5200) may be fixed to the first component (5300) in a manner similar to that described above for the first golf club head (100) embodiment and the second club head embodiment (2100). In some embodiments, the materials of the first (5300) and second (5200) components may also be similar to those described above for the first golf club head (100) embodiment.

[0254] The outer shape of the rear sole extension (5500) can mechanically lock or hold the second component (5200) onto the first component. The fan-shaped rear extension (5500) with a weight channel (5540) prevents the rigid part from sliding on the first component (5300). To overcome this manufacturing problem, the second component (5200) can be made of a semi-rigid or flexible material, allowing the second component (5200) to bend around or over the first component. In this embodiment, the second component (5200) can be snapped or locked into place. In some embodiments, the fan-shaped outer shape of the rear sole extension (5500) enables the second component (5200) to be fixed to the first component (5300) without using an adhesive or with less use of an adhesive.

[0255] Furthermore, the golf club head (5100) includes a sole panel (5556), and the sole panel (5556) covers the sole opening (5555) of the first component (5300). When the sole panel (5556) covers the sole opening (5555), it combines with the toe-side span (5557), the heel-side span (5559), and the rear end (5180) to form the entire sole (5120). The sole panel (5556) has the same shape as the sole opening (5555), and as a result, the sole panel (5556) covers the entire sole opening (5555) by joining the rear end (5180), the toe-side span (5557), the heel-side span (5559), and the front sole portion (5810). In most embodiments, the sole panel (5556) is adhered to the sole opening (5555).

[0256] Similar to the sole opening (5555), the sole panel (5556) can be of any shape, but in most embodiments, the sole panel (5556) is generally rectangular. The sole panel (5556) follows the general shape of the sole (5120). In some embodiments, the sole panel (5556) can be square, rectangular, circular, oval, elliptical, triangular, polygonal, pentagonal, hexagonal, trapezoidal, or any other desired shape.

[0257] The sole panel (5556) has a width that is measured from the toe side span (5557) to the heel side span (5559). In most embodiments, the sole panel (5556) has a greater width closer to the return portion (5177) than near the rear end (5180). This feature matches the outer shape of the sole opening (5555) and helps to provide an enclosed golf club head (5100). Similar to the width of the sole opening (5555), in some embodiments, the sole panel (5556) width can be equal or uniform from the return portion (5177) to the rear end (5180). Additionally, in some embodiments, the sole panel (5556) width can be greater near the rear end (5180) than near the return portion (5177).

[0258] The sole panel width can be from 0.5 inches to 6.0 inches. The width can be 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, 1.0 inches, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, 1.5 inches, 1.6 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, 2.5 inches, 2.6 inches, 2.7 inches, 2.8 inches, 2.9 inches, 3.0 inches, 3.1 inches, 3.2 inches, 3.0 inches, 3.4 inches, 3.5 inches, 3.6 inches, 3.7 inches, 3.8 inches, 3.9 inches, 4.0 inches, 4.1 inches, 4.2 inches, 4.3 inches, 4.4 inches, 4.5 inches, 4.6 inches, 4.7 inches, 4.8 inches, 4.9 inches, 5.0 inches, 5.1 inches, 5.2 inches, 5.3 inches, 5.4 inches, 5.5 inches, 5.6 inches, 5.7 inches, 5.8 inches, 5.9 inches, or 6.0 inches.

[0259] Furthermore, the sole panel (5556) has a length, which is measured from the return portion (5177) to the rear end (5180). In most embodiments, the sole panel (5556) has a length equal to the length near the toe side span (5557) near the heel side span (5559). This feature helps the sole panel (5556) to match the exact length of the sole opening (5555). In some embodiments, the length near the heel side span (5559) may be smaller than the length near the toe side span (5557). In contrast, in some embodiments, the length near the toe side span (5557) may be smaller than the length near the heel side span (5559).

[0260] The sole panel length can be from 0.5 inches to 6.0 inches. The length can be 0.5 inches, 0.6 inches, 0.7 inches, 0.8 inches, 0.9 inches, 1.0 inches, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, 1.5 inches, 1.6 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, 2.5 inches, 2.6 inches, 2.7 inches, 2.8 inches, 2.9 inches, 3.0 inches, 3.1 inches, 3.2 inches, 3.0 inches, 3.4 inches, 3.5 inches, 3.6 inches, 3.7 inches, 3.8 inches, 3.9 inches, 4.0 inches, 4.1 inches, 4.2 inches, 4.3 inches, 4.4 inches, 4.5 inches, 4.6 inches, 4.7 inches, 4.8 inches, 4.9 inches, 5.0 inches, 5.1 inches, 5.2 inches, 5.3 inches, 5.4 inches, 5.5 inches, 5.6 inches, 5.7 inches, 5.8 inches, 5.9 inches, or 6.0 inches. VI) Manufacturing method First method

[0261] Referring to FIG. 61, a method (10) of manufacturing a golf club head (100) according to a first embodiment includes forming a first component (300), forming a second component (200), applying an adhesive to a first component lip (450), aligning the second component (200) with the first component (300), mating the second component (200) with the first component (300) such that the second component (200) covers the lip (450), curing the adhesive to permanently fix the second component (200) to the first component (300) to form a hollow golf club head (100) (step 4040 of FIG. 50). The method 10 can be used to form a golf club head similar to the first, second, third, or fourth golf club head (100, 2100, 3100, or 4100) described above. For simplicity, the reference numbers of the method described below refer to the first club head (100), but this method (10) is applicable to all of the above club heads (100, 2100, 3100, or 4100) or variations thereof.

[0262] Referring to FIG. 15, as described above, the first component (300) can further include a plurality of casting support bars including one or more heel end casting support bars (1510) and one or more toe end casting support bars (1512). The casting support bars stabilize the cast portion of the first component (300) when the metal cools after casting. The stabilization provided by the casting support bars prevents the front portion of the cast component from folding towards or away from the first component sole portion rear extension (500) while the component cools after casting. The casting support bars are removed from the cast first component (300) and do not exist in the completed golf club head (100).

[0263] An alternative method of manufacturing a golf club head (100) includes the steps of casting a first component (300), forming a wax pattern of the first component (300), adding a wax support bar to the wax pattern, investing the modified wax pattern, casting the investment, trimming the metal casting support bars (1510, 1512), forming the first component (300), forming the second component (200), applying an adhesive to the first component (300), aligning the second component (200) with the first component (300), mating the second component (200) with the first component (300) such that the second component (200) covers a lip (450), curing the adhesive to permanently fix the second component (200) to the first component (300) to form a hollow golf club head (100). When adding a support bar to the wax pattern, the attachment point of the support bar is the inner surface of the wax pattern of the first component (300) to avoid marling or distortion of the outer surface of the first component (300). The advantage of adding a support bar is that the casting of the first component is supported against distortion while in the post-casting cooling stage.

[0264] The first component (300) can be coupled to the second component (200) by the first component lip (450) to form the body of the golf club head (100). The first component lip (450) including the crown portion lip (455), the sole portion lip (460), and the mass portion vertical lip (750) is completely covered by the second component (200) when the first component (300) is coupled to the second component (200) to form the body of the golf club head (100). The second component sole portion rear notch (240) comprises a part of the peripheral end (220) at the trailing edge (230). When the first component (300) is coupled to the second component (200) by the first component lip (450) (to form the body of the golf club head (100)), a part of the peripheral end (220) of the trailing edge (230) is joined along the mass portion trailing edge shelf (1042).

[0265] The first component (300) can be joined to the second component (200) by an adhesive. In many embodiments, an adhesive such as an adhesive, epoxy, epoxy gasket, tape (e.g., VHB tape), or any other adhesive material can be placed at the junction between the second component (200) and the first component lip (450). In some embodiments, the first component tabs (457) on the first component lips (450 and 455) can abut the second component (200), leaving a gap between the first component lips (450 and 455) and the second component (200). This gap can accommodate the adhesive. The gap can have a uniform height or thickness because the first component tabs (457) have a uniform height. This uniform height of the gap can create a uniform bond between the first component and the second component. In other embodiments, the second component (200) can be joined to the first component (300) by a fastener, clip, press fit, or any other suitable attachment means (not shown). In other embodiments, the first component (300) can be joined to the second component (200) by an adhesive along with suitable mechanical attachment means. In other embodiments, the first component (300) can be joined to the second component (200) using laser welding to heat the second component (200) material to adhere it to the first component (300) material.

[0266] In some embodiments, when the first component is joined to the second component to form the golf club head 100, the surface of the first component (300) is not offset from the surface of the second component (200). When the first component (300) is joined to the second component (200) to form the golf club head (100), the nominal outer surface of the first component is not offset above or below the nominal outer surface of the second component at the junction of the joint (i.e., the outer surfaces of the first component (300) and the second component (200) are in the same plane). Second method

[0267] Referring to FIG. 62, a second method (20) of manufacturing a golf club head (100) comprises the following steps: (step 1: 21) casting an unfinished first component; (2: 22) cutting a portion of the unfinished first component to form a finished first component; (3: 23) injection molding a second component; (4: 24) permanently fixing the second component to the first component; and (5: 25) finishing the club head. The second method 20 can be used to form a golf club head similar to the first, second, third, or fourth golf club head (100, 2100, 3100, or 4100) described above. For simplicity, the reference numerals in the following method description refer to the first club head (100), but this method (20) can be applicable to all of the aforementioned club heads (100, 2100, 3100, or 4100) or their variations.

[0268] Forming the first component in the first step (21) can start with casting an unfinished version of the first component (300). The first component (300) can be cast as a full club head with a thin-walled region. Most of the thin-walled region can be located approximately where the second component (200) will later be attached. The peripheral section around the end of the thin-walled region will ultimately form a lip (450) of the first component (300). The unfinished first component is cast using the thin-walled region because it helps the first component maintain its desired shape during the casting process. Casting the first component (300) without using the thin-walled region can result in some warping or other casting quality issues. Thus, casting with the thin-walled region that will later be removed ensures that the first component maintains its desired shape and allows the second component (200) to fit correctly thereon during step 3.

[0269] After the unfinished first component is removed from the mold in which it was cast, a laser is used (second step: 22) to cut out the unwanted portions of the thin-walled regions, leaving only the peripheral section that forms the lip of the second component (450). The lip can be ground or polished as necessary. In some embodiments, the striking face (170) of the club head is integrally cast as part of the first component (300). In other embodiments, the first component (300) can be cast without a striking face (with an opening or void in the front portion of the first component). In these embodiments, a face plate is provided separately by casting or forging a face plate from a metallic material. The face plate can be welded, laser welded, or swedged (swagging) in a conventional manner and placed into the front opening of the first component (300).

[0270] The third step (23) can include injection molding the second component. The third step (23) can include providing a composite material (typically in pellet form), melting the composite material, injecting the melted composite material into a mold to form an unfinished second component, cutting the sprue, and polishing the gate region to finish the second component (200). As described above, the composite material can include a polymer resin and reinforcing fibers. The composite material can be provided in pellets that include both the resin and the fibers. The composite pellets are melted and injected into the mold to form the unfinished second component. The injection molding process of the third step (23) can be similar to the injection molding process disclosed in Patent Cooperation Treaty (PCT) application number PCT / US2020 / 047702, which is hereby incorporated by reference in its entirety.

[0271] The fourth step (24) can include applying an adhesive (such as a two-part epoxy) to the first component lip (450), aligning and placing the second component (200) over the first component lip (450), and drying the adhesive. One or more first component tabs (457) on lips (450) and (455) can provide a gap between the first component lip (450) and the second component. This gap can accommodate the adhesive. The gap can have a uniform height or thickness because the first component tabs (457) have a uniform height. This uniform height of the gap can create a uniform bond between the first component (300) and the second component (200).

[0272] In some embodiments of this second method (20), a functionalized bonding film or layer can be used instead of an adhesive. The functionalized bonding film can be provided in one or more strip regions corresponding to the shape and sides of the first component lips (450, 455). The functionalized bonding film includes a first and a second side. The film can be configured to bond to the material of the first component on the first side and to the material of the second component on the second side. The bonding film can bond the first and second components together when placed under the required temperature and pressure conditions for a set time.

[0273] After the adhesive is applied to the first component lips (450, 455), the second component can be placed or slid over the first component lip. The second component can slide over the first component lip until the outer edge of the second component contacts the rest of the first component. As shown in FIG. 5, the first component lip includes a recessed offset (459) that the second component fills when the club head is assembled. The third step can further include drying the adhesive and bonding the first component to the second component.

[0274] The fifth step (25) can include polishing, cleaning, coating, and / or painting the club head. In some embodiments, the fifth step (25) can further include placing a removable weight (1300) within a weight recess (540) and securing the removable weight (1300) using a fastener. In other embodiments, the fifth step (25) can further include placing a movable weight (2350) within a weight channel (2540) and securing the movable weight using a fastener. Third method

[0275] As shown in FIG. 63, the third method (30) includes the following steps, namely, (step 1: 31) forming a first component, (step 2: 32) providing a second component as a toe portion (3212) and a heel portion (3214), (step 3: 33) fixing the second component toe portion (3212) to the first component (3300), (step 4: 34) fixing the second component heel portion (3214) to the first component (3300), and (step 5: 35) completing the club head. The first step (31) can include casting an unfinished first component, laser cutting unwanted portions of the unfinished first component, and optionally welding a face plate to the first component to form a completed first component. The third method (30) can be used to form a golf club head similar to the third or fourth golf club head (3100 or 4100) described above. For simplicity, the reference numbers in the following method description refer to the third club head (3100), but this method (30) can be applicable to all of the aforementioned club heads (3100 or 4100) or variations thereof.

[0276] The first step (31) of forming the first component (3300) may be the same as steps 1 and 2 (21 and 22) of the second method (20) described above. However, in this manufacturing process, the crown brace (3560) remains after the laser cutting of the unfinished first component. The completed first component comprises an opening on the heel side (configured to receive the second component heel portion (3214)) and an opening on the toe side (configured to receive the second component toe portion (3212)).

[0277] The second step (32) of providing the second component (3200) may be the same as step 3 (23) of the second method (20) described above. However, in the third manufacturing process (30), the second component (3200) is provided as two separate components, namely, the toe portion (3212) and the heel portion (3214). In some embodiments, the toe portion (3212) and the heel portion (3214) may be injection molded simultaneously from the same sprue and gate and then separated from each other. In other embodiments, the toe portion (3212) and the heel portion (3214) are injection molded individually at different times. After injection molding, the toe and heel portions (3212 and 3214) are finished by cutting or polishing any excess material that entered the mold left from the gates of the mold.

[0278] Steps 3 and 4 (33 and 34) can be performed in any desired order. Step 3 (33) includes applying an adhesive on the outer peripheral lip (not shown) of the first component (3300), sliding the toe portion (3212) onto the lip of the first component (3300), and allowing the adhesive to cure / set. The toe portion (3212) can be assembled onto the first component (3300) by sliding it in the direction from the toe to the heel. Step 4 (34) includes applying an adhesive on the outer peripheral lip of the first component (3300), sliding the heel portion (3214) onto the lip of the first component (3300), and allowing the adhesive to cure / set. The heel portion (3214) can be assembled onto the first component (3300) by sliding it in the direction from the heel to the toe. In some embodiments of the method, steps 3 and 4 (33 and 34) are first performed by applying the adhesive, sliding the toe portion (3212) and the heel portion (3214) individually onto the first component (3300), and then joining them to allow the adhesive to dry.

[0279] Since the toe portion (3212) and the heel portion (3214) are geometrically configured to slide onto the first component (3300) from the side, the first component (3300) can have an outer shape at the rear end of the club head that would not be possible otherwise. For example, in embodiments having an integral second component, the second component generally has to be slid onto the first component (3300) in the direction from the rear to the front. This directional assembly required for the integral second component determines that the first component must have an outer shape with an appropriate draft angle. For example, in some embodiments having an integral second component, the sole rear extension cannot have a region with a width smaller than the trailing edge of the extension. From this perspective, forming the second component as two components (toe and heel portions) allows the first component to have a complex outer shape that is not restricted by a rear-to-front direction draft angle. VII) T-shaped design function

[0280] As described above, embodiments of the hollow golf club head (100, 2100, 3100, 4100, or 5100) described in this specification can include at least two main components. The first component (300, 2300, 3300, 4300, or 5300) made of metal includes a striking portion and a sole extension (500, 2500, 3500, 4500, or 5500) that forms a "T" shape. The second non-metallic component (200, 2200, 3200, 4200, or 5200) includes the rear portion of the crown (110, 2110, 3110, 4110, or 5110) and wraps around the first component so as to also include a part of the sole (120, 2120, 3120, 4120, or 5120). The higher-density "T" shaped sole of the first component (300, 2300, 3300, 4300, or 5300) is coupled to the second component (200, 2200, 3200, 4200, or 5200) that wraps the crown with a lower density, reducing the mass of the crown and shifting the center of gravity (CG) of the golf club head lower to optimize the mass characteristics. The weight saved from the second component (200, 2200, 3200, 4200, or 5200) can be redistributed to other positions of the golf club head (100, 2100, 3100, 4100, or 5100) to further optimize the CG, increase the MOI, and manipulate the shape of the shot trajectory.

[0281] The CG of the golf club head (100, 2100, 3100, 4100, or 5100) can move downward toward the rear of the golf club head including the first component (300, 2300, 3300, 4300, or 5300) and the second component (200, 2200, 3200, 4200, or 5200), and the second component (200, 2200, 3200, 4200, or 5200) includes a second material having a second density lower than the first material density as compared to an alternative golf club head that includes only the first material having a certain density. Example Example 1

[0282] The comparative example club head and the example club head of this application are compared in Table 1. The comparative example club is completely metallic and has the same total mass and total volume as the example club head. The example club head was similar to the golf club head of the first embodiment described above. The example club head included a first component made of metal and a second component made of a polymer attached to the first component and surrounding the hollow interior. The first component included a striking face, a striking face return, and a rear extension on the sole. The second component included a crown portion, a sole toe portion, and a sole heel portion.

Table 1

[0283] The comparative example club head and the example club head have the same volume of about 445 cm 3 . The comparative example club, which is entirely composed of a metallic material, has a CGy of 0.895 inches, which is the height of the CG on the ground contact surface (105). The example golf club head has a CGy of 0.887 inches. It is desirable to reduce the value of CGy. The CGy of the example golf club head is 0.008 inches lower than that of the comparative example club.

[0284] As described above, CGz is measured as the distance from the center of the striking face (175) to the rear end of the golf club head in a direction perpendicular to the loft face (198). A larger CGz is located further rearward of the golf club and is advantageous for ball flight control. The CGz of the comparative example club is 1.913 inches. The example golf club head has a CGz of 1.986 inches. The CGz of the example golf club head is 0.073 inches further rearward than the CGz of the comparative example club.

[0285] The position of the CG serves to determine the launch characteristics of the ball (e.g., ball trajectory, ball spin, and ball speed), the moment of inertia (MOI), and performance characteristics (e.g., swing speed, square at impact). A high MOI helps prevent rotation of the golf club head during the swing and helps square the hitting face during impact with the ball. Impacting the ball with a square hitting face helps ensure a straight ball path and optimal height / trajectory as compared to slicing or hooking the ball when the hitting face is not square. Also, the lower the CG, the more the ball speed and spin are improved, adding distance and preventing the ball from rolling backward upon landing.

[0286] The MOI of the exemplary golf club head is greater than the MOI of the comparative example golf club. The MOI values of IXX and IYY are the MOI values about the X-axis (190) and Y-axis (192), respectively. A higher MOI is desirable as it helps prevent rotation of the golf club head during the swing and helps square the hitting face during impact with the ball, so a larger MOI is preferred. The IXX value of the comparative example club is 584.45 and the IYY value is 834.30. The IXX value of the exemplary golf club head is 652.71 and the IYY value is 875.94. The exemplary golf club head has an 11.7% improvement in IXX and a 5.0% improvement in IYY compared to the comparative example club.

[0287] The ball flight of the golf ball struck by the exemplary golf club head has improved CGy and CGz values and is directly related to the improved IXX and IYY values. The improved CG values lead to lower ball spin at impact and a longer carry for ball flight.

[0288] In an alternative embodiment, an embedded high density weight was added to the exemplary golf club head. The exemplary golf club head having the weight has a CGy of 0.890 inches and a CGz of 2.013 inches. The CGy of the exemplary golf club head having the weight is 0.005 inches smaller than the CGy of the comparative example golf club head, but the CGz of the exemplary golf club head having the weight is 0.100 inches larger than the CGz of the comparative example golf club head. The exemplary golf club head having the weight has an IXX value of 678.31 and an IYY value of 901.78. Both of these MOI values are 16% and 8.1% larger, respectively, than the IXX and IYY of the comparative example golf club head. Example 2

[0289] A series of club head components were compared to each other through finite element analysis (FEA) simulation tests of golf ball impact in each club head. The club head components were at least metal components comprising a face, a hitting face return, and a sole extension having a rear weight channel for holding a movable weight at a center position. The components tested were club heads that were not fully assembled. They did not include a second component having a lower density. Rather, this test separated the metal club head components because simulations and comparisons of single components can be more accurate than complex simulations of assembled club heads. The simulation test considered the relative vertical displacement of the rear weight after a center face impact by a golf ball moving at 80 mph. The rear weight in the simulation had a mass of 32 grams.

[0290] A series of club head components included first, second, third, fourth, fifth, sixth, seventh, and eighth test components. The first test component was similar to the first component (300) of the first golf club head (100) described above, except that the first test component had a rear weight channel that held a movable weight at a central position rather than a single rear weight. The first test component did not have any brace between the face return and the trailing edge of the rear extension.

[0291] The second test component was similar to the first component (4300) of the fourth golf club head (4100) described above, specifically, similar to the variations of FIGS. 43 and 44. The second test component had a toe skirt brace (similar to 4566) and a heel skirt brace (similar to 4568). The third test component was similar to the first component (4300) of the fourth golf club head (4100) described above, specifically, similar to the variations of FIGS. 45 and 46. The third test component had a toe skirt brace (similar to 4566), a heel skirt brace (similar to 4568), and a central crown brace (similar to 4560).

[0292] The fourth test component was the same as the first component (4300) of the fourth golf club head (4100) described above, specifically, the same as the variations shown in FIGS. 47 and 48. The fourth test component had a toe-side brace (similar to 4557) and a heel-side brace (similar to 4559). The toe-side and heel-side braces of the fourth test component were separated by a greater width towards the rear end of the fourth test component. The fifth test component was the same as the first component (4300) of the fourth golf club head (4100) described above, specifically, the same as the variations shown in FIGS. 49 and 50. The fifth test component had a toe-side brace (similar to 4557) and a heel-side brace (similar to 4559). The toe-side and heel-side braces of the fifth test component were separated by a smaller width towards the rear end of the fifth test component, and as a result, they formed a V shape when viewed from above.

[0293] The sixth test component was the same as the first component (4300) of the fourth golf club head (4100) described above, specifically, the same as the variations shown in FIGS. 51 and 52. The sixth test component had a toe skirt brace (similar to 4566), a heel skirt brace (similar to 4568), a toe-side brace (similar to 4557), and a heel-side brace (similar to 4559). The toe-side and heel-side braces of the sixth test component were separated by a greater width towards the rear end of the sixth test component. The seventh test component was the same as the first component (4300) of the fourth golf club head (4100) described above, specifically, the same as the variations shown in FIGS. 53 and 54. The seventh test component had a toe skirt brace (similar to 4566), a heel skirt brace (similar to 4568), a toe-side brace (similar to 4557), and a heel-side brace (similar to 4559). The toe-side and heel-side braces of the seventh test component were parallel to each other.

[0294] The eighth test component was the same as the first component (4300) of the fourth golf club head (4100) described above, specifically, similar to the variations of FIGS. 55 and 56. The eighth test component had a toe skirt brace (similar to 4566), a heel skirt brace (similar to 4568), and a pair of cross braces (similar to the first brace 4570 and the second brace 4572 described above).

[0295] When a golf ball impacts the club head away from the center with respect to the center of the line of gravity, the golf club head applies torque around the center of gravity. The center of the line of gravity is a theoretical line that extends substantially perpendicular to the face and coincides with the center of gravity. The induced torque effect around the center of gravity caused by an impact away from the line is known as gear effect in the golf industry. Since the gear effect can contribute to the measurement, the relative movement of some of the test components cannot be accurately measured based on a fixed coordinate system. For example, when a golf ball strikes the face above the center of the line of gravity, the gear effect can cause a downward movement of the rear movable weight. Therefore, when measuring the relative vertical displacement of the rear weight channel and the weight, the measurement must be made with respect to a coordinate system that follows the overall movement of the golf club head.

[0296] For performing accurate simulation tests, the coordinate system was set within each test component. The coordinate system was linked to a theoretical plane. The theoretical plane was parallel to the loft plane and was offset 1.25 inches behind the loft plane. This is because this region of the golf club head is sufficiently distant from the critical stress zones in the crown and sole. Separating the theoretical plane from the critical stress zones separates the anchor coordinate system and enables the coordinate system to accurately follow the overall movement of the club head components. Linking the coordinate system to the overall movement of the club head components enables accurate measurement of the relative vertical bend of the movable weight. For the purposes of this embodiment, "relative vertical bend" should be understood to mean the bend in the direction from the sole, which is parallel to the loft plane (and the theoretical plane), to the crown. In other words, the relative vertical bend is a measure of the amplitude of the impact-induced oscillation of the rear weight relative to the other test golf club head components.

[0297] As shown graphically in FIG. 64, the rear weight of the first test component (without braces) bent more than 0.3 inches. The second test component (with toe and heel skirt braces) showed improvement with the rear weight bending approximately 0.15 inches at most. The fifth test component (with V-shaped toe and heel side braces) showed a maximum relative vertical weight displacement of approximately 0.12 inches. The fourth test component (with rearward wide toe and heel side braces) had performance similar to that of the fifth test component. The fourth test component showed a maximum relative vertical displacement of approximately 0.11 inches. The eighth test component (with skirt braces and cross-intersecting crown braces) showed a maximum relative vertical displacement of approximately 0.075 inches. The third, sixth, and seventh test components had performance superior to any of the other components.

[0298] The graph of FIG. 65 shows the third, sixth, and seventh test components compared to the first test component of the reference line. The graph of FIG. 66 is an enlarged view of the graph of FIG. 65. As shown in the graph of FIG. 66, the third test component (having a skirt brace and a center crown brace) showed a maximum relative vertical displacement of approximately 0.065 inches. The sixth test component (having a skirt brace and a rearwardly wide toe and heel side brace) showed a slightly lower maximum relative vertical displacement of approximately 0.057, and the seventh test component (having a skirt brace and parallel toe and heel side braces) showed a maximum relative vertical displacement of approximately 0.054 inches.

[0299] A rear weight that bends more upwardly bounces more downwardly and includes greater material fatigue and stress in the sole rear extension. For a fully assembled golf club head having the two-component design described herein, the lip or overlap joint structure that connects the first and second components has a risk of delamination when the rear weight oscillates or vibrates at a high amplitude (a high value of relative vertical displacement). Thus, the test components that show a smaller relative vertical displacement of the rear weight form a more durable golf club head. This simulation test showed that adding braces to the first component improved the durability of the golf club head. In particular, by including a combination of two skirt braces, a toe side brace, and a heel side brace to the first component (such as in FIGS. 51 - 54), the best stability to the rear weight, and thus the most excellent durability, was provided.

[0300] The performance of a complete golf club head is superior to the performance of a series of club head components tested (i.e., the first component of metal). For the golf club head embodiments described herein, a second component, typically including a polymeric material, provides some support to the first component. The attached second component reduces the relative vertical displacement of the rear weight. Thus, any component of a series of tested club head components can form a sufficiently durable club head when connected to a properly designed second component. However, a first component (metal) having a smaller relative vertical displacement of the rear weight can be connected to a second component that is thinner, lighter, or less durable to achieve an equally durable overall club head. Example 3

[0301] A second comparison was made among the first test component, the third test component, and the seventh test component described in Example 2 above. This comparative test was conducted through finite element analysis (FEA) simulation tests of golf ball impact in each club head. The simulation test considered the relative vertical displacement of the rear weight after toe-side (away from the center) face impact by a golf ball moving at 80 mph. The face was impacted 1 inch from the geometric center of the face toward the toe end.

[0302] As shown in the graph of FIG. 67, the first test component (without braces) showed a relative vertical displacement of the rear weight exceeding 0.5 inches. The third test component (having a skirt brace and a center crown brace) showed a maximum relative vertical displacement of the rear weight of approximately 0.1 inch. The seventh test component (having a skirt brace and parallel toe and heel side braces) showed a maximum relative vertical displacement of the rear weight of approximately 0.08 inch. This comparison shows that braces increase club head durability for off-center hit shots as well as for center hit shots.

[0303] The replacement of one or more claimed elements constitutes a reconstruction and not a repair. Further, effects, other advantages, and solutions to problems have been described with respect to specific embodiments. However, an advantage, other advantageous aspect, and solution to a problem, and any one or more elements that cause or reveal any advantage, advantageous aspect, or solution, do not constitute a material, essential, or inherent feature or element of any or all of the elements of the claims unless such advantage, advantageous aspect, solution, or element is expressly recited in such claims.

[0304] The rules of golf are sometimes changed (new rules may be applied by golf standard organizations and / or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St Andrews (R&A), etc., or old rules may be abolished or changed), so golf equipment related to the devices, methods, and products described herein may or may not conform to the rules of golf at any given time. Accordingly, golf equipment related to the methods, devices, and / or products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The methods, devices, and / or products described herein are not limited in this regard.

[0305] Industry customs, rules set by golf bodies such as the United States Golf Association (USGA) or the R&A, and nomenclature rules can enhance this description of the terms without departing from the scope of this application.

[0306] The above example may be described in connection with a hollow body golf club, but the devices, methods, and products described herein may be applicable to other types of golf clubs such as iron-type golf clubs, wedge-type golf clubs, or putter-type golf clubs. Alternatively, the devices, methods, and products described herein may be applicable to other types of sports equipment such as hockey sticks, tennis rackets, fishing poles, ski poles, and the like.

[0307] Furthermore, the embodiments and limitations described herein are not provided to the public under the doctrine of disclosure where the embodiments and / or limitations are (1) not expressly claimed in the claims and (2) are equivalent or potentially equivalent to the claimed elements and / or limitations in the claims under the doctrine of equivalents.

[0308] The various features and advantages of the present disclosure are described in the following sections.

[0309] Item 1: A golf club head, comprising a body, the body including a striking face, a rear end, a toe end, a heel end, a crown, a sole, a skirt, and a trailing edge, the body further including a striking face, a striking face return, a rear extension having a weight channel, and a crown brace attached to the striking face return and the rear extension, a first component, a crown portion, a sole toe portion, and a sole heel portion, a second component, the second component being configured to couple to the first component to form an enclosed hollow interior of the golf club head, the first component comprising a first material having a first density, the second component comprising a second material having a second density, the first density being greater than the second density, the striking face having a striking face center, the weight channel being centered at the rear end of the golf club head, the striking face return of the first component extending rearward from the striking face and including a front crown portion and a front sole portion, the rear extension extending from the front sole portion of the striking face return toward the rear end, the rear extension further comprising a rear extension axis extending through the center of the rear extension, the first component mass being 85% to 96% of the mass of the golf club head.

[0310] Item 2: The golf club head according to Item 1, wherein the crown brace is attached to the front crown portion of the striking face return and to the sole rear extension adjacent to the weight channel at the rear end of the golf club head.

[0311] Item 3: The golf club head according to Item 2, wherein the crown brace and the weight channel have a hammer head shape.

[0312] Item 4: The crown brace further comprises a crown brace longitudinal axis, the crown brace has a maximum length, and the crown brace longitudinal axis bisects the crown brace along the maximum length. The golf club head according to item 2.

[0313] Item 5: The crown brace longitudinal axis is offset toward the heel end parallel to the rear extension axis. The golf club head according to item 4.

[0314] Item 6: The crown brace longitudinal axis is offset toward the toe end parallel to the rear extension axis. The golf club head according to item 4.

[0315] Item 7: The crown brace longitudinal axis is non-parallel to the rear extension axis so as to form an acute angle with the rear extension axis. The golf club head according to item 4.

[0316] Item 8: The X-axis extends through the center of the striking face in a direction parallel to the ground plane when the club head is in the address position, from the heel end to the toe end of the golf club head. The Y-axis extends through the center of the striking face in a direction perpendicular to the X-axis, from the crown to the sole of the golf club head. The Z-axis extends through the center of the striking face in a direction perpendicular to the X-axis and the Y-axis, from the striking face to the rear end of the golf club head. A loft face substantially parallel to the striking face and in contact with the center of the striking face forms a loft angle with the ground plane. The XY plane extends through the X-axis and the Y-axis. The YZ plane extends through the Y-axis and the Z-axis. The golf club head according to item 4.

[0317] Item 9: The weight channel is exposed at the rear end and the sole of the body. The golf club head according to item 1.

[0318] Item 10: The golf club head according to item 1, wherein the weight channel is configured to receive a movable weight at one of three positions.

[0319] Item 11: The golf club head according to item 1, wherein the rear extension includes a toe side wall and a heel side wall extending between the weight channel and the front sole portion of the striking face return.

[0320] Item 12: The golf club head according to item 10, wherein the weight channel further includes a mounting wall having three screw holes, the three screw holes including a toe side screw hole, a central screw hole, and a heel side screw hole, and the central screw hole is located at the central point of the length of the mounting wall.

[0321] Item 13: The golf club head according to item 1, wherein the rear extension has a rear extension width measured in the toe-to-heel direction at the rear of the rear periphery of the front sole portion of the striking face return, and the rear extension width ranges from 25% to 85% of the total width of the sole.

[0322] Item 14: The golf club head according to item 13, wherein the rear extension width adjacent to the weight channel can range from 1 inch to 2.5 inches.

[0323] Item 15: The golf club head according to item 12, wherein the movable weight is fixed by a threaded fastener attached to one of the three screw holes.

[0324] Item 16: The golf club head according to item 12, wherein the weight channel further includes a sole wall that enters inward from the sole, the mounting wall is oriented substantially perpendicular to the sole, and the sole wall enters inward by a distance approximately equal to the height of the mounting wall.

[0325] Item 17: A golf club head comprising a body, the body comprising a striking face, a rear end, a toe end, a heel end, a crown, a sole, a skirt, and a trailing edge, the body further comprising a first component comprising the striking face, a striking face return, a rear extension having a weight channel, and a plurality of crown braces, and a second component comprising a crown portion, a sole toe portion, and a sole heel portion, the second component being configured to couple to the first component to form an enclosed hollow interior of the golf club head, the first component comprising a first material having a first density, the second component comprising a second material having a second density, the first density being greater than the second density, the striking face having a striking face center, the weight channel being centered at the rear end of the golf club head, the striking face return of the first component extending rearward from the striking face and comprising a first component crown portion and a first component sole portion, the rear extension extending from the first component crown portion of the striking face return toward the rear end, the rear extension further comprising a rear extension axis extending through the center of the rear extension, the first component mass being 85% to 96% of the mass of the golf club head.

[0326] Item 18: The golf club head according to item 17, wherein the plurality of crown braces define an opening within the first component, the number of the openings being selected from the group consisting of three, four, five, and six openings.

[0327] Item 19: The golf club head according to item 17, wherein the plurality of crown braces comprises two crown braces, each of the two crown braces being attached to the front crown portion and to the rear extension adjacent to the weight channel at the rear end of the golf club head.

[0328] Item 20: The golf club head according to item 19, wherein the two crown braces are attached to the rear extension at different points.

Claims

1. A golf club head, It has a body, the body includes a striking face, a back end, a toe end, a heel end, a crown, a sole, a skirt, and a trailing edge; The body further comprises: a first component including the striking face, a striking face return, a rear extension having a weight channel, and a crown brace attached to the striking face return and the rear extension; a second component including a crown portion, a sole-toe portion, and a sole-heel portion; the second component is configured to couple to the first component to form an enclosed hollow interior of the golf club head; the first component comprises a first material having a first density; the second component comprises a second material having a second density; the first density is greater than the second density; the striking face having a striking face center; the weight channel is centrally located at the rear end of the golf club head; the striking face return of the first component extends rearwardly from the striking face and includes a forward crown portion and a forward sole portion; the rear extension extends from the forward sole portion toward the rear end of the striking face return; the rear extension further comprises a rear extension axis extending through a center of the rear extension; A golf club head, wherein the first component mass is between 85% and 96% of the mass of the golf club head.

2. 2. The golf club head of claim 1, wherein the crown brace is attached to the front crown portion of the striking face return and to the sole rear extension adjacent the weight channel at the rear end of the golf club head.

3. The golf club head of claim 2 , wherein the crown brace and the weight channel comprise a hammerhead shape.

4. The crown brace further comprises a crown brace longitudinal axis; the crown brace has a maximum length; The golf club head of claim 2 , wherein the crown brace longitudinal axis bisects the crown brace along the maximum length.

5. The golf club head of claim 4 , wherein the crown brace longitudinal axis is offset toward the heel end parallel to the rear extension axis.

6. The golf club head of claim 4 , wherein the crown brace longitudinal axis is offset toward the toe end parallel to the rear extension axis.

7. The golf club head of claim 4 , wherein the crown brace longitudinal axis is non-parallel to the rear extension axis so as to form an acute angle with respect to the rear extension axis.

8. an X-axis extends from the heel end to the toe end of the golf club head and through the center of the striking face in a direction parallel to the ground plane when the club head is in an address position; a Y-axis extends from the crown to the sole of the golf club head and perpendicular to the X-axis through the center of the striking face; a Z-axis extends from the striking face to a rear end of the golf club head and perpendicular to the X-axis and the Y-axis through the striking face center; a loft plane that is substantially parallel to the striking face and tangent to a center of the striking face forms a loft angle with respect to the ground contact surface; an XY plane extends through the X-axis and the Y-axis; The golf club head of claim 4 , wherein a YZ plane extends through the Y axis and the Z axis.

9. The golf club head of claim 1 , wherein the weight channel is exposed at the rear end and at the sole of the body.

10. The golf club head of claim 1 , wherein the weight channel is configured to receive a movable weight in one of three positions.

11. The golf club head of claim 1 , wherein the rear extension comprises a toe sidewall and a heel sidewall extending between the weight channel and the forward sole portion of the striking face return.

12. the weight channel further comprises a mounting wall having three threaded holes; The three screw holes include a toe side screw hole, a central screw hole, and a heel side screw hole, The golf club head of claim 10 , wherein the central screw hole is located at a midpoint of the length of the mounting wall.

13. the rear extension has a rear extension width measured in a heel-to-toe direction rearward of a rear periphery of the forward sole portion of the striking face return; The golf club head of claim 1 , wherein the rear extension width is in the range of 25% to 85% of the overall width of the sole.

14. The golf club head of claim 13 , wherein the rear extension width adjacent the weight channel can range from 1 inch to 2.5 inches.

15. The golf club head of claim 12 , wherein the movable weight is secured by a threaded fastener attached to one of the three threaded holes.

16. the weight channel further comprising a sole wall, the sole wall extending inwardly from the sole; the mounting wall is oriented substantially perpendicular to the sole; The golf club head of claim 12 , wherein the sole wall is recessed inwardly a distance approximately equal to a height of the mounting wall.

17. A golf club head, It has a body, the body includes a striking face, a back end, a toe end, a heel end, a crown, a sole, a skirt, and a trailing edge; The body further comprises: a first component comprising the striking face, a striking face return, a rear extension having a weight channel, and a plurality of crown braces; a second component including a crown portion, a sole-toe portion, and a sole-heel portion; the second component is configured to couple to the first component to form an enclosed hollow interior of the golf club head; the first component comprises a first material having a first density; the second component comprises a second material having a second density; the first density is greater than the second density; the striking face having a striking face center; the weight channel is centrally located at the rear end of the golf club head; the striking face return of the first component extends rearwardly from the striking face and includes a first component crown portion and a first component sole portion; the rear extension extends from the first component crown portion toward the rear end of the striking face return; the rear extension further comprises a rear extension axis extending through a center of the rear extension; A golf club head, wherein the first component mass is between 85% and 96% of the mass of the golf club head.

18. the plurality of crown braces defines a number of openings in the first component; 18. The golf club head of claim 17, wherein the number of openings is selected from the group consisting of three, four, five and six openings.

19. the plurality of crown braces comprises two crown braces; 18. The golf club head of claim 17, wherein each of the two crown braces is attached to the forward crown portion and to the rear extension adjacent the weight channel at the rear end of the golf club head.

20. The golf club head of claim 19 , wherein the two crown braces are attached to the rear extension at different points.

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