Multiple Material Iron Golf Club Head

Abstract

There is a need for a clubhead that can be used by players with mid-to-low handicaps, possessing the compact size and solid feel and sound of a traditional tour iron, without sacrificing the high moment of inertia and perimeter weighting of a conventional game-improving iron. [Solution] The cavity can accommodate an insert 340. The insert may contain a low-density material and allow weight to be concentrated around the periphery of the golf club head. The rear 303 of the golf club head has a flex seam 330 extending from heel to toe. The golf club head has an upper portion 308 above the flex seam and a lower portion 309 below the flex seam. The lower portion may have a depth greater than the depth of the upper portion. The striking surface can be formed by the low-density insert.

Description

Technical Field

[0001] (Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 857,741, filed Jun. 5, 2019, U.S. Provisional Patent Application No. 62 / 865,831, filed Jun. 24, 2019, and U.S. Provisional Patent Application No. 62 / 925,912, filed Oct. 25, 2019, all of which are incorporated herein by reference.

[0002] The present disclosure generally relates to golf equipment, and more particularly to multi-material iron golf club heads and methods of manufacturing such golf club heads.

Background Art

[0003] Typically, iron-type golf club heads include various styles such as muscle-back, cavity-back, or tour irons. Golfers with low handicaps and high skill levels prefer compact and aesthetically smooth tour irons. Tour irons have high loft, low center of gravity (hereinafter, “CG”), short shaft length, small profile, and thin topline. Tour irons generally have a smooth and classic appearance and a desirable sound. Forged tour irons are thought to provide an improved “feel” and an aesthetic look, particularly over other types of irons such as cast irons. Generally, low handicap golfers, such as tour players, desire iron-type club heads with a low CG that is close to the face of the club. Tour irons have a smaller sweet spot for straight flight, allowing these golfers to further shape their shots by manipulating the portion of the club face that impacts the golf ball. While difficult for high handicap golfers to use effectively, tour irons meet a niche demand for highly skilled and often low handicap golfers.

[0004] On the other hand, game-improvement irons are typically designed to cater to high-handicap golfers who desire increased forgiveness and higher loft in their irons. High-handicap golfers tend to play with iron-type clubheads that have a higher moment of inertia (MOI), which gives the clubhead more forgiveness. Game-improvement irons, such as deep cavity back, muscle back, or hollow body irons, allow for perimeter weighting, which increases the forgiveness of the clubhead and allows the face to curve more, resulting in greater distance. However, game-improvement irons naturally do not feel like solid tour irons and are not pure for golfers accustomed to traditional solid irons. Game-improvement irons have a larger profile and give a bulky feel. Such game-improvement irons may also have a thicker topline and other shaping features that many golfers find less aesthetically pleasing. The golf clubheads described herein meet the demands of golfers who want a club that shares the benefits of both game-improvement and tour irons.

[0005] In this field, there is a need for a clubhead that can be used by players with medium to low handicaps, possessing the compact size and solid feel and sound of a conventional tour iron, without sacrificing the high moment of inertia and perimeter weighting of conventional game-improvement irons. [Brief explanation of the drawing]

[0006] [Figure 1] Figure 1 shows an exploded perspective view of a golf club head according to one embodiment.

[0007] [Figure 2] Figure 2 shows a front view of the golf club head shown in Figure 1.

[0008] [Figure 3] Figure 3 shows a rear view of the golf club head shown in Figure 1.

[0009] [Figure 4] Figure 4 shows a toe side view of the golf club head shown in Figure 1.

[0010] [Figure 5] Figure 5 shows a toe side view of the golf club head from Figure 1, in cross-section along the VV line in Figure 3.

[0011] [Figure 6] Figure 6 shows a toe side view of the golf club head of Figure 1, in a cross-section along the VV line in Figure 3, according to a first embodiment with multiple material inserts.

[0012] [Figure 7] Figure 7 shows a toe side view of the golf club head of Figure 1, in a cross-section along the VV line in Figure 3, according to a second embodiment with multiple material inserts.

[0013] [Figure 8] Figure 8 shows a toe side view of the cross-section of the golf club head of Figure 1, along the VV line in Figure 3, according to a third embodiment with multiple material inserts.

[0014] [Figure 9] Figure 9 shows a toe side view of the golf club head of Figure 1, in a cross-section along the VV line in Figure 3, according to a fourth embodiment with multiple material inserts.

[0015] [Figure 10] Figure 10 shows a front perspective view of a lightweight insert according to one embodiment.

[0016] [Figure 11] Figure 11 shows a front view of the lightweight insert shown in Figure 10.

[0017] [Figure 12] Figure 12 shows a rear view of the lightweight insert shown in Figure 10.

[0018] [Figure 13] Figure 13 shows a cross-sectional view of the golf club head along the XII-XII line of the lightweight insert in Figure 10.

[0019] [Figure 14] Figure 14 shows a front perspective view of a second lightweight insert according to an embodiment.

[0020] [Figure 15] Figure 15 shows a front view of the lightweight insert in Figure 14.

[0021] [Figure 16] Figure 16 shows a front perspective view of a modified example of the lightweight insert in Figure 14.

[0022] [Figure 17] Figure 17 shows a toe side view of a cross-section of a golf club head according to an embodiment having a rear shelf.

[0023] [Figure 18] Figure 18 shows a toe side view of a cross-section of a golf club head according to an embodiment having a rear shelf at an angle of 90 degrees from the loft plane.

[0024] [Figure 19] Figure 19 shows a toe side view of a cross-section of the golf club head of Figure 1 along the V-V line of Figure 3, including a tape layer.

[0025] [Figure 20] Figure 20 shows a rear perspective view of the golf club head of Figure 1, including an exploded view of the toe cavity and the toe weight.

[0026] [Figure 21] Figure 21 shows an exploded view of a golf club head according to a second embodiment.

[0027] [Figure 22]Figure 22 shows a rear view of the golf club head shown in Figure 21.

[0028] [Figure 23] Figure 23 shows a side view of the heel of the golf club head from Figure 21, in cross-section along line XVI-XVI in Figure 22.

[0029] [Figure 24] Figure 24 shows a front perspective view of the body of the golf club head shown in Figure 21.

[0030] [Figure 25] Figure 25 shows a rear perspective view of the golf club head shown in Figure 21.

[0031] [Figure 26] Figure 26 shows a side view of the heel of the golf club head from Figure 21, in cross-section along line XVI-XVI in Figure 22.

[0032] [Figure 27] Figure 27 shows a side view of the heel of the golf club head of Figure 21 in cross-section along line XVI-XVI in Figure 22, according to a first embodiment having a partially filled insert.

[0033] [Figure 28] Figure 28 shows a side view of the heel of the golf club head of Figure 21 in cross-section along line XVI-XVI in Figure 22, according to a second embodiment having a partially filled insert.

[0034] [Figure 29] Figure 29 shows a side view of the heel of the golf club head of Figure 21 in cross-section along line XVI-XVI in Figure 22, according to a third embodiment having a partially filled insert.

[0035] [Figure 30] Figure 30 shows a heel side view of the golf club head of Figure 21 in cross-section along line XVI-XVI in Figure 22, according to a fourth embodiment having a partially filled insert.

[0036] [Figure 31] Figure 31 shows a modified version of the golf club head of Figure 22, which has an enclosed rear section.

[0037] [Figure 32] Figure 32 shows a modified version of the golf club head from Figure 22, which has an enclosed rear section and fixed features.

[0038] [Figure 33] Figure 33 shows a side view of a tow screw weight according to one embodiment.

[0039] [Figure 34] Figure 34 shows a perspective view of the tow screw weight shown in Figure 33.

[0040] [Figure 35] Figure 35 shows a front view of a golf club head according to one embodiment.

[0041] [Figure 36] Figure 36 shows a front view of the body of the golf club head shown in Figure 35, without an insert.

[0042] [Figure 37] Figure 37 shows a cross-sectional view of the golf club head shown in Figure 35.

[0043] [Figure 38] Figure 38 shows a magnified view of the top rail shown in Figure 37.

[0044] [Figure 39] Figure 39 shows a front view of the body of a golf club head, in an embodiment similar to that of the golf club head in Figure 35.

[0045] [Figure 40] Figure 40 shows a perspective view of the body of the golf club head shown in Figure 39.

[0046] [Figure 41] Figure 41 shows a cross-sectional view of the golf club head shown in Figure 39.

[0047] [Figure 42] Figure 42 shows a front view of the body of a golf club head, in an embodiment similar to that of the golf club head in Figure 35.

[0048] [Figure 43] Figure 43 shows a perspective view of the body of the golf club head shown in Figure 42.

[0049] [Figure 44] Figure 44 shows a cross-sectional view of the golf club head shown in Figure 42.

[0050] [Figure 45] Figure 45 shows a front view of the body of a golf club head, in an embodiment similar to that of the golf club head in Figure 35.

[0051] [Figure 46] Figure 46 shows a front view of the body of a golf club head, in an embodiment similar to that of the golf club head in Figure 35.

[0052] [Figure 47] Figure 47 shows a perspective view of the body of the golf club head shown in Figure 46.

[0053] [Figure 48] Figure 48 shows a rear view of a golf club head having at least toe and heel weights, according to an embodiment similar to the golf club head in Figure 35.

[0054] [Figure 49] Figure 49 shows a rear view of a golf club head having multiple weights, similar to the golf club head in Figure 35.

[0055] [Figure 50] Figure 50 shows a rear view of a golf club head having multiple weights, similar to the golf club head in Figure 35.

[0056] [Figure 51] Figure 51 shows a cross-sectional view of a golf club head according to one embodiment.

[0057] [Figure 52] Figure 52 shows a cross-sectional view of the golf club head from Figure 51, including fixed features.

[0058] [Figure 53] Figure 53 shows the statistical plot area chart of the golf club comparison test.

[0059] [Figure 54] Figure 54 shows a method for manufacturing a golf club head according to one embodiment.

[0060] [Figure 55] Figure 55 shows a method for manufacturing a golf club head according to a second embodiment.

[0061] It is well understood by golf enthusiasts that tour irons are visually distinguishable from game-improvement irons by both their size and appearance. Therefore, tour irons have different design requirements than game-improvement irons. The golf clubs described herein meet the market demand for tour-style irons while retaining the functional advantages of game-improvement irons.

[0062] Specifically, the golf club heads described herein share the aesthetically appealing features of tour irons (e.g., compact size, forged, medium feel) and the performance advantages of game-improvement irons (e.g., perimeter weighting and high forgiveness). Golf club heads having a body that forms a cavity are described herein, and inserts can be fitted within the cavity, and the cavity can be enclosed by a rear cap of the body or by a faceplate of the body. Inserts can be alternately exposed to the outside of the club head through one or more openings to maximize the mass of the insert and benefit the weight distribution within the club head. Thus, the golf club heads provide golfers with tour-style iron clubs while maintaining the level of forgiveness necessary for intermediate or beginner golfers to make the most accurate shots possible for their skill level. Generally, tour irons are designed for highly skilled golfers or players with low to medium handicaps, while game-improvement irons are designed for beginner to intermediate golfers with high handicaps (greater than 10). The golf club heads described here offer an option for golfers who want to play with a set of tour irons but lack the skill to use traditional tour irons.

[0063] Furthermore, the golf club heads offer highly skilled golfers the option to improve shot accuracy through a high MOI design. While the golf club heads described herein may have a lower MOI than certain game-improvement irons or standard irons, they nevertheless have a higher MOI than other golf club heads in the same category, namely tour irons or small irons. Additionally, the disclosed golf club heads offer a desirable low CG for advanced golfers. The golf club heads described herein are exemplified by, but are not limited to, these embodiments.

[0064] Golf club heads can be manufactured by a method that includes swaging (or swatting) the face plate onto the body of the golf club head. In a surface melting process, the boundary between the swaged face plate and the body can be laser-welded. The insert is not damaged by swaging or laser welding.

[0065] For simplicity and clarity, the drawings illustrate general construction methods, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring this disclosure. Furthermore, elements in the drawings are not necessarily drawn to a consistent scale. For example, the dimensions of some elements in the drawings may be exaggerated relative to others to help improve understanding of embodiments of this disclosure. The same reference numeral in different drawings indicates the same element. [Modes for carrying out the invention]

[0066] This specification describes golf clubs having a hollow golf club head, or a partially / approximately hollow golf club head, each comprising a low-density insert (a hollow golf club head or a partially / approximately hollow golf club head is hereinafter referred to as a "golf club head"). A golf club comprises a golf club head, a shaft, and a grip. A golf club head comprises a body having a hosel, a front, a rear, a top rail, and a sole. The body may include a cavity. The faceplate, sole, rear, and top rail surround the cavity. In some embodiments, the cavity of the golf club head may be sealed from the front by a faceplate. In some embodiments, the cavity may be open at the rear of the club, partially exposing the cavity. An insert may be fitted into the cavity. The front of the golf club head may further comprise a faceplate that seals the cavity from the front.

[0067] One embodiment of a golf club head described herein includes a body forming a cavity and a low-density insert, the cavity opening toward the front of the golf club head. The body has an internal cavity formed in the center of the club head. The body may be cast or forged. The cavity may receive and accommodate the low-density insert.

[0068] The golf club head has a low-density center, a high-density periphery, and, as mentioned above, a low-density insert for shifting weight to the periphery, thereby improving overall forgiveness. The insert contains a low-density material such as aluminum, titanium, or a composite material. Filling the cavity with a solid insert improves the acoustic and feel of the golf club head compared to other similar hollow-body irons. In some embodiments, adhesive and / or tape are used to further secure the insert within the cavity and prevent rattling.

[0069] The faceplate seals the front opening of the golf club head and forms the cavity. Swaging, press-fitting, and other low-temperature methods are used to secure the faceplate. TIG welding is not used. In some embodiments, the faceplate can be further secured to the body by laser welding, as laser welding is very precise and does not create a large heat-affected zone (HAZ) that affects the insert, tape, and / or adhesive. If the faceplate is TIG welded to the front of the golf club head body, the insert, tape, and / or adhesive are exposed to high temperatures and damaged, thereby impairing the weight distribution of the insert and the material properties of the tape and / or adhesive.

[0070] The high density of the periphery of the golf club head can also be achieved by a toe weight and / or a tip weight in the hosel. In some embodiments, the body may further include a toe cavity. The toe weight may be mounted within the toe cavity. The toe weight may contain a high-density material such as tungsten. Furthermore, in some embodiments, the golf club head may include a toe screw weight for swing weight.

[0071] In a second embodiment of the golf club head, the cavity of the body is exposed through an opening in the upper rear portion. Similar to the first embodiment, the golf club head of the second embodiment comprises a body and a low-density insert. The body can be cast or forged. The body has a rear opening in the upper portion of the body. The low-density insert is housed within the cavity of the body. In this embodiment, the insert includes a material that can be injected into the cavity, such as a thermoplastic composite, foam, or other filler-damping material.

[0072] The golf club head further comprises a face plate that forms the front boundary of the cavity. The injection molding process can form a low-density insert within the cavity of the body. The golf club head may further include a toe weight in the toe cavity of the body and / or a tip weight in the hosel for perimeter weighting. In addition, the golf club head may include a toe screw weight for swing weight.

[0073] In the description and claims, terms such as “first,” “second,” “third,” “fourth,” etc., are used to distinguish similar elements, if any, and are not necessarily used to describe a specific order or chronological order. Terms used in this way are interchangeable under appropriate circumstances. For example, the embodiments described herein may operate in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” “equip,” and “have” and their variations are intended to include non-exclusive inclusion. A process, method, article, or apparatus containing a list of elements is not necessarily limited to these elements and may include other elements not expressly indicated or inherent in such a process, method, article, or apparatus.

[0074] Terms such as “front,” “back,” “rear,” “top,” and “bottom” in the specification and claims are used for descriptive purposes, if any, and are not necessarily used to describe permanent relative positions. It should be understood that such terms are interchangeable under appropriate circumstances so that embodiments of the apparatus, methods, and / or articles described herein may operate in orientations other than those illustrated or otherwise described herein.

[0075] The term "join" and similar terms should be understood broadly and refer to connecting two or more elements mechanically and / or otherwise. For example, two or more mechanical elements may be mechanically joined but not electrically joined, or otherwise not joined. The joining may last for any length of time, e.g., permanent or semi-permanent, or even just momentary.

[0076] As used herein, the term MOI can be a quantity that represents the body's tendency to resist angular acceleration. MOI is also known as angular mass or rotational inertia. MOI determines the torque required to achieve a desired angular acceleration about an axis of rotation. A higher MOI makes the clubhead more forgiving; that is, even if the golf ball is struck off-center on part of the striking surface, the golfer will notice a more consistent shot. MOI is increased by shifting weight away from the center of the golf clubhead toward the periphery of the golf clubhead. To increase the MOI while maintaining the desired overall weight of the golf clubhead, the center of the golf clubhead must contain either a cavity or a lighter material than the main golf clubhead.

[0077] The embodiments of golf clubs described herein may apply to one or more golf clubs within a set of irons. In some embodiments, a set of irons includes irons having varying club head sizes, shaft lengths, lie angles, loft angles, head weights, and / or other parameters. Each club head in a set of irons may conventionally be numbered in the range of 1 to 10. Most commonly, a set is numbered from 3 to 9. Furthermore, a set of irons may include one or more wedges having higher loft angles than the numbered irons.

[0078] In some embodiments, the golf club head may be a wedge. In many embodiments, the loft angle of the golf club head is less than about 50 degrees, less than about 49 degrees, less than about 48 degrees, less than about 47 degrees, less than about 46 degrees, less than about 45 degrees, less than about 44 degrees, less than about 43 degrees, less than about 42 degrees, less than about 41 degrees, or less than about 40 degrees. Furthermore, in many embodiments, the loft angle of the golf club head is greater than about 16 degrees, greater than about 17 degrees, greater than about 18 degrees, greater than about 19 degrees, greater than about 20 degrees, greater than about 21 degrees, greater than about 22 degrees, greater than about 23 degrees, greater than about 24 degrees, or greater than about 25 degrees.

[0079] In many embodiments, the loft angle of the golf club head is less than approximately 64 degrees, less than approximately 63 degrees, less than approximately 62 degrees, less than approximately 61 degrees, less than approximately 60 degrees, less than approximately 59 degrees, less than approximately 58 degrees, less than approximately 57 degrees, less than approximately 56 degrees, less than approximately 55 degrees, or less than approximately 54 degrees. Furthermore, in many embodiments, the loft angle of the golf club head is greater than approximately 46 degrees, greater than approximately 47 degrees, greater than approximately 48 degrees, greater than approximately 49 degrees, greater than approximately 50 degrees, greater than approximately 51 degrees, or greater than approximately 52 degrees.

[0080] In many embodiments, the golf club head may have a total volume of 1.9 cubic inches to 2.7 cubic inches. In some embodiments, the total volume of the golf club head may be 1.9 cubic inches to 2.4 cubic inches, 2.0 cubic inches to 2.5 cubic inches, 2.1 cubic inches to 2.6 cubic inches, 2.2 cubic inches to 2.7 cubic inches, 2.3 cubic inches to 2.7 cubic inches, or 2.4 cubic inches to 2.7 cubic inches. In other embodiments, the total volume of the golf club head 100 may be 1.9 cubic inches, 2.0 cubic inches, 2.1 cubic inches, 2.2 cubic inches, 2.3 cubic inches, 2.4 cubic inches, 2.5 cubic inches, 2.6 cubic inches, or 2.7 cubic inches.

[0081] In some embodiments, the golf club head may contain a total mass of 200-210 grams, 210-220 grams, 220-230 grams, 230-240 grams, 240-250 grams, 250-260 grams, 255-260 grams, 260-270 grams, 265-275 grams, 270-280 grams, 275-280 grams, or 250-270 grams, 270 grams, and 270 grams. In other embodiments, the total mass can be 200 grams, 205 grams, 210 grams, 220 grams, 225 grams, 230 grams, 235 grams, 240 grams, 245 grams, 250 grams, 255 grams, 260 grams, 265 grams, 270 grams, 275 grams, 280 grams, 285 grams, 290 grams, 295 grams, or 300 grams.

[0082] The golf club heads described herein can be viewed from various viewpoints while in the address position, including, but not limited to, front views, rear views, toe side views, heel side views, top views, bottom views, and various perspective views. For example, a front view of golf club head 100 shows the club head viewed from a direction parallel to the ground plane 10, in front of the loft plane 20. A rear view of golf club head 100 shows the club head viewed from a direction parallel to the ground plane 10, behind the rear 103. A toe side view of golf club head 100 shows the club head viewed from a toe-heel direction parallel to the ground plane 10. A heel side view of golf club head 100 shows the club head viewed from a heel-toe direction parallel to the ground plane 10. A bottom view of golf club head 100 shows the club head viewed from a bottom-to-top direction perpendicular to the ground plane 10. The top view of the golf club head 100 shows the club head viewed from the direction perpendicular to the ground surface 10, from the top to the bottom. I. Golf club head with insert and sealing faceplate

[0083] This section describes golf club head 100. As mentioned above, golf club head 100 can be a forgiving, tour-style golf club head. Golf club head 100 can have a body with a cavity that houses an insert. The golf club head comprises a face plate, a body, and an insert. The body comprises an upper portion, a lower portion, a sole, a rear, and a top rail. The rear may further comprise a flex seam. The flex seam is the boundary between the upper and lower portions of the golf club head. The face plate and part of the body define the strike face of the golf club head. The face plate, sole, rear, and top rail surround the cavity.

[0084] The body cavity opens towards the front of the golf club head and is sealed by a faceplate. The faceplate can be swaged and laser-welded to the body. The club head is a tour iron club head and has a volume of 1.8 cubic inches to 2.7 cubic inches (30 cubic centimeters (cc) to 45 cc). The body of the golf club head can be cast or forged from metal material.

[0085] The insert contains a low-density material and fills the cavity formed by the body of the golf club head. Reducing the mass at the center of the golf club head allows for the concentration of extra mass around it, increasing the moment of inertia value of the golf club head. As described above, the golf club head comprises a lower portion and an upper portion. The lower portion has a greater depth than the upper portion. This results in the lower portion having more mass concentrated around the heel end, toe end, and sole. Lowering the mass of the body results in a lower CG, increasing the launch angle and decreasing spin. As described above, there is a need in the art for an iron that bridges the gap between a tour iron having a relatively high moment of inertia from periphery weighting and a low CG from low-mass positioning. In some embodiments, a tip weight placed in the hosel and / or a toe weight placed in the toe cavity of the body provide additional periphery weighting. A. Part of a golf club head

[0086] Referring to Figures 1 to 13, the golf club head 100 comprises a face plate 155, a body 110, and an insert 140, as described above. The body 110 may further comprise an upper portion 108, a lower portion 109, a sole 107, a rear 103, a toe side 101, a heel side 102, and a top rail 106. The face plate 155 and part of the body can define the strike face 111. The face plate 155, sole 107, rear 103, and top rail 106 surround the cavity 120. The upper portion 108 is bounded by the top rail 106. The lower portion 109 is bounded by the sole 107. The rear 103 may include a flex seam 130. The flex seam 130 can extend from the toe side 101 to the heel side 102 of the golf club head. The flex seam 130 defines its upper portion 108 against the top rail 106. The flex seam 130 defines its lower portion 109 against the sole 107. The flex seam 130 exhibits a uniform upper portion depth 116 end, as will be described later. As shown in Figures 4 to 12, the flex seam 130 is depicted as an inflection point in the toe side view of any cross section cut from the top rail toward the sole.

[0087] As shown in Figures 2 and 3, the ground plane 10 serves as the reference to the ground when the golf club is in the address position. As shown in Figure 4, the face plane 20 is parallel to the strike face 111. As shown in Figure 2, the center plane 45 is perpendicular to the ground plane 10, perpendicular to the loft plane 20, and coincides with the center point 80 of the strike face 111. As shown in Figures 2 and 4, the golf club head 100 may have a coordinate system centered on the CG 60 of the golf club head 100. The golf club head 600 described below may have similar coordinate axes. The reference axis of the x-axis 30 extends through CG 60 in the toe-heel direction. The x-axis 30 is parallel to the strike face. The reference axis of the y-axis 40 extends through CG 60 in the top rail-sole direction. The y-axis 40 is perpendicular to the ground plane 10 when the golf club head 100 is in the address position. The reference axis of the z-axis 50 extends in the front-rear direction through CG60. The z-axis 50 is parallel to the ground plane 10 and perpendicular to the x-axis 30 and y-axis 40. Furthermore, the reference axis of the hosel axis 70 extends through the concentric center of the hosel 105. The lead edge axis 35 is parallel to the ground plane 10 and extends in the heel-toe direction, coinciding with the lowest point on the nearly planar strike face 111 and along the center of the strike face 111. The lead edge plane coincides with the lead edge axis 35 and is parallel to the ground plane 10. 1) Upper and lower parts of the golf club head

[0088] As shown in Figures 4 and 5, the golf club head 100 comprises an upper portion 108 and a lower portion 109. As described above, the upper portion 108 can be separated from the lower portion 109 by a flex seam 130. The upper portion 108 of the rear 103 of the body may include a uniform depth 116 measured perpendicular to the loft plane 20 from the strike face 111 to the rear 103. The rear 103 comprises an upper wall 131 and a lower wall 132. By remaining substantially parallel to the loft plane 20, the upper wall of the rear 103 allows for a constant depth 116 in the upper portion 108 of the golf club head 100. At the flex seam 130, the rear contour transitions between the upper portion 108 and the lower portion 109 of the golf club head 100, shifting the depth of the golf club head 100. This change in depth leads to the lower portion 109 having a greater depth 118 than the upper portion 108, as will be described later. The greater the depth of the lower portion 109, the more beneficial it is to reduce the CG of the golf club head 100 and improve the launch characteristics.

[0089] This contour of the rear 103 of the golf club head 100 allows for a lower mass placement in the golf club head 100 compared to a golf club head with a flat rear design. By lowering the mass within the club head, the center of gravity (CG) is lowered. This allows for improved ball launch and spin characteristics of the golf ball upon impact by the golf club head 100. The full advantages of the CG position are best understood by comparison with a golf club head having a flat rear, as provided in Example 3 below. In some embodiments, the golf club head 100 can have a CG 0.030 inches to 0.050 inches lower than the CG of the flat-back comparison golf club head. In some embodiments, the CG is lowered by 0.030 inches to 0.032 inches, 0.032 inches to 0.034 inches, 0.034 inches to 0.036 inches, 0.036 inches to 0.038 inches, 0.038 inches to 0.040 inches, 0.040 inches to 0.042 inches, 0.042 inches to 0.044 inches, 0.044 inches to 0.046 inches, 0.046 inches to 0.048 inches, or 0.048 inches to 0.050 inches.

[0090] The rear contour can be varied between embodiments to allow the upper portion 108 and the lower portion 109 to have different depths, volumes, or masses. As shown in the cross-sectional views of Figures 17 and 18, in some embodiments, the lower wall 132 of the rear 103 may have a shelf 139 just below the bend seam 130. The shelf 139 may be located between the upper wall 131 and the rest of the lower wall 132. In these embodiments, the shelf 139 extends rearward and / or downward from the bend seam 130. In embodiments such as that shown in Figure 18, the shelf 139 is substantially perpendicular to the loft plane 20. By varying the rear contour, the depth, volume, or mass of the upper and lower portions 108, 109 can be changed, which affects the position of the CG and the MOI value. 2) Height of the upper and lower parts

[0091] As shown in Figures 4 and 5, the golf club head 100 includes an upper portion 108 and a lower portion 109, which are divided by a flex seam 130. The upper portion 108 has a height 188 measured along the center plane 45 from the top rail 106 to the flex seam 130, in a direction parallel to the loft plane 20. The upper portion height 188 may be between 0.60 inches and 0.90 inches. In some embodiments, the upper height 188 may be between 0.60 inches and 0.65 inches, 0.65 inches and 0.70 inches, 0.70 inches and 0.75 inches, 0.75 inches and 0.80 inches, 0.80 inches and 0.85 inches, 0.085 inches and 0.90 inches, 0.60 inches and 0.70 inches, 0.70 inches and 0.80 inches, or between 0.80 inches and 0.90 inches.

[0092] The lower portion 109 includes a height 189 measured parallel to the loft plane 20 along the center plane 45 from the top rail 106 to the bend seam 130. The lower portion height 189 may be between 0.80 inches and 1.10 inches. In some embodiments, the lower height 189 may be between 0.80 inches and 0.85 inches, 0.85 inches and 0.90 inches, 0.90 inches and 0.95 inches, 0.95 inches and 1.0 inches, 1.0 inches and 1.05 inches, 1.05 inches and 1.10 inches, 0.9 inches and 1.0 inches, or 1.0 inches and 1.1 inches.

[0093] The ratio of the upper section height 188 to the lower section height 189 can be between 9:8 (54:48) and 6:11 (54:99). In some embodiments, the ratio of the upper section height 188 to the lower section height 189 can be between 9:8 (54:48) and 6:8 (54:72), between 6:8 (54:72) and 9:11 (54:66), or between 9:11 (54:66) and 6:11 (54:99). A higher ratio of the upper section height 188 to the lower section height 189 results in a lower CG because the lower section 109 has greater depth and mass, as described below. Low CG improves launch and spin characteristics by reducing the torque applied to the golf club head 100 upon impact with the golf ball. Low CG can also increase ball speed and improve the feel of the golf club head 100. 3) Depth of the upper and lower parts of the golf club head

[0094] As shown in Figures 4 and 5, the upper portion 108 of the golf club head 100 can have a uniform depth. The upper portion depth 116 of the club head 100 can be 0.200 inches to 0.250 inches. In some embodiments, the upper portion depth 116 can be 0.200 inches to 0.210 inches, 0.205 inches to 0.215 inches, 0.210 inches to 0.220 inches, 0.215 inches to 0.225 inches, 0.220 inches to 0.230 inches, 0.225 inches to 0.235 inches, 0.230 inches to 0.240 inches, 0.235 inches to 0.245 inches, 0.240 inches to 0.250 inches, or 0.245 inches to 0.250 inches.

[0095] The lower portion 109 includes a depth 118 measured perpendicular to the loft plane 20, along the center plane 45, from the strike face 111 to the outer surface of the rear 103. The lower portion depth 118 can vary in the top rail-sole direction and / or heel-toe direction. The lower portion depth 118 is equal to or greater than the depth of the upper portion 116 of the golf club head 100. The lower portion depth 118 may be between 0.270 inches and 0.780 inches. In other embodiments, the lower portion depth 118 is 0.270 inches to 0.320 inches, 0.320 inches to 0.380 inches, 0.380 inches to 0.430 inches, 0.430 inches to 0.480 inches, 0.480 inches to 0.530 inches, 0.530 inches to 0.580 inches, 0.580 inches to 0.630 inches, 0.630 inches to 0.680 inches, 0.680 inches to 0.730 inches, 0.7 Possible ranges from 30 inches to 0.780 inches, 0.270 inches to 0.470 inches, 0.320 inches to 0.520 inches, 0.370 inches to 0.570 inches, 0.420 inches to 0.620 inches, 0.470 inches to 0.670 inches, 0.420 inches to 0.620 inches, 0.470 inches to 0.670 inches, 0.520 inches to 0.720 inches, or between 0.570 inches and 0.770 inches.

[0096] In the toe 101 and heel 102 of the club head 100, the lower portion depth 118 may differ from the lower portion depth 118 in the center plane 45. The minimum lower portion depth 118 in the toe 101 may be between 0.300 inches and 0.460 inches. In other embodiments, the lower portion depth 118 of the toe region 101 may be between 0.300 inches and 0.320 inches, 0.320 inches and 0.330 inches, 0.330 inches and 0.340 inches, 0.340 inches and 0.360 inches, 0.360 inches and 0.380 inches, 0.380 inches and 0.400 inches, 0.400 inches and 0.420 inches, 0.420 inches and 0.440 inches, or 0.440 inches and 0.460 inches.

[0097] The lower portion depth 118 in the heel 102 can similarly differ from the lower portion depth in the center plane 45. The minimum lower portion depth 118 within the heel region 102 may be between 0.270 inches and 0.315 inches. In other embodiments, the lower portion depth 118 of the heel region 102 may be between 0.270 inches and 0.280 inches, 0.280 inches and 0.290 inches, 0.290 inches and 0.300 inches, 0.300 inches and 0.310 inches, 0.310 inches and 0.320 inches, 0.320 inches and 0.340 inches, 0.340 inches and 0.360 inches, 0.360 inches and 0.380 inches, 0.380 inches and 0.400 inches, 0.400 inches and 0.420 inches, 0.420 inches and 0.440 inches and 0.460 inches.

[0098] The maximum depth of the club head 100 is located within the lower portion 109 of the body 110. The maximum depth of the club head 100 is measured perpendicular to the loft plane 20 from the strike face 111 to the outer surface of the rear 103. The maximum depth may be between 0.670 inches and 0.770 inches. In other embodiments, the maximum depth may be between 0.670 inches and 0.690 inches, 0.690 inches and 0.710 inches, 0.710 inches and 0.730 inches, 0.730 inches and 0.750 inches, or 0.750 inches and 0.770 inches.

[0099] In some embodiments, the ratio between the upper portion depth 116 and the lower portion depth 118 can be between 1:3 and 4:5. In some embodiments, the ratio between the upper portion depth 116 and the lower portion depth 118 can be between 1:3 and 1:2, 1:2 and 2:3, or 2:3 and 4:5. In club heads with a larger ratio between the upper portion depth 116 and the lower portion depth 118, the lower portion extends further to the rear. Conversely, in club heads with a smaller ratio between the upper portion depth 116 and the lower portion depth 118, the lower portion does not protrude to the rear. These embodiments can appear smoother and resemble a tour iron with a thinner profile. 4) The volume of the upper and lower portions of the head and cavity of a golf club.

[0100] Referring to Figures 4 and 5, the upper portion 108 and lower portion 109 of the golf club head 100 may include volume. The volume is measured from the plane adjacent to the heel 102 and coinciding with the end / periphery of the face plate 155 to the toe 101. The volume of the upper portion 108 may be between 0.20 cubic inches and 0.60 cubic inches. In some embodiments, the volume of the upper portion 108 may be between 0.20 cubic inches and 0.30 cubic inches, 0.25 cubic inches and 0.35 cubic inches, 0.30 cubic inches and 0.40 cubic inches, 0.35 cubic inches and 0.45 cubic inches, 0.40 cubic inches and 0.50 cubic inches, 0.45 cubic inches and 0.55 cubic inches, or 0.50 cubic inches and 0.60 cubic inches. In some embodiments, the volume of the upper portion 108 is 0.48 cubic inches.

[0101] As shown in Figure 5, the upper portion 108 and the lower portion 109 together form a body 110, which defines a cavity 120. A portion of the cavity 120 within the upper portion 108 of the body 110 can have a volume of 0.05 cubic inches to 0.40 cubic inches (0.82 cc to 6.55 cc). In some embodiments, the cavity volume within the upper portion 108 may be between 0.05 cubic inches to 0.15 cubic inches, 0.10 cubic inches to 0.20 cubic inches, 0.15 cubic inches to 0.25 cubic inches, 0.20 cubic inches to 0.30 cubic inches, 0.25 cubic inches to 0.35 cubic inches, 0.30 cubic inches to 0.40 cubic inches, or 0.35 cubic inches to 0.45 cubic inches. In some embodiments, the cavity volume within the upper portion 108 is 0.17 cubic inches. In some embodiments, the ratio of the upper portion volume of the club head to the cavity volume within the upper portion may range from 11:10 to 12:1.

[0102] To properly position the CG low within the golf club head 100, the golf club head 100 below the flex seam 130 (i.e., the lower portion 109) has a larger volume than the golf club head 100 above the flex seam 130 (i.e., the upper portion 108). The volume of the lower portion 109 of the club head 100 is the same as that of the upper portion 108 (i.e., measured from the plane adjacent to the heel 102 and coinciding with the end / periphery of the faceplate 155 to the toe). The volume of the lower portion 109 may be between 1.15 cubic inches and 1.55 cubic inches. In some embodiments, the volume of the lower portion 109 may be between 1.15 cubic inches and 1.35 cubic inches, 1.25 cubic inches and 1.45 cubic inches, 1.35 cubic inches and 1.55 cubic inches, 1.20 cubic inches and 1.30 cubic inches, 1.30 cubic inches and 1.40 cubic inches, or 1.40 cubic inches and 1.50 cubic inches. In some embodiments, the volume of the upper portion is 1.36 cubic inches.

[0103] A portion of the cavity 120 within the lower portion 109 can have a volume of 0.15 cubic inches to 0.60 cubic inches (2.46 cc to 9.83 cc). In some embodiments, the cavity volume within the lower portion 109 may be between 0.15 cubic inches to 0.25 cubic inches, 0.20 cubic inches to 0.30 cubic inches, 0.25 cubic inches to 0.35 cubic inches, 0.30 cubic inches to 0.40 cubic inches, 0.35 cubic inches to 0.45 cubic inches, 0.40 cubic inches to 0.50 cubic inches, 0.45 cubic inches to 0.55 cubic inches, or 0.50 cubic inches to 0.60 cubic inches. In some embodiments, the cavity volume within the lower portion 109 is 0.37 cubic inches. In some embodiments, the ratio of the volume of the lower part of the club head to the volume of the cavity within the lower part can be in the range of 1.1:1 to 10:1. 5) Total volume of the cavity

[0104] Referring again to Figure 1, the golf club head 100 may include a body 110 containing a cavity 120 in the central portion of the golf club head 100. The cavity 120 is filled with a low-density insert 140, which increases the forgiveness of the golf club head 100 without sacrificing the solid feel and appearance of a tour iron. The forgiveness of the golf club head 100 corresponds to the amount of perimeter weighting influenced by the volume of the cavity 120. A larger cavity removes more mass from the central region of the golf club head 100 than a smaller cavity. As a result, a larger cavity allows more weight to be placed around the perimeter of the golf club head 100.

[0105] Cavity 120 can have a volume of 0.2 cubic inches to 0.8 cubic inches (3.28 cc to 13.11 cc). In some embodiments, the volume of cavity 120 can be 0.2 cubic inches to 0.3 cubic inches, 0.2 cubic inches to 0.25 cubic inches, 0.25 cubic inches to 0.30 cubic inches, 0.30 cubic inches to 0.35 cubic inches, 0.35 cubic inches to 0.40 cubic inches, 0.40 cubic inches to 0.50 cubic inches, 0.40 cubic inches to 0.45 cubic inches, 0.45 cubic inches to 0. It can be between 50 cubic inches, 0.50 cubic inches to 0.60 cubic inches, 0.50 cubic inches to 0.65 cubic inches, 0.55 cubic inches to 0.60 cubic inches, 0.60 cubic inches to 0.65 cubic inches, 0.65 cubic inches to 0.70 cubic inches, 0.70 cubic inches to 0.80 cubic inches, 0.70 cubic inches to 0.75 cubic inches, or 0.75 cubic inches to 0.80 cubic inches. In other embodiments, the cavity 120 is 0.20 cubic inches, 0.22 cubic inches, 0.26 cubic inches, 0.28 cubic inches, 0.30 cubic inches, 0.32 cubic inches, 0.34 cubic inches, 0.36 cubic inches, 0.38 cubic inches, 0.40 cubic inches, 0.42 cubic inches, 0.44 cubic inches, 0.46 cubic inches, 0.48 cubic inches, 0.50 cubic inches, 0.54 cubic inches, 0.56 cubic inches, 0.58 cubic inches, 0.60 cubic inches, 0.62 cubic inches, 0.64 cubic inches, 0.66 cubic inches, 0.68 cubic inches, 0.70 cubic inches, 0.72 cubic inches, 0.74 cubic inches, 0.76 It may have a volume of cubic inch, 0.78 cubic inches, or 0.80 cubic inches.

[0106] As described above, the cavity 120 can have a volume of 5% to 60% of the total volume of the club head. In some embodiments, the cavity 120 can have a volume of 5% to 10%, 10% to 30%, 15% to 35%, 20% to 40%, 25% to 45%, 30% to 50%, 35% to 55%, or 40% to 60% of the total volume of the club head. In one embodiment, the volume of the cavity 120 is 17% to 32% of the club head volume.

[0107] By increasing the volume of the cavity 120, weight is removed from the central region of the body 110. This saved weight can be redistributed around the golf club head 100 to give it greater forgiveness. The height, depth, and volume of the upper and lower portions 108, 109 of the body 110 give the club head 100 a low-positioned CG60. Thus, the golf club head 100 has a lower CG than a golf club head with a flat rear, as illustrated in Embodiment 3 below. As described above, the golf club head 100 may have a CG60 that is 0.030 inches to 0.050 inches lower than the CG of a flat-back comparative golf club head. The lower the CG60, the better the launch characteristics, better spin characteristics, and higher ball speed of the golf club head 100 compared to a flat-back golf club head. 6) Golf club head thickness profile

[0108] The thickness of the rear 103 of the body 110 also affects the weight of the golf club head 100, and therefore its CG position. The thickness is measured from the outer surface of the rear 103 to the inner surface of the rear 103 within the cavity 120. In some embodiments, the rear 103 of the body 110 is thicker in the portion adjacent to the sole 107 of the body 110. Due to the density of the material of the body 110, the greater thickness in the portion adjacent to the sole 107 shifts the mass downward compared to a golf club head body with a uniform rear thickness. As shown in the cross-sectional view of Figure 5, the rear 103 of the body 110 may have a thickness 113. The rear thickness 113 may range from 0.030 inches to 0.100 inches. In some embodiments, the thickness 113 may be 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, or 0.100 inches. The rear thickness 113 can be constant across the rear 103. In some embodiments, the rear thickness 113 varies across the rear 103 in the heel-toe direction and / or the top rail-sole direction. Varying the thickness 113 of the rear 103 can help shift mass toward the sole 107 and rear 103 of the golf club head 100. Shifting mass toward the sole 107 and rear 103 lowers the CG, which improves launch characteristics, spin characteristics, and increases ball speed. 7) Body cavity

[0109] As shown in Figures 1 and 5, the body 110 may include an inner perimeter 127 that defines the outer boundary of the cavity 120. The inner perimeter 127 surrounds the cavity 120. The perimeter 127 internally borders the top rail 106, sole 107, toe 101, and heel 102. The inner perimeter 127 can follow the contour of the outer edge of the golf club head 100. The perimeter 127 of the cavity 120 extends as close as possible to the edge of the golf club head 100, thereby maximizing the size of the cavity 120. As a result, the size and weight advantages of the low-density insert 140 are also maximized.

[0110] In some embodiments (not shown), the periphery 127 tapers gently in the cross-section of the golf club head 100 cut in the front-to-back direction, such that the cavity 120 covers a larger area closer to the front 104 and a smaller area closer to the rear 103. In these embodiments, this tapered shape allows the larger area adjacent to the front 104 to incorporate more surface area of ​​the low-density insert, thereby positioning it closer to the front 104. The internal cavity area left for the low-density insert is smaller, leaving more high-density material at the rear 103 of the golf club head 100. Thus, the shape of the cavity 120 allows more mass to be placed adjacent to the rear 103 and sole 107 of the golf club head 100, allowing the CG to be moved downward and backward. 8) The cavity in the golf club head

[0111] As shown in Figures 1 and 5, the front 104 of the body 110 further includes a recess 142 for receiving the faceplate 155. The recess 142 connects to the front opening of the cavity 120 but is not considered part of the cavity 120. The recess 142 includes a periphery 143 that substantially follows the contour of the golf club head 100, including, but not limited to, the top rail 106, the edge of the body in the toe 101, the sole 107, and substantially vertical dividing lines adjacent to the heel 102. The periphery 143 of the recess 142 is offset from the inner periphery 127 that defines the cavity 120. The bottom surface of the recess 142 is larger than the area enclosed by the inner periphery 127 at the front of the cavity 120, so that it is bounded by the periphery 143. The recess 142 has a depth approximately equal to the thickness of the faceplate 155, which will be described later.

[0112] The faceplate 155 aligns with the recess 142, is located within the cavity 120, and sits on the recess 142. The insert 140 (described below) fits into the cavity to the extent that it is coplanar with the recess 142. The remaining volume of the cavity 120 is filled by the faceplate 155 seated on the recess 142. Together, the insert 140 and the faceplate 155 fill the entire volume of the cavity 120 and the recess 142 of the golf club head 100. The insert 140 does not cover the recess 142, but rather sits flush with it. As a result, the insert 140 does not interfere with the faceplate 155 seated on the recess 142.

[0113] In other embodiments described below, the insert 140 does not fill the volume of the cavity 120 all the way to the recess 142, but only partially. Again, these embodiments require an insert 140 that does not interfere with the faceplate 155 that sits on the recess 142. B. Golf club head insert

[0114] In contrast to conventional single-material tour irons, the golf club head 100 features a low-density insert 140 that fits into a cavity 120 of the body 110. As illustrated in Figure 1, the insert 140 is molded to fit into the cavity 120. The insert 140 either completely fills or partially fills the cavity 120, as described above. In some embodiments, the insert 140 shares the same wall geometry as the cavity 120. The shape of the insert 140 may be identical or substantially identical to the shape of the cavity 120. In embodiments where the insert substantially fills the cavity 140, the volume and other dimensions of the insert 120 substantially correspond to the respective volumes and other dimensions of the cavity 140. As described below, manufacturing tolerances and the insertion of tape and / or adhesive into the cavity 120 may require the insert 140 to have a slightly smaller volume compared to the cavity 120. 1) Multiple material (multiple density) inserts

[0115] Referring to Figures 6 to 9, in some embodiments, a multi-material insert 440 is used instead of insert 140. The multi-material insert 440 may have similar dimensions and volume to insert 140. The multi-material insert 440 may include a first portion 450 and a second portion 460 of different materials having different densities. In some embodiments, the first portion 450 is a low-density portion and the second portion 460 is weight. Adding weight to the low portion of insert 440 lowers the CG60 of the golf club head 100, thereby improving launch characteristics and increasing ball speed. Adding weight to lower CG60 can also increase ball speed and improve the feel of the golf club head 100. In other embodiments, the first portion 450 is a vibration-damping material and the second portion 460 is a low-density material. Forming the first portion 450 from a vibration-damping material may affect the feel and sound of the golf club head 100. By forming the insert 440 from multiple materials, the feel, sound, and perimeter weighting of the golf club head 100 can be altered.

[0116] Insert 440 can be formed together with the first portion 450 and the second portion 460 in any orientation or combination relative to each other, as long as the first portion 450 and the second portion 460 form an insert 440 configured to fit within the cavity 120 of the body 110 as described above. The first portion 450 may be separated from the second portion 460 or may be formed integrally with a single multi-material insert 440. Various embodiments of the multi-material inserts 440, 440B, 440C, and 440D are shown in Figures 6 to 9 and described below.

[0117] Referring to Figure 6, the insert 440 includes a first portion 450 and a second portion 460. The insert 440 can be designed to fit within the cavity 120 of the golf club head 100. The cross section in Figure 6 is cut along the center plane 45 of the golf club head 100. The first portion 450 of the insert 440 is adjacent to the strike plate 155 and includes a first material. The second portion 460 of the insert 440 is adjacent to the rear 103 of the body 110 and includes a second material. The first portion 450 overlaps with the second portion 460. The first portion 450 of the insert 440 includes a front surface that abuts against the rear surface 128 of the face plate 155. The second portion 460 does not engage with the face plate 155. The second portion 460 includes a front surface that engages with the rear surface of the first portion 450. The second portion 460 is enclosed within the cavity 120 section of the lower portion 109 of the golf club head 100.

[0118] In some embodiments, one or both of the engaging surfaces of the first and second portions 450, 460 are provided with small features (not shown) extending outward from a substantially flat surface in order to increase the engaging surface area. These small features may include projections, lips, ribs, hooks, or any other suitable features. These features allow the first portion 450 to be secured to the second portion 460 through a molding process or a co-molding process.

[0119] Referring here to Figures 7-9, three further exemplary embodiments of the multi-material insert are depicted in a cross-sectional view of the club head 100 along the central plane 45. A second embodiment of the multi-material insert 440B includes a first portion 450B and a second portion 460B arranged as shown in Figure 7. In this embodiment, the first portion 450B forms the upper part of the insert 440B, and the second portion 460B forms the lower part of the insert 440B. Both the first portion 450B and the second portion 460B are coplanar with the face plate 155. The first portion 450B fills a portion of the cavity 120 in the upper portion 108 of the body 110. The second portion 460B fills a portion of the cavity 120 in the lower portion 109 of the body 110. The second portion 460B is coplanar with the entire internal sole wall of the cavity 120.

[0120] A third embodiment of the multi-material insert 440C includes a first portion 450C and a second portion 460C arranged as shown in Figure 8. In this embodiment, the first portion 450C comprises the majority of the volume of the insert 440C. The first portion 450C partially extends into the rear end of the insert 440C. The entirety of the second portion 460C is located behind the first portion 450C. The first portion 450C is flush with the faceplate 155 from the top rail 106 to the sole 107 within the cavity of the golf club head 100. The second portion 460C does not engage with the faceplate 155. The second portion 460C partially fills a portion of the cavity 120 within the lower portion 109 of the body 110 and is fully positioned within that portion. The second portion 460C engages with a portion of the internal sole wall and rear rear wall of the cavity 120. In some embodiments, the second portion 460C is formed from a high-density material.

[0121] A fourth embodiment of the multi-material insert 440D includes a first portion 450D and a second portion 460D arranged as shown in Figure 9. In this embodiment, the first portion 450D partially extends into the rear end of the insert 440D. The first portion 450D engages with the second portion 460D along a plane angled with respect to the loft plane 20. Furthermore, the first portion 450D is wider adjacent to the bottom of the insert 440D than adjacent to the top of the insert 440D. With respect to the golf club head 100, the first portion 450D is wider adjacent to the sole 107 than adjacent to the top rail 106. Within the cavity 120 of the golf club head 100, the first portion 450D is flush with the faceplate 155 from the top rail 106 to the sole 107. The second portion 460D does not engage with the faceplate 155. The second portion 460D partially fills a portion of the cavity 120 within the lower portion 109 of the body 110, and is fully positioned within that portion. The second portion 460C engages with the rear wall of the cavity 120. In some embodiments, the second portion 460D is formed from a high-density material. The golf club head 100 having the multi-material insert 440 provides improved feel and sound compared to a tour iron without an insert.

[0122] In yet another embodiment of the golf club head 100 having a multi-material insert (not shown), a second portion similar to the second portions 460, 460B, 460C, and 460D may be positioned primarily on the toe 101 of the golf club head 110. This provides a toe weight effect similar to that of the toe weight 161 described below. Embodiments having a second portion of the insert acting as a toe weight do not require an external toe weight. This eliminates the need for welding on the toe weight, resulting in improved aesthetics and simplified manufacturing. 2) Lightweight inserts

[0123] In some embodiments, a lightweight insert 240 is used instead of the insert 140. The lightweight insert 240 shown in Figures 10 to 13 has a similar shape and size to the insert 140. In other words, the lightweight insert 240 is configured to fit within the cavity 120 of the golf club head 100. The lightweight insert 240 is divided into an upper insert portion 250 (towards the top rail of the golf club head) and a lower insert portion 260 (towards the sole of the golf club head). The upper insert portion 250 can be separated from the lower insert portion 260 by an insert flex seam 245. The upper insert portion 250 may be solid. The lower insert portion 260 includes a recess 269 extending inward from the front surface 241 of the insert 240, giving the lower insert portion 260 a shell-out structure and reducing the insert weight.

[0124] The insert 240 includes a front surface 241, a rear surface 242, a perimeter 244, and an insert flex seam 245. The depth 243 of the insert 240 can be measured perpendicular to the front surface 241 in the front-rear direction. The front surface 241 is approximately parallel to the loft surface 20. In some embodiments, a portion of the rear surface 242 of the upper portion 250 of the insert is also approximately parallel to the loft surface 20. The lower portion 260 of the insert 240 has a greater depth 243 than the upper portion 250 of the insert. The upper portion 250 of the insert has a maximum depth less than the maximum depth of the lower portion 260 of the insert. In some embodiments, the upper portion 250 of the insert includes a uniform depth 243. The ratio of the depth 243 of the upper portion 250 of the insert to the depth 243 of the lower portion 260 of the insert can range from 1:3 to 1:10.

[0125] The upper portion 250 and lower portion 260 of the insert may each include lengths measured in the heel-toe (approximately horizontal) direction. The maximum upper portion length 248 of the insert can be greater than the maximum lower portion length 249 of the insert. In some embodiments, the shorter lower portion 260 is due to a toe weight occupying the space at the bottom of the golf club 100. Due to the toe weight in these embodiments, the lower portion of the insert cavity is shorter than the upper portion of the insert cavity.

[0126] The upper insert portion 250 is solid and bounded by the insert perimeter 244. The perimeter of the upper insert portion 250 comprises a top rail end 256, a toe end 251, and a heel end 252. The insert perimeter 244 can be configured to be flush with the wall of the cavity 120. In some embodiments, the toe end 251 has a bend to connect the longer upper insert portion 250 to the lower insert portion 260. The upper insert portion 250 forms part of the front surface 241 of the insert 240. The front surface 241 of the insert 240 is adjacent to and / or flat with the back of the faceplate of the clubhead, as shown in Figure 13.

[0127] The lower portion 260 of the insert includes a rear wall 263, a toe end wall 261, a heel end wall 262, a bottom wall 267, and a top wall 266, which together form a recess 269 (or cavity) within the insert 240. In some embodiments, the recess 269 opens only toward the face plate and not toward the other walls of the cavity 120. In some embodiments, one or more ribs 268 are present across the recess 269 to provide structural support to the insert 240. One or more ribs 268 can further provide structural support to the face. One or more ribs 268 can be oriented substantially perpendicular to the face plate when the insert 240 is installed in the club head body. One or more ribs 268 can be oriented substantially parallel to the top rail-sole direction. One or more ribs 268 can alter the feel or sound of the club when it impacts the golf ball. In some embodiments, at least one of the ribs 268 may have a rounded peg cutoff point (not shown) for accommodating the gate cutoff required for the die-casting method. In other embodiments, one or more ribs 268 are thick enough to cut off without requiring a rounded peg cutoff point.

[0128] One or more ribs 268 divide, separate, and / or subdivide the insert recess 269 into multiple sections or one or more smaller recesses. In some embodiments, one or more ribs 268 subdivide the lower portion 260 into two, three, four, five, six, seven, or eight sections or smaller recesses. The insert shown in Figures 10 and 11 is divided into five recesses.

[0129] The lower portion recess 269 reduces the material volume of the insert 240 and, therefore, reduces the weight of the insert 240. In some embodiments, the lightweight insert 240 can be 5 to 10 grams lighter than a similar insert lacking the lightweight recess. In some embodiments, the lightweight insert 240 can be 5 to 6 g, 5.5 to 6.5 g, 6 to 7 g, 6.5 to 7.5 g, 7 to 8 g, 7.5 to 8.5 g, 8 to 9 g, 8.5 to 9.5 g, or 9 to 10 g lighter than a similar insert lacking the lightweight recess. In some embodiments, the lightweight insert 240 can be about 5 g, 6 g, 7 g, 8 g, 9 g, or 10 g lighter than a similar insert lacking the lightweight recess. For example, in one comparison, the 7-iron lightweight insert weighs 7.1 grams less than a 7-iron solid aluminum insert such as the one described above for the golf club head 100.

[0130] A second embodiment of the lightweight insert 270 is shown in Figures 14 to 16. A modified example of this embodiment is shown in Figure 17. The lightweight insert 270 is similar to the lightweight insert 240. The lightweight insert 270 comprises a front surface 271, a rear surface, a perimeter 274, and an insert flex seam 275. The depth of the lightweight insert 270 can be similar to that of the lightweight insert 240. The upper portion 280 of the insert is defined above the insert flex seam 275, and the lower portion 290 of the insert is defined below the insert flex seam 275. The upper portion 280 of the insert comprises at least one connecting rail 284 that forms two or more openings 285 (or lightweight zones). The two or more openings 285 reduce the amount of material required to form the insert 270, and therefore also reduce the weight of the insert 270.

[0131] Within the upper portion 280 of the insert, the perimeter 274 forms a frame that supports at least one connecting rail 284. The perimeter 274 comprises a top rail 286, a heel end rail 282, and a toe end rail 281. The heel end rail 282 and the toe end rail 281 connect the top rail 286 to the lower portion 290 of the insert. The upper portion 280 of the insert can be formed integrally with the lower portion 290 of the insert by an insert flex seam 275. At least one connecting rail 284 extends from one end of the perimeter frame to the other end of the perimeter frame. At least one connecting rail 284 can extend in a direction inclined from the toe-heel direction, the top rail-sole direction, or any of the aforementioned directions. At least one connecting rail 284 may include one, two, three, four, five, six, seven, eight, nine, ten, or more connecting rails 284.

[0132] The upper portion 280 of the insert may include a subset of the connecting rails 284. In some embodiments, the subset of the connecting rails 284 may be positioned horizontally (generally in the toe-heel direction). In some embodiments, the subset of the connecting rails 284 may be positioned vertically (generally from the upper rail towards the sole direction). In some embodiments, the horizontally positioned subset of the connecting rails 284 intersects with the vertically positioned subset of the connecting rails 284.

[0133] The two or more openings 285 may include gaps, openings, recesses, holes, or areas without material. The two or more openings 285 are formed by the perimeter 274 and at least one connecting rail 284. In some embodiments, the two or more openings 285 are arranged in a grid pattern across the upper portion 280 of the insert. The portions of the rails 284 forming the two or more openings 285 may have rounded breakpoints at their intersections (not shown) which serve the same function as breakpoints (not shown) on the lower portion 290 of the insert. The pattern of the openings 285 helps to reduce the weight of the insert 270.

[0134] The lower portion 290 of the second lightweight insert 270 is similar to the lower portion 250 of the first lightweight insert 240. In the embodiment shown in Figure 14, the insert includes two ribs 298 that subdivide the lower portion recess 299 into three recesses. The three recesses may have unequal dimensions due to the position of the ribs 298 adjacent to any end of the recess 299. In the embodiment shown in Figure 16, the insert 270 includes five ribs 298 that subdivide the lower portion recess 299 into six recesses. In some embodiments (not shown), one or more gate cutoff points can be positioned coincidentally with one or more ribs 298.

[0135] The lower portion recess 299 and the upper portion opening 285 of the insert reduce the material volume of the insert 270, and therefore reduce the weight of the second lightweight insert 270. In some embodiments, the second lightweight insert 270 may be 5 to 12 grams lighter than a similar insert lacking the lightweight recess 299 and opening 285. In some embodiments, the lightweight insert 270 can be 5 to 6 g, 5.5 to 6.5 g, 6 to 7 g, 6.5 to 7.5 g, 7 to 8 g, 7.5 to 8.5 g, 8 to 9 g, 8.5 to 9.5 g, 9 to 10 g, 9.5 to 10.5 g, 10 to 11 g, 10.5 to 11.5 g, or 11 to 12 g lighter than a similar insert lacking the lightweight recess 299 and opening 285. In some embodiments, the lightweight insert 270 can be approximately 5g, 6g, 7g, 8g, 9g, 10g, 11g, or 12g lighter than a similar insert lacking the lightweight recesses 299 and openings 285. 3) Volume of the cavity filled with the insert of the golf club head

[0136] As described above, the insert 140 can completely or partially fill the cavity 120 of the golf club head 100. The insert 140 can fill between 80% and 100% of the volume of the cavity 120. In some embodiments, the insert 140 can fill between 80% and 85%, 85% and 90%, 90% and 95%, 95% and 100%, 80% and 90%, or 90% and 100% of the volume of the cavity 120. In contrast to conventional hollow-body irons, the golf club head 100 does not have a cavity that is completely filled with air. Rather, the cavity 120 is at least partially filled with the insert 140.

[0137] Referring back to Figures 6-9, in embodiments having a multi-material insert such as insert 440, the first portion 450 can fill most of the cavity 120. The second portion 460 can fill the remaining portion of the cavity 120. In some embodiments not shown, the first and second portions together only partially fill the cavity 120. In embodiments having a multi-material insert 440, the first portion 450 can fill 20% to 90% of the volume of the cavity 120. In some embodiments, the first portion 450 can fill 20% to 30%, 30% to 40%, 40% to 50%, 50% to 60%, 60% to 70%, 70% to 80%, or 80% to 90%. The second portion 460 can fill 10% to 80% of the volume of the cavity 120. In some embodiments, the second portion 460 can be filled with 10% to 20%, 20% to 30%, 30% to 40%, or 40% to 50%.

[0138] Since the first and second parts 450 and 460 are formed from different materials with different densities, as will be explained in detail below, the volume of the first and second parts 450 and 460 affects the total weight of the golf club head 100. In the design of a golf club head, many design parameters must be considered together. By forming the insert from multiple materials, the mass distribution can be controlled to increase perimeter weighting and lower the CG, leading to improved launch characteristics and higher ball speed. 4) Tape layer combined with the insert of the golf club head

[0139] In some embodiments, the tape layer 150 is positioned within the cavity 120, between the insert 140 and the strike face 111. As seen in Figure 19, the tape layer 150 is sandwiched between the insert 140 and the face plate 155. Embodiments of a golf club head having a multi-material insert, such as 440, may similarly include the tape layer 150 between the first portion 450 and the face plate 155, or between the first portion 450 of the insert 440 and the body 110. In a golf club head 100, the insert 140 fits within the body 110, the tape layer 150 can optionally be placed on top of the insert 140, and the face plate 155 covers the tape layer 150 and fills the recess 142 in the body 110.

[0140] In some embodiments (not shown), the second tape layer may be coplanar with the inner surface of the rear 103 of the body 110 within the cavity 120. The second tape layer may be sandwiched between the rear 103 of the body 110 and the insert 140. In some embodiments, the third tape layer may be coplanar with the bottom of the cavity 120. The third tape layer may be sandwiched between the sole 107 of the body 110 and the insert 140. The golf club head 100 may include one or more of the first tape layer 150, the second tape layer, and the third tape layer.

[0141] The tape layer 150, the second tape layer, or the third tape layer may include a material such as a very high bonding (VHB) tape. The VHB tape is compressible such that the original thickness of the tape layer 150 when first installed (measured perpendicular to the strike face 111) is greater than the thickness of the compression tape layer in the assembled golf club head 100. The second and third tape layers may also be compressible. The compressibility of one or more tape layers reduces the possibility of rattle caused by manufacturing tolerances between the body 110 and the insert 140. Furthermore, one or more tape layers can provide vibration damping and positively influence the feel and sound of the golf club head 100. C. Faceplate of a golf club head

[0142] A full golf club head 100 is formed by a combination of a body 110, an insert 120, and a faceplate 155. The body 110 has an opening for a cavity 120 at the front 104 of the golf club head 100. The opening is covered by the faceplate 155 so as to completely seal the cavity 120 and the insert 140. As shown in Figures 2 and 3, the cavity 120 and the insert 140 are not visible from the outside of the golf club head 100 when the insert 140 is positioned inside the cavity 120. By concealing the insert 140 within the golf club head 100, the appearance of the golf club head 100 can resemble that of a conventional tour iron.

[0143] Therefore, a portion of the front 104 of the body 110 and the faceplate 155 form the strike face 111. The strike face 111 can cover 70% to 95% of the surface area of ​​the front 104 of the golf club head 100. In some embodiments, the strike face 111 can cover 70% to 80%, 75% to 85%, 80% to 90%, or 85% to 95% of the front surface area of ​​the golf club head 100. Furthermore, the front surface of the strike face 111 may have one or more grooves. In some embodiments, the grooves extend beyond the edge of the faceplate 155 onto a portion of the body 110.

[0144] The faceplate 155 may include a different material from the body 110, as described below. In some embodiments, the material of the faceplate 155 is stronger than the material of the body 110. To take advantage of the benefits of the faceplate 155 material, the majority of the strike face 111 is formed by the faceplate 155. The faceplate 155 can form 50% to 95% of the surface area of ​​the front 104 of the golf club head 100. In some embodiments, the faceplate 155 can form 50% to 60%, 60% to 70%, 70% to 80%, 80% to 90%, or 85% to 95% of the surface area of ​​the strike face 111. Despite having different materials, the insert 140 firmly supports the faceplate 155, so both the faceplate 155 and body 110 portions of the strike face 111 give a solid feel. The body 110, insert 140, and faceplate 155 all contribute to the consistent feel and sound of the golf club head 100 when it impacts the golf ball on various areas of the faceplate 155. 1) Other faceplate features

[0145] The support provided to the faceplate 155 by the insert 140 allows a thin faceplate 155 to be used in the golf club head 100. As shown in Figure 5, the faceplate 155 of the golf club head 100 has a thickness 112. The thickness 112 can range from 0.030 inches to 0.100 inches. In some embodiments, the thickness 112 of the faceplate may be 0.030 inches, 0.040 inches, 0.050 inches, 0.060 inches, 0.070 inches, 0.080 inches, 0.090 inches, or 0.100 inches. The thickness 112 of the faceplate can be constant across the faceplate 155. In some embodiments, the thickness 112 of the faceplate can be varied in the heel-toe direction or the top rail-sole direction. In some embodiments, the thickness 112 of the faceplate can be varied radially from the center of the faceplate 155.

[0146] In other embodiments, the faceplate 155 may further include a variable thickness region. In some embodiments, the central region of the faceplate 155 may be thicker than the peripheral region of the faceplate 155. In some embodiments, the thickened central region may include an elliptical shape. The thickness of the faceplate 155 may taper from the center to the periphery. D. Other perimeter weighting of the golf club head (tip weight, toe weight)

[0147] The golf club head 100 may further comprise other perimeter-type weights in addition to the perimeter weighting and swing characteristics provided by the insert 140 and body 110. In some embodiments, the golf club head 100 may further comprise a tip weight 160. The tip weight 160 is a weight that fits into the joint between the hosel 105 and the golf club shaft. The tip weight 160 gives the club head 100 additional perimeter weighting. As shown in Figure 20, the tip weight 160 fits into the hosel 105 of the body 110. The tip weight 160 may be cylindrical, spherical, cubic, or any other suitable shape. The tip weight 160 may be positioned higher or lower within the hosel 105 than shown in Figure 20.

[0148] As shown in Figures 1 and 20, the body 110 of the golf club head 100 may further comprise a toe cavity 114. The toe cavity 114 is designed to accommodate a toe weight 161, which improves the perimeter weighting and swing characteristics of the golf club head 100. Figures 3 and 4 show the toe cavity 114 with the toe weight 161 attached. Figure 20 shows the toe weight 161 removed from the toe cavity 114. In some embodiments, the toe cavity 114 is located partially within the sole 107 and partially within the toe 101. In some embodiments, the toe cavity 114 is located entirely within the toe 101 of the golf club head 100 and adjacent to the sole 107. In some embodiments, the toe cavity 114 is located entirely within the sole 107 and adjacent to the toe 101. In some embodiments, the toe cavity 114 is located entirely within the toe 101. In some embodiments, the toe cavity 114 is located in the center of the toe 101 and is approximately halfway between the top rail 106 and the sole 107.

[0149] In some embodiments, the toe cavity 114 is visible from the rear view of the body 110 of the club head 100. In other embodiments, the toe cavity 114 is not visible from the rear view of the body 110. In some embodiments, the toe cavity 114 is visible from the toe side view of the body 110. In other embodiments, the toe cavity 114 is not visible from the toe side view of the body 110. In some embodiments, the toe cavity 114 is visible from the sole view of the body 110. In other embodiments, the toe cavity 114 is not visible from the sole view of the body 110. In the embodiments of Figures 1 to 13, the toe cavity 114 is visible from the rear view, the sole view, and the toe side view.

[0150] The toe weight 161 is formed to match the contour of the toe cavity 114 of the body 110. The outer wall of the toe weight 161 is designed to follow the curvature of the golf club head body 110. In some embodiments, the mass of the toe weight 161 may be 5% to 45% of the mass of the body 110. In some embodiments, the mass of the toe weight 161 may be 5% to 20%, 5% to 15%, 10% to 20%, 15% to 25%, 20% to 40%, 20% to 30%, 30% to 40%, or 35% to 45% of the mass of the body 110.

[0151] In some embodiments, the body 110 of the golf club head 100 may further include a toe screw weight port (not shown) in the toe 101. The golf club head 100 may further include a toe screw weight that fits into the screw weight port. In some embodiments, the toe screw weight may have a mass between 2 grams and 15 grams, as described below. To customize the golf club head 100 to suit a golfer's swing, a screw weight having one weight value can be replaced with different screw weights having different weight values.

[0152] In some embodiments, there are combinations of the weights described above, including an insert, a tow weight, a tip weight, and a tow screw weight. Other embodiments may include a multi-material insert combined with one or more of the tow weight, tip weight, and tow screw weight. Yet another embodiment may include a lightweight insert combined with one or more of the tow weight, tip weight, and tow screw weight. For example, some embodiments include a lightweight insert, a tip weight, and a tow screw weight. E. Materials

[0153] The materials forming the body 110, insert 140, and faceplate 155 affect the mass distribution of the golf club head 100. As a result, the MOI and CG of the golf club head 100 are also affected by the density of the materials. Furthermore, these materials provide the necessary strength and flexibility for the golf club head 100. The golf club head 100 comprises one or more, two or more, three or more, or four or more materials. In some embodiments, the materials may have a first density, a second density, a third density, a fourth density, a fifth density, or a sixth density.

[0154] In some embodiments, the faceplate 155 may include a first material of a first density. The body 110 may include a second material of a second density. The insert 140 may include a third material of a third density. The third density may be lower than the first density and / or the second density. In some embodiments, the faceplate 155 may be the same material (and therefore the same density) as the body 110. As described above, in some embodiments, the insert 440 may include two or more materials whose densities differ from each other and may be different from or the same as the material of the faceplate 155 and / or the body 110. 1) Body material

[0155] The body 110 may include materials such as steel, steel alloys, or any other suitable material. In some embodiments, the body 110 may include materials of different densities for the faceplate 155 and the insert 140. The material may be selected from the group consisting of steel-based materials or steel alloys. In some embodiments, the body material may be 8620 carbon steel containing iron, about 0.17–0.23 wt% carbon, 0.15–0.35 wt% silicon, 0.60–0.90 wt% manganese, 0.15–0.30 wt% molybdenum, 0.40–0.70 wt% nickel, 0.40–0.65 wt% chromium, 0.040 wt% phosphorus, and trace amounts of other elements. In some embodiments, the body material may be 300 grade steel containing iron, about 18-19 wt% nickel, 8.5-9.5 wt% cobalt, 4.6-5.2 wt% molybdenum, 0.5-0.8 wt% titanium, 0.05-0.15 wt% aluminum, and trace amounts of other elements. In some embodiments, the body material may be maraging steel containing iron, about 17-19 wt% nickel, 8-12.5 wt% cobalt, 3.0-5.2 wt% molybdenum, 0.15-1.6 wt% titanium, 0.05-0.15 wt% aluminum, and trace amounts of other elements. The density of the body material 110 may be in the range of 7.70-8.10 grams per cubic centimeter (hereinafter, "g / cc"). In some embodiments, the density of the body material may be 7.70 g / cc, 7.75 g / cc, 7.80 g / cc, 7.85 g / cc, 7.90 g / cc, 7.95 g / cc, 8.05 g / cc, or 8.10 g / cc. In one embodiment, the density of the body material is 7.85 g / cc. 2) Insert material

[0156] The insert 140 includes materials such as titanium, titanium alloys, aluminum, aluminum alloys, elastomers, polymer matrix composites, any other suitable low-density material, or any other suitable density material lower than the material of the body 110. The aluminum alloy may be a high-strength aluminum alloy or a composite aluminum alloy coated with a high-strength alloy. The polymer matrix composite may be a glass-filled elastomer, a stainless steel-filled elastomer, a tungsten-filled elastomer, a thermoplastic polyurethane (TPU), a thermoplastic elastomer (TPE), or any other elastomer matrix composite, a Kevlar® (aramid) fiber-reinforced polymer, a carbon fiber-reinforced polymer, or any combination of a suitable resin and a suitable reinforcing fiber. The polymer matrix composite may be an elastomer matrix composite. In some embodiments, the metallic material may be a steel-based material, a titanium-based material, an aluminum alloy, a titanium alloy, or any combination thereof. The steel-based material may be 17-4PH stainless steel, 431, 455, 475, C300, maraging steel, or other types of stainless steel. The aluminum alloy can be a high-strength aluminum alloy or a composite aluminum alloy coated with a high-strength alloy. The titanium alloy can be Ti-9S, Ti-6-4, or i-15-3-3-3. The titanium alloy can be an α-β titanium alloy.

[0157] The insert 140 may contain materials of different densities from the body 110 and the faceplate 155. Suitable materials for the insert 140 may include any material having a density lower than that of the body material. In some embodiments, particularly those with a metal insert material, the density of the insert 140 material can be in the range of 2.4 to 5.0 g / cc. In some embodiments, the density of the insert 140 material may be 2.4 g / cc, 2.5 g / cc, 2.6 g / cc, 2.7 g / cc, 2.8 g / cc, 2.9 g / cc, 3.0 g / cc, 3.1 g / cc, 3.2 g / cc, 3.3 g / cc, 3.4 g / cc, 3.5 g / cc, 3.6 g / cc, 3.7 g / cc, 3.8 g / cc, 3.9 g / cc, 4.0 g / cc, 4.1 g / cc, 4.2 g / cc, 4.3 g / cc, 4.4 g / cc, 4.5 g / cc, 4.6 g / cc, 4.7 g / cc, 4.8 g / cc, 4.9 g / cc / cc, or 5.0 g / cc. In one embodiment, the material of the insert 140 is aluminum, and the density of the insert 140 material is approximately 2.7 g / cc. In another embodiment, the material of the insert 140 is titanium, and the density of the material of the insert 140 is approximately 4.5 g / cc.

[0158] In some embodiments, particularly those having a polymer matrix composite material, the density of the insert 140 can be in the range of 1.0 to 12.0 g / cc. In preferred embodiments of the polymer matrix composite material, the density of the insert 140 can be in the range of 1.0 g / cc to 5.0 g / cc. In some embodiments, the density of the insert 140 can be 1.0 g / cc, 1.5 g / cc, 2.0 g / cc, 2.5 g / cc, 3.0 g / cc, 3.5 g / cc, 4.0 g / cc, 4.5 g / cc, or 5.0 g / cc. A lower density of the insert 140 makes the central part of the club head housing the insert 140 lighter, allowing weight to be redistributed around the club head. This redistributed weight increases the MOI.

[0159] In some embodiments of the golf club head 100, the insert 440 includes separate parts formed from different materials and densities. In some embodiments, the first and second parts 450, 460 of the insert 440 can each be formed from any of the materials described above for a single-material insert. In some embodiments, the first part 450 of the insert 140 is formed from an elastomer or polymer matrix composite material having a density of 0.8 g / cc to 1.4 g / cc, and the second part 460 of the insert 440 is formed from aluminum or an aluminum alloy having a density of 1.5 g / cc to 3.0 g / cc.

[0160] In some embodiments of the golf club head 100, the first portion 450 of the insert 440 may include any of the above-mentioned materials having a density of 1.0 g / cc to 12.0 g / cc. In some embodiments, the second portion 460 of the insert 440 may include a material having a higher density than the body material. In some embodiments, the second portion 460 of the insert 440 may include any of the materials described below for the toe weight 161 and may be a weight portion having a density of 14.0 to 19.6 g / cc. In some of these embodiments, the toe weight 161 is not necessary because the second portion 460 of the insert 140 serves a similar purpose.

[0161] The weight of insert 140 or 440 can range from 10 grams to 50 grams. In some embodiments, the weight of insert 140 may be 10 grams, 11 grams, 12 grams, 13 grams, 14 grams, 15 grams, 16 grams, 17 grams, 18 grams, 19 grams, 20 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, 35 grams, 36 grams, 37 grams, 38 grams, 39 grams, 40 grams, 41 grams, 42 grams, 43 grams, 44 grams, 45 grams, 46 grams, 47 grams, 48 ​​grams, 49 grams, or 50 grams. In embodiments of a multi-material insert in which the second portion 460 of the insert contains a material similar to the material of the tow weight 161 described below, the weight of the insert 140 or 440 can be in the range of 10 grams to 70 grams. In some embodiments, the weight of the multi-material insert 140 or 440 can be 10 grams to 20 grams, 20 grams to 30 grams, 30 grams to 40 grams, 40 grams to 50 grams, 50 grams to 60 grams, or 60 grams to 70 grams.

[0162] Furthermore, inserts 140 and 440 provide structural support to the strike face 111. In embodiments having a metal insert material, insert 140 or 440, or a portion of insert 140 or 440, may include a Rockwell B hardness of 30 HRB to 100 HRB. In some embodiments, insert 140 or 440, or a portion of insert 140 or 440, may have a Rockwell B hardness between 30 HRB to 40 HRB, 40 HRB to 50 HRB, 50 HRB to 60 HRB, 60 HRB to 70 HRB, 70 HRB to 80 HRB, 80 HRB to 90 HRB, and 90 HRB to 100 HRB. In other embodiments, insert 140 or a portion of insert 140 may have a Rockwell B hardness between 30 HRB to 40 HRB, 40 HRB to 50 HRB, 50 HRB to 60 HRB, 60 HRB to 70 HRB, 70 HRB to 80 HRB, 80 HRB to 90 HRB, and 90 HRB to 100 HRB. HRB, 3HRB, 32HRB, 33HRB, 34HRB, 35HRB, 36HRB, 37HRB, 38HRB, 39HRB, 40HRB, 41HRB, 42HRB, 43HRB, 44HRB, 4 5HRB, 46HRB, 47HRB, 48HRB, 49HRB, 50HRB, 51HRB, 52HRB, 53HRB, 54HRB, 55HRB, 56HRB, 57HRB, 58HRB, 59HRB It may have 60HRB, 61HRB, 62HRB, 63HRB, 64HRB, 65HRB, 66HRB, 67HRB, 68HRB, 69HRB, 70HRB, 71HRB, 72HRB, 73HRB, 74HRB, 75HRB, 76HRB, 77HRB, 78HRB, 79HRB, 80HRB, 81HRB, 82HRB, 83HRB, 84HRB, 85HRB, 86HRB, 87HRB, 88HRB, 89HRB, 90HRB, 91HRB, 92HRB, 93HRB, 94HRB, 95HRB, 96HRB, 97HRB, 98HRB, 99HRB, or 100HRB. In other embodiments having a metal insert, insert 140 or 440, or a portion of insert 140 or 440, may include a Rockwell C hardness between 30 HRC and 60 HRC. In some embodiments, insert 140 or 440 may have a hardness between 30 HRC and 40 HRC, 35 HRC and 45 HRC, 40 HRC and 50 HRC, 45 HRC and 50 HRC, or 50 HRC and 60 HRC.In other embodiments, the insert may have a Rockwell C hardness of 30HRC, 31HRC, 32HRC, 33HRC, 34HRC, 35HRC, 36HRC, 37HRC, 38HRC, 39HRC, 40HRC, 41HRC, 42HRC, 43HRC, 44HRC, 45HRC, 46HRC, 47HRC, 48HRC, 49HRC, 50HRC, 51HRC, 52HRC, 53HRC, 54HRC, 55HRC, 56HRC, 57HRC, 58HRC, 59HRC, or 60HRC. In embodiments including a titanium or titanium alloy insert 140 or 440, the insert hardness is 44HRC. 3) Faceplate material

[0163] The faceplate 155 can be formed from a faceplate material. In some embodiments, the faceplate material is the same material as the body 110 material. In other embodiments, the faceplate material is different from the body material. In some embodiments, the faceplate 155 may contain materials of different densities than the body 110 and the insert 140.

[0164] The faceplate material can be a steel-based material, a titanium-based material, a titanium alloy, or any combination thereof. The steel-based material may be carbon steel, 17-4PH stainless steel, 431, 455, 475, C300, maraging steel, or other types of stainless steel. The titanium alloy may be Ti-7S+(ST721), Ti-9S, Ti-6-4, Ti-15-3-3-3, or any other suitable titanium alloy. This titanium alloy may also be an α-β type titanium alloy. In embodiments where the faceplate 155 is a titanium-based material, an aluminum alloy, a titanium alloy, or any combination thereof, the density of the faceplate 155 material can be in the range of 2.6 to 8.7 g / cc. In some embodiments, the density of the faceplate material may be 2.6 g / cc, 2.8 g / cc, 3.0 g / cc, 3.2 g / cc, 3.4 g / cc, 3.6 g / cc, 3.8 g / cc, 4.0 g / cc, 4.2 g / cc, 4.4 g / cc, 4.6 g / cc, 4.8 g / cc, 5.0 g / cc, 5.2 g / cc, 5.4 g / cc, 5.6 g / cc, 5.8 g / cc, 6.0 g / cc, 6.2 g / cc, 6.4 g / cc, 6.6 g / cc, 6.8 g / cc, 7.0 g / cc, 7.2 g / cc, 7.4 g / cc, 7.6 g / cc, 7.8 g / cc, 8.0 g / cc, 8.2 g / cc, 8.4 g / cc, 8.6 g / cc, or 8.7 g / cc. In embodiments where the faceplate 155 is made of a steel-based material, the density of the faceplate material can be in the range of 7.7 g / cc to 8.1 g / cc. 4) Tip weight material

[0165] The tip weight 160 may include a different material from the body 110, faceplate 155, and insert 140 or 440. The tip weight 160 may include a high-density material such as tungsten or any other suitable metal or metal alloy material. The density of the tip material 160 can be in the range of 1.1 g / cc to 19.6 g / cc. In some embodiments, the density of the tip weight 160 material is 1.1g / cc, 1.5g / cc, 2.0g / cc, 2.5g / cc, 3.0g / cc, 3.5g / cc, 4.0g / cc, 4.5g / cc, 5.0g / cc, 5.5g / cc, 6.0g / cc, 6.5g / cc, 7.0g / cc, 7.5g / cc, 8.0g / cc, 8.5g / cc, 9.0g / cc, 9.5g / cc, 10.0g / cc, 10.5g / cc, 11.0g / cc, 11.5g / cc, 12.0g / cc, 12.5g / cc, Possible weights include 13.0g / cc, 13.5g / cc, 14.0g / cc, 14.5g / cc, 15.0g / cc, 15.5g / cc, 15.8g / cc, 16.0g / cc, 16.2g / cc, 16.4g / cc, 16.6g / cc, 16.8g / cc, 17.0g / cc, 17.2g / cc, 17.4g / cc, 17.6g / cc, 17.8g / cc, 18.0g / cc, 18.2g / cc, 18.4g / cc, 18.6g / cc, 18.8g / cc, 19.0g / cc, 19.2g / cc, 19.4g / cc, or 19.6g / cc. The weight of tip weight 160 can range from 0 grams to 18 grams. In some embodiments, the weight of the tip weight 160 can be 0 grams (in embodiments without a tip weight), 1 gram, 2 grams, 3 grams, 4 grams, 5 grams, 6 grams, 7 grams, 8 grams, 9 grams, 10 grams, 11 grams, 12 grams, 13 grams, 14 grams, 15 grams, 16 grams, 17 grams, or 18 grams. In most embodiments, the tip weight 160 is in the range of 0 to 9 grams. 5) Tow weight material

[0166] The tow weight 161 may include a different material from the body 110, faceplate 155, tip weight 160, and insert 140 or 440. The tow weight 161 may include a high-density material such as tungsten or any other suitable metal or metal alloy material. The density of the tow weight 161 material may range from 14.0 to 19.6 g / cc. In some embodiments, the density of the tow weight 161 material may be 14.0 g / cc, 14.2 g / cc, 14.4 g / cc, 14.6 g / cc, 14.8 g / cc, 15.0 g / cc, 15.2 g / cc, 15.4 g / cc, 15.6 g / cc, 15.8 g / cc, 16.0 g / cc, 16.2 g / cc, 16.4 g / cc, 16. The tow weight may be 6g / cc, 16.8g / cc, 17.0g / cc, 17.2g / cc, 17.4g / cc, 17.6g / cc, 17.8g / cc, 18.0g / cc, 18.2g / cc, 18.4g / cc, 18.6g / cc, 18.8g / cc, 19.0g / cc, 19.2g / cc, 19.4g / cc, or 19.6g / cc. The weight of the tow weight 161 can range from 10 grams to 40 grams. In some embodiments, the weight of the tow weight 161 may be 10 grams, 11 grams, 12 grams, 13 grams, 14 grams, 15 grams, 16 grams, 17 grams, 18 grams, 19 grams, 20 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, 35 grams, 36 grams, 37 grams, 38 grams, 39 grams, or 40 grams. In some embodiments, the weight of the tow weight 161 may range from 12 grams to 26.5 grams. 6) Tow screw weight material

[0167] The tow screw weight (swing weight) may contain any high-density material similar to that of the tip weight or tow weight. The density of the tow screw material may be the same as that of the tip weight material. The weight of the tow screw weight may be the same as that of the tip weight as described above. II. Golf club head with rear opening

[0168] A golf club head 600 is described herein. Similar to the golf club head 100, the golf club head 600 may be a tour-style golf club head having the forgiveness described above. The golf club head 100 may include a body 610 having a cavity 620 that houses an insert 640. The golf club head 600 comprises a face plate 655, a body 610, and an insert 640. The body 610 includes an upper portion 608, a lower portion 609, a sole 607, a rear 603, and a top rail 606. The rear 603 may further comprise a flex seam 630. The flex seam 630 is the boundary between the upper portion 608 and the lower portion 609 of the golf club head 600. The face plate 655 and part of the body define the strike face 611 (hitting surface) of the golf club head. The faceplate 655, sole 607, rear 603, and top rail 606 surround the cavity 620.

[0169] Figures 21-32 show a golf club head 600 similar to the golf club head 100. The golf club head 600 comprises a body 610 forming a cavity 620, a face plate 655, a rear opening 680, and a low-density insert 640 within the cavity. The body 610 includes an upper portion 608, a lower portion 609, a sole 607, a rear 603, and a top rail 606. The rear 603 may further comprise a flex seam 630, which is the boundary between the upper portion 608 and the lower portion 609 of the golf club head 600. The face plate 655 and a portion of the body 610 define the strike face 611 (hitting surface) of the golf club head 600.

[0170] Body 610 is similar to body 110. The faceplate 655, sole 607, and rear 603 form a cavity 620 with a rear opening 680 in the upper portion 608 of the golf club head 600. The rear opening 680 of body 610 partially exposes the cavity 620. After assembly, the insert 640 is visible through the opening 680 in the rear 603. Body 610 further includes a recess 642 in the front 604 of body 610 for receiving the faceplate 655, similar to the recess 142 described above for club head 100.

[0171] The insert 640 is housed within the cavity 620. The insert 640 may include a non-metallic or polymer-based material. The insert material can be injected into the cavity 620 of the golf club head 600 through the rear opening 680 to form the insert 640 within the cavity 620. In other embodiments, the insert 640 may include a metallic material similar to the insert 140 described above. The faceplate 655 seals the cavity 620 at the front 604 of the golf club head 600. The faceplate 655 and the front 604 of the body 610 together define the strike face 611.

[0172] The Golf Club Head 600 is a tour iron club head with a volume of 1.8 cubic inches to 2.7 cubic inches (30 cubic centimeters (cc) to 45 cc). The body 610 of the Golf Club Head 600 can be cast or forged from metal material.

[0173] The insert 640 contains a low-density material and fills the cavity 620 formed by the body 610 of the golf club head 600. Reducing the central mass of the golf club head 600 allows for the concentration of extra mass around it, increasing the moment of inertia value of the golf club head 600. As described above, the golf club head 600 includes a lower portion 609 and an upper portion 608. The lower portion 609 has a greater depth than the upper portion 608. This gives the lower portion 609 more mass concentrated around the heel 602, toe 601, and sole 607. Reducing the mass of the body 610 results in a lower CG 60, which increases the launch angle, reduces spin, and increases ball speed. As described above, there is a need in the art for an iron that combines a relatively high moment of inertia from periphery weighting with a low CG from low mass positioning, which is characteristic of a tour iron. In some embodiments, a tip weight 660 located within the hosel and / or a toe weight 661 located within the toe cavity 614 of the body 610 provide additional perimeter weighting. In some embodiments, a toe screw weight 662 (swing weight) located within the toe screw weight cavity 663 (swing weight cavity) of the body 610 provides additional perimeter weighting.

[0174] Golf club head 600 can be described using the same reference planes and axes as golf club head 100. The definitions of the ground plane 10, loft plane 20, center plane 45, center point 80, lead edge axis 35, lead edge plane, x-axis 30, y-axis 40, z-axis 50, and hosel axis 70 are the same for golf club head 600 as they are for golf club head 100. A. Part of a golf club head

[0175] As described and illustrated above in Figures 22 and 23, the body 610 includes at least an upper portion 608, a lower portion 609, a sole 607, a top rail 606, a rear 603, a front 604, a toe 601, a heel 602, and a hosel 605, which are similar to the upper portion 108, lower portion 109, sole 107, top rail 106, rear 103, front 104, toe 101, heel 102, and hosel 605 of the golf club head 100, respectively. In some embodiments, a face plate 655 is welded or swaged onto the front opening of the body 610.

[0176] Body 610 features a flex seam 630 and a rear contour similar to that of the golf club head 100. The heights of the upper and lower sections 608, 609, the depths of the upper and lower sections 608, 609, and the thickness of the rear 603 are similar to those of the upper and lower sections 108, 109, the depths of the upper and lower sections 108, 109, and the thickness of the rear 103 of the golf club head 100.

[0177] Body 610 further includes an opening wall 682 at the rear of body 610. The opening wall 682 defines a rear opening 680. The rear opening 680 of body 610 is located in the upper portion 608 of the club head 600, above the flex seam 630. The uniform depth of the upper portion 608, which is linked to the position of the rear opening 680 within the upper portion 608, allows for a flat surface surrounding the opening 680. On all sides of the opening wall 682 of body 610 (rear opening 680), the outer surface of the golf club head 600 is flat. This flat surface is necessary to provide a seal around the rear opening 680 while the insert material is injected into the cavity 620 during manufacturing, as will be further described below.

[0178] To identify the size of the rear opening 680, a projection area of ​​the rear 603 (excluding the hosel 605 or sole 607) parallel to the loft plane 20 can be taken. The projection area of ​​the rear 603 can be compared to the projection area enclosed by the opening wall 682. The opening wall 682 encloses an area between 25% and 50% of the projection area of ​​the rear 603 of the club head 600 (covered by the rear opening). In some embodiments, the opening wall 682 can enclose percentages of the rear area of ​​25%-30%, 25%-35%, 30%-40%, 35%-45%, 40%-50%, or 45%-50%. In other embodiments, the opening wall 682 can surround a percentage of the rear area of ​​25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or 50%.

[0179] In some embodiments, the insert 640 is visible through the rear opening 680. In some embodiments, 10% to 60% of the insert is visible through the rear opening 680. In some embodiments, 10% to 20%, 15% to 25%, 20% to 30%, 25% to 35%, 30% to 40%, 35% to 45%, 40% to 50%, 45% to 55%, or 50% to 60% of the insert 640 is visible through the rear opening 680. In some embodiments, a badge (not shown) is placed over the rear opening 680. In these embodiments, the badge can cover 10% to 60% of the insert. In some embodiments, the badge can cover 10% to 20%, 15% to 25%, 20% to 30%, 25% to 35%, 30% to 40%, 35% to 45%, 40% to 50%, 45% to 55%, or 50% to 60% of the insert 640.

[0180] The rear 603, with its opening wall 682 defining the rear opening 680, contributes to the low mass of the upper portion 608. Filling the rear opening 680 with a material having a lower density than the body material results in a golf club head 600 with a low CG. Reducing the mass of the upper portion 608 lowers the CG and allows for weight distribution to the periphery, improving the forgiveness of the golf club head. Various design parameters can contribute to the low mass of the upper portion. As described above for the golf club head 100, maintaining a uniform upper portion depth also contributes to the low mass of the upper portion 608.

[0181] Since the material used to form the body 610 generally has a higher density than the material of the insert 640, the mass of the upper portion 608 can be reduced by replacing the portion of the rear body 610 surrounded by the opening wall 682 with the insert material. Compared to a similar golf club head with a solid rear that is entirely formed from the body material, the golf club head 600 has a lower CG due to the rear opening 680. The projected area percentage of the opening 680 and the density of the insert material can reduce the mass of the upper portion 608 by between 1 gram and 17 grams. In some embodiments, the mass of the upper portion 608 can be reduced by 1 gram to 3 grams, 3 grams to 5 grams, 5 grams to 7 grams, 7 grams to 9 grams, 9 grams to 11 grams, 11 grams to 13 grams, 13 grams to 15 grams, or 15 grams to 17 grams. In other embodiments, the mass of the upper portion 608 can be reduced by 1 gram, 2 grams, 3 grams, 4 grams, 5 grams, 6 grams, 7 grams, 8 grams, 9 grams, 10 grams, 11 grams, 12 grams, 13 grams, 14 grams, 15 grams, 16 grams, or 17 grams. This reduction in the mass of the upper portion 108 of the body 610 helps to lower the CG, improve launch and spin characteristics, and increase ball speed.

[0182] The body 610 of the golf club head 600 defines a cavity 620. The cavity 620 of the body 610 can be configured to accept a low-density insert 640 that increases the MOI of the golf club head 600 without sacrificing the desired solid feel of a tour iron. The area, volume, and contour of the cavity 620 are similar to those of the cavity 120. Adjacent to the front opening of the cavity 620, the body 610 includes an inner rim 627 similar to the inner rim 127 of the golf club head 100. The sole 607, top rail 606, rear 603, inner rim 627, and faceplate 655 define the cavity 620. The cavity 620 connects to the rear opening 680 of the body 610 and is sealed at the front 604 of the body 610 by the faceplate 655. Cavity 620 is exposed through the rear opening 680 of the rear 603 of the body 610. B. Inserts in golf club heads

[0183] The insert 640 is configured to fit within the cavity 620 of the body 610 in order to increase the MOI and maintain the solid feel of the golf club head 600. The volume of the insert 640 can be similar to that of the insert 140 of the golf club head 100. In some embodiments, the insert 640 extends beyond the cavity 620 into the rear opening 680, so the volume of the insert 640 can be larger than the volume of the cavity 620.

[0184] The insert 640 either completely or partially fills the cavity 620, as described above for the golf club head 100. The insert 640 can fill a percentage of the volume of the cavity 620, as described for the golf club head 100. In some embodiments, as shown in Figure 26, the insert 640 can fill 100% of the cavity 620 and extend into the rear opening 680. As shown in Figure 27, the insert 640 can fill 60% of the cavity 620. As shown in Figure 28, the insert 640 can fill 70% of the cavity 620 and partially extend into the rear opening 680. As shown in Figure 29, the insert 640 can fill 80% of the cavity 620 and partially extend into the rear opening 680. As shown in Figure 30, the insert 640 can fill 90% of the cavity 620 and partially extend into the rear opening 680. In some embodiments (not shown), the insert 640 can fill only the cavity 620 and not the rear opening 680. In some embodiments, the insert 640 can contain a metallic material and fill only the cavity 620. In this exemplary embodiment (not shown), the opening wall 682 of the body 610 can be tapered to fuse into the insert 640, providing a less defined boundary for the rear opening 680.

[0185] In some embodiments, the insert 640 is formed before being inserted into the golf club head 600, as described below. In other embodiments, the insert 640 is formed within the cavity 620 of the body 610. In these embodiments, the opening wall 682 forming the rear opening 680 can function as a port for the insert 640 to be injected into the cavity 620, as described later. C. Body cavity

[0186] The front surface of the body cavity 620 can be sealed by a faceplate 655. The faceplate 655 and strike face 611 can be similar to the faceplate 155 and strike face 611 of the golf club head 100. However, in some embodiments, the strike face 611 can be formed integrally with the body 610. The strike face 611 has a thickness 612 similar to the thickness 112 of the strike face 111 of the golf club head 100.

[0187] The body 610 is partially or completely filled by an insert 640, which is fixed within the golf club head 600 by a face plate 655. In some embodiments, the cavity 620 further accommodates a tape layer 150 and / or adhesive, similar to the tape layer 150 and / or adhesive of the golf club head 100.

[0188] The cavity 620 can vary in dimensions in the toe-heel direction. In some embodiments, the rear 603 of the golf club head 600 includes a thickened area, as shown in Figure 31. This thickened area of ​​the body 610 can provide additional weight to a particular area of ​​the golf club head 600. Furthermore, as shown in Figures 31 and 32, weld beads 648, projections, recesses, or seams (hereinafter collectively referred to as “weld beads”) can be inserted into the cavity 620. Weld beads can be positioned along the periphery of the faceplate 655. In some embodiments, the weld beads 648 are generated during the manufacturing step of welding the faceplate 655 to the body 610 to form the strike face 611. As illustrated in Figures 31 and 32, the weld beads 648 can extend rearward from the back of the strike face 611. In some embodiments, the weld bead 648 not only structurally bonds the strike plate 655 to the body 610 but also helps to hold the insert 640 within the cavity 620. The weld bead 648 may be of a locking shape. The weld bead 648 can separate a periphery of the cavity 620 that has a front-to-rear depth greater than the front-to-rear depth of the cavity in the weld bead. This change in the depth of the cavity 620 caused by the weld bead 648 allows the insert to have a thicker or deeper (front-to-rear) dimension adjacent to the top rail 606 and sole 607 than in the weld bead 648, preventing the insert from sliding, moving, or being removed in the top-to-rear direction. F. Other circumferential weighting of the golf club head (tip weight, toe weight)

[0189] In some embodiments, the golf club head 600 further comprises a shaft tip weight 660 similar to the shaft tip weight 160 of the golf club head 100. In some embodiments, the body 610 further comprises a toe cavity 614 that accommodates a toe weight 661, similar to the toe cavity 114 and toe weight 161 of the golf club head 100.

[0190] As shown in Figures 24 and 25, the golf club head 600 may further include a toe screw cavity 663 and a toe screw weight 662 for adjusting the swing weight. The toe screw weight 662 may contain a weight of 2 grams to 15 grams, as described for the additional toe screw weight of the golf club head 100. The toe screw weight 662 can be removed and replaced with different screw weights 662 having different weight values ​​to customize the golf club head 600 to suit the golfer's swing.

[0191] As shown in Figures 33 and 34, the toe screw weight 662 of the golf club head 600 may include a head 690 and a shaft 695. The head 690 may include an outer surface 691, an inner surface 692, and an outer rim 694. The shaft 695 protrudes outward from the inner surface 692 of the head. The inner surface 692 of the head further includes a slot 396 extending radially outward from the shaft 695. The slot 693 may allow air to be expelled from the body cavity 620 during manufacturing. The slot 693 may be oriented roughly perpendicular to the outer rim 694 of the toe screw weight head 690 (or perpendicular to the plane tangent to the outer rim 694 of the toe screw weight head 690). Slot 693 can be spaced radially apart from each other at angles of approximately 180 degrees, 120 degrees, 90 degrees, 72 degrees, 60 degrees, 51 degrees, 45 degrees, between 10 and 45 degrees, between 45 and 90 degrees, between 90 and 180 degrees, between 180 and 270 degrees, or between 270 and 360 degrees.

[0192] The tow screw weight 662 may have one, two, three, four, five, six, seven, eight, or more slots 693. Each slot 693 may have a depth. The depth of each slot 693 may range from 0.002 inches to 0.010 inches. In some embodiments, the depth of each slot 693 may range from 0.002 inches to 0.004 inches, 0.003 inches to 0.005 inches, 0.004 inches to 0.006 inches, 0.005 inches to 0.007 inches, 0.006 inches to 0.008 inches, 0.007 inches to 0.009 inches, or 0.008 inches to 0.010 inches. The depth of the slots 693 may affect the speed at which air can flow through the slots 693. The slot 693 cut or formed in the head of the tow screw weight 662 prevents the tow screw weight 662 from sealing the tow screw cavity 663 when the tow screw weight 662 is accepted into the tow screw cavity 663. The slot 693 allows air to move in and out of the body cavity 620 even when the tow screw weight 662 is installed in the tow screw cavity 663. The slot 693 can also allow air to be expelled from the body cavity 620 while the insert material 140 is injected into the body cavity 620 during manufacturing. In embodiments with a low viscosity insert, the depth of the slot 693 can also prevent the insert material from flowing or escaping through the slot 693 during manufacturing.

[0193] The tow screw weight shaft 695 may comprise a neck 696, a threaded portion 698, and a non-threaded portion 699. The neck 696 may be located between the threaded portion 698 and the tow screw weight head 690 of the shaft 695. The neck 696 may have a diameter 697 smaller than the diameter of the corresponding area of ​​the tow screw cavity 663. The neck diameter 697 may be 0.005 inches to 0.015 inches smaller than the diameter of the corresponding area of ​​the tow screw cavity 663. In some embodiments, the corresponding area of ​​the tow screw cavity 663 has a diameter that is 0.005 inches to 0.008 inches, 0.007 inches to 0.010 inches, 0.009 inches to 0.012 inches, or 0.011 inches to 0.015 inches smaller than the neck diameter 697.

[0194] The threaded portion 698 of the shaft 695 can be positioned adjacent to the neck 696 of the shaft 695, near the tow screw weight head 690. The threaded portion 698 can contain 1 to 10 threads. In some embodiments, the threaded portion 698 can be between 1 / 4 and 1 / 2 of the length of the shaft 695. In other embodiments, the threaded portion 698 is about 1 / 3 of the length of the shaft 695. The purpose of the threaded shaft portion 698 is to engage with the corresponding threads on the tow screw cavity 663 to hold the tow screw weight 662 on the golf club head body 610. In addition, the threaded shaft portion 698 can be offset from the threads of the tow screw cavity by tolerance or gap. In some embodiments, tolerance gaps can provide sufficient space for air to pass between the tow screw weight 662 and the tow screw cavity 663 during the injection molding process that forms the insert. Furthermore, the tolerance gap between the threads of the tow screw weight and the threads of the tow screw cavity can prevent the insert material from flowing out of the cavity 620 during the manufacturing process. Despite the insert material coming into contact with the threaded portion 698 of the tow screw weight, the tow screw weight may remain removable due to the different material properties of the metal tow screw weight 662 and the insert 640.

[0195] Beyond the threaded portion 698, the remaining unthreaded portion 699 of the shaft 695 can extend at least partially into the toe screw cavity 663. The unthreaded shaft portion 699 may have a diameter smaller than the diameter of the corresponding portion of the toe screw cavity 663 configured to receive the unthreaded shaft portion 699. In some embodiments, the unthreaded shaft portion 699 can extend at least partially into the body cavity 620 of the club head 600. The purpose of the unthreaded shaft portion 699 is to allow weight to be added to the toe screw weight 662.

[0196] The tow screw weight shaft is constructed with tolerances that allow air to pass between the tow screw weight 662 and the corresponding tow screw cavity 663. In embodiments of the golf club head 600 having an injection-molded insert, the threaded portion of the shaft of the tow screw weight 662 prevents the insert material from flowing out of the body cavity during the manufacturing process, as described below. The slot is also sized to prevent the insert material from flowing out if it passes through the threaded portion of the tow screw weight 662.

[0197] The aforementioned slots, shaft diameter, and shaft threading of the tow screw weight 662 allow air to be vented through the tow screw weight 662, enabling the insert 620 to be injection molded without leaving flash (excess, undesirable material between metal parts of the mold interface surface, including within the vents). By exhausting air through the tow screw weight 662, as described below, the need for post-injection molding processes to clean the flash can be eliminated or reduced.

[0198] While the aforementioned perimeter weighting contributes to the perimeter weighting and high MOI of the club head, the perimeter body also plays a crucial role in perimeter weighting. Molding the perimeter portion of the body to contain more material can alter the weight and increase the MOI. D. Material of the club head body with a rear opening

[0199] The materials used to form the components of the golf club head 600 may be the same as the materials used to form the components of the golf club head 100, as described above. In particular, the body 610 may include the same body material as the body 110. The insert 640 may include the same insert material as the insert 140. The face plate 655 may include the same face plate material as the face plate 155. The toe weight 661, tip weight 660, and toe screw weight 662 may include the same toe weight 161, tip weight 160, and toe screw weight materials as the golf club head 100. III. Golf club heads with rear and front openings

[0200] Here, we describe the golf club head 300. Similar to the golf club heads 100 and 600, the golf club head 300 can be a tour-style golf club head with the forgiveness described above. Referring to Figures 35-38, the golf club head 300 may include a body 310 having a cavity 320 that houses an insert 340. Unlike the golf club heads 100 and 600, the golf club head 300 does not include a metal faceplate. The golf club head comprises a body 310 and an insert 340. The insert 340 is exposed at the front of the golf club head 300 and functions as a strike face (also called the "hitting surface") 311 for impacting the golf ball. The strike face 311 formed by the insert may have grooves. The strike face 311 may be coplanar with the front 304 of the body 310. The insert material of the strike face 311 may be configured to impact the golf ball. In some embodiments, the insert material strike face 311 can be formed from a polymer or composite material.

[0201] The body 310 includes an upper portion 308, a lower portion 309, a sole 307, a rear portion 303, a front portion 304, a toe area 301, a heel area 302, and a top rail 306. The rear portion 303 may further include a flex seam 330, which is the boundary between the upper portion 308 and the lower portion 309 of the golf club head 300. The sole 307, rear portion 303, and top rail 306 surround the cavity 320.

[0202] Figures 35–52 show several variations of the golf club head 300, which may be similar to the golf club heads 100 and 600. The golf club head 300 includes a body 310 that forms a cavity 320. The body 310 defines a rear opening 380 in its upper portion 308. The rear opening 380 exposes the cavity 320 at least partially. The body 310 further defines a front opening or recess 342. The front opening exposes (and / or connects) the cavity 320 at least partially. The front opening can be sized to cover a large portion of the strike face 311. After assembly, the insert 340 is visible through the rear opening 380 and the front opening 342.

[0203] The insert 340 is housed within the cavity 320. The insert 340 may include a non-metallic or polymer-based material. The insert 340 may include a low-density material. The insert material can be injected into the cavity 320 of the golf club head 300 through a rear opening 380 or a front opening 342 to form the insert 340 within the cavity 320. In other embodiments, the insert 340 includes a metallic material similar to that of the insert 140 described above. The insert 340 extends completely from the front 304 to the rear 303 of the golf club head 300.

[0204] In some embodiments, the golf club head 300 can be a tour or game-improvement iron club head and may have a volume of 1.8 cubic inches to 2.7 cubic inches (30 cubic centimeters (cc) to 45 cc). The body 310 of the golf club head 300 can be cast or forged from a metal material. In some embodiments, the insert 340 can be injection molded into the cavity 320 of the body 310. The insert 340 can be formed from a polymer or composite material. In some embodiments, the golf club head 300 can be a game-improvement iron having a larger volume than a tour iron. In some embodiments, the golf club head 300 may be a game-improvement iron having a blade length greater than 2.7 inches and / or 2.7 inches to 2.9 inches, or 2.8 inches to 2.9 inches.

[0205] Insert 340 contains a low-density material similar to that of the inserts in club heads 100 and 600. However, the insert 340 of the golf club head 300 can further increase the moment of inertia of the golf club head compared to the inserts in golf club heads 100 and 600 because it can replace the higher-density body material. In other words, the body 310 of the golf club head 300 contains less material than the bodies of golf club heads 100 and 600. Specifically, the golf club head 300 lacks a metal faceplate. Instead, the low-density insert 340 of the golf club head 300 forms the strike face 311 of the golf club head 300. Because a high-density faceplate is not used in the golf club head 300, the mass of the body 310 can be significantly reduced. The saved weight can be redistributed as any built-in weight or removable weight. By distributing the saved weight around the club head 300, the moment of inertia can be increased. CG can also be lowered in the same way as described for the 100 and 600 golf club heads.

[0206] In some embodiments, a tip weight 360 located within the hosel and / or a tow weight 361 located within the tow cavity 314 of the body 310 provide additional perimeter weighting. The tip and / or tow weights may have a density greater than that of the body material and greater than that of the insert. The body material may, but is not limited to, steel-based materials or steel alloys. The body material may have a density of 7.70 to 8.10 g / cc. The insert material may, but is not limited to, glass-filled elastomers, stainless steel-filled elastomers, tungsten-filled elastomers, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or any other elastomer matrix composite, Kevlar® (aramid) fiber-reinforced polymer, carbon fiber-reinforced polymer, or any suitable polymer matrix composite (in other words, any combination of suitable resin and suitable reinforcing fibers). In some embodiments, the insert material may have a density of 0.8 g / cc to 1.4 g / cc. In other embodiments, the insert material may have a density of 1.0 g / cc to 12.0 g / cc. The metal body material and the polymer or composite insert material may be the same as those described above for the body and insert of the golf club head 600.

[0207] In some embodiments, a toe screw weight 362 (swing weight) positioned within a toe screw weight cavity 363 (swing weight cavity) of the body 310 provides additional perimeter weighting. In some embodiments, the internal contour of the cavity 320 is modified to leave body material in locations where additional weight is required. In some embodiments, the rear 303 of the club head 300 is provided with one or more weight ports for receiving removable weights. In some embodiments, the rear 303 of the club head can be configured to receive tungsten weights in the low toe region 301 or the low heel region 302. These weights can be co-molded, swaged, or welded to the body.

[0208] Golf club head 300 can be described using the same reference plane and axes as golf club head 100. The definitions of the ground plane 10, loft plane 20, center plane 45, center point 80, lead edge axis 35, lead edge plane, x-axis 30, y-axis 40, z-axis 50, and hosel axis 70 are the same for golf club head 300 as they are for golf club head 100. E. Part of a golf club head

[0209] As described above and shown in Figures 28-31, the body 310 includes at least an upper portion 308, a lower portion 309, a sole 307, a top rail 306, a rear 303, a front 304, a toe 301, a heel 302, and a hosel 305, each being similar to the upper portion 108, lower portion 109, sole 107, top rail 106, rear 103, front 104, toe 101, heel 102, and hosel 105 of the golf club head 100.

[0210] Body 310 has a flex seam 330 and a rear contour similar to the flex seam 130 and rear contour of the golf club head 100. The heights of the upper and lower sections 308, 309, the depths of the upper and lower sections 308, 309, and the thickness of the rear 303 are similar to the heights of the upper and lower sections 108, 109, the depths of the upper and lower sections 108, 109, and the thickness of the rear 103 of the golf club head 100.

[0211] Body 310 further comprises an opening wall 382 similar to the opening wall 682 of golf club head 600. The opening wall 382 defines a rear opening 380. The position, size, and dimensions (including the projected area) of the rear opening 380 can be similar to those of the rear opening 380 of golf club head 300. The CG position and weight of golf club head 300 can be affected in a similar manner to those described for golf club heads 100 and 600. However, golf club head 300 can have more extreme changes in CG position compared to similar clubs lacking the low-density insert, because golf club head 300 has additional arbitrary weight due to the removal of the metal strike plate. By replacing the metal strike plate with part of the insert 340, a large amount of weight that can be redistributed around the periphery of golf club head 300 is released, lowering the CG and / or increasing the moment of inertia.

[0212] The golf club head 300 can be compared to a similar golf club head having a metal body including a metal face plate (corresponding to the front opening 642 of the golf club head 300) and a metal upper rear wall portion (covering the area corresponding to the rear opening 380 of the golf club head 300). By replacing the metal body material that would otherwise have occupied the rear opening 380 and the front opening 342, the insert 340 can reduce the mass of the upper portion 308 by 1 to 70 grams. In some embodiments, the mass of the upper portion 308 can be reduced by 1 to 10 grams, 10 to 20 grams, 20 to 30 grams, 30 to 40 grams, 40 to 50 grams, 50 to 60 grams, or 60 to 70 grams. This reduction in the mass of the upper portion 308 of the body 310 helps to lower the CG, improve launch and spin characteristics, and increase ball speed.

[0213] As shown in Figure 36, the body 310 of the golf club head 300 defines a cavity 320. The cavity 320 of the body 310 can be configured to accept a low-density insert 340. The area, volume, and contour of the cavity 320 are similar to those of the cavity 120. The sole 307, top rail 306, and rear 303 define the cavity 320. The cavity 320 is exposed through the front opening 342 and rear opening 380 of the body 310. F. Golf club head insert

[0214] The insert 340 is configured to fit within the cavity 320 of the body 310 in order to increase the MOI and maintain the solid feel of the golf club head 300. Since the insert 340 forms a strike face as well as the internal central insert, the volume of the insert 340 can be larger than the volume of the insert 140 of the golf club head 100. In some embodiments, the insert 340 completely fills the cavity 320, having the same volume as the cavity 320. As shown in Figure 37, the insert 640 can be formed within the cavity 320 of the body 310. The rear opening 380 can function as a port for injecting the insert 340 into the cavity 320, as will be described later. G. Body cavity

[0215] As shown in Figures 35 and 30, the body 310 of the golf club head 300 can define the edge or wall of the cavity 320. As shown in Figures 39 to 45, in some embodiments, the body 310 further comprises one or more fixing features 345, locking mechanisms, arches, tubes, or other mechanisms that intrude into the cavity space (hereinafter collectively referred to as “fixing features”). The fixing features 345 can be located internally. The fixing features 345 are not visible from the outside in the finished golf club head 300. The fixing features 345 can geometrically fix the insert 340 within the cavity 320. The material of the insert 340 can flow around one or more fixing features 345 and then harden around them so that the insert 340 is permanently fixed within the cavity 320. The fixing features 345 can also add weight to a specific area of ​​the golf club head 300.

[0216] The body 310 may have 1 to 6 fixed features 345. In some embodiments, the body 310 has one, two, three, four, five, or six fixed features 345. One or more fixed features 354 may extend from one or more of the rear 303, sole 307, toe region 301, or heel region 302. In some embodiments, one or more fixed features 345 extend between the rear 303 and the sole 307. In some embodiments, one of the fixed features 345 has first and second ends that both connect to the rest of the body 310 in the toe region 301. In some embodiments, one of the fixed features 345 has first and second ends that both connect to the rest of the body 310 in the heel region 302. In some embodiments, one of the fixed features 345 has first and second ends that both connect to the rest of the body 310 in the sole 307.

[0217] In the embodiments shown in Figures 39 to 41, the golf club head 300 includes two fixed features 345 extending from the rear 303 to the sole 307. In the embodiments shown in Figures 42 to 44, one fixed feature 345 extends from the toe end of the sole 307 to the heel end of the sole 307. In the embodiment shown in Figure 45, a single fixed feature 345 (or arch) includes first and second ends that both connect to the body 310 in the heel region 302. As shown in Figure 45, one or more fixed features 345 can define a channel 346, opening, through hole, or tube (hereinafter collectively referred to as "channel") that can be filled with insert material. The channel 346 may have a minimum diameter of 0.065 inches. In some embodiments, the channel 346 may have a diameter of 0.065–0.075 inches, 0.070–0.080 inches, 0.075–0.085 inches, or 0.080–0.090 inches. In some embodiments, the channel 346 may have a diameter greater than 0.080 inches or greater than 0.090 inches. The diameter of the channel 346 under and / or surrounded by the fixed feature allows the insert material to flow when the insert material is injected into the cavity during manufacturing.

[0218] One or more fixing features 345 may have a cross-sectional shape that is circular, oval, elliptical, or any other shape configured to facilitate the flow of insert material around the fixing feature. Figure 44 illustrates a fixing feature having a circular cross-section. In some embodiments, the cavity 620 further includes an undercut within the top rail 306 and / or sole 307. The undercut 347 can help mechanically secure the insert 640 within the cavity 320. Golf clubs having a top rail 306 and sole 307 with an undercut 347 are shown in embodiments of Figures 37 and 38.

[0219] Referring to Figures 51 and 52, in some variations of the golf club head 300, there is no rear opening 380. Instead, the body 310 covers the entire rear 303 of the club head 300. In these embodiments, the cavity 320 is exposed only at the front 304 of the club head 300. These embodiments may include one or more undercuts 347 and / or one or more fixing features 345 to hold the insert 340 within the cavity 320. H. Other circumferential weighting of the golf club head (tip weight, toe weight)

[0220] The golf club head 300 may include a toe weight 361 similar to the toe weights 161 and 661, a tip weight 360 similar to the tip weights 160 and 660, and a toe screw weight 362 similar to the toe screw weight 662. As shown in Figures 48-50, the golf club head 300 may additionally or alternatively include a plurality of weights 365 positioned at the rear of the club head 300. In some embodiments, such as shown in Figure 48, the club head 300 may include a toe weight 361 and a heel weight 364. In some embodiments, the toe weight 361 and heel weight 364 may be fixed within the receiving cavity of the club head 300 by swaging, welding, co-forging, or other means. In other embodiments, the toe weight 361 and heel weight 364 are fixed to the club head 300 via a fastening mechanism. For example, in the embodiment shown in Figure 49, the toe weight 361 and heel weight 364 are screwed into receiving holes in the club head 300. In some embodiments, as shown in Figure 50, a plurality of weights 365 are fixed to or formed on the rear 303 of the club head 300. IV. Golf Club Head Characteristics A. Golf club head measurement

[0221] The golf club heads 100, 300, and 600 can be tour irons. The golf club heads 100, 300, and 600 described in this specification can be tour iron heads including blade length, hosel-X length, offset distance, and upper portion depth characteristics of tour irons. Hereinafter, the features that identify the golf club head 100 as a tour iron will be described. The golf club heads 300 and 600 can have tour iron characteristics similar to those of the golf club head 100.

[0222] As shown in FIG. 2, the golf club head 100 has a blade length 173. The blade length 173 is measured as the maximum distance from the edge of the striking face 111 within the heel region 102 to the edge of the club head 100 within the toe region 101. The blade length of a typical tour iron can be less than 2.8 inches. The blade length of a game improvement iron is generally greater than 2.8 inches. The blade length 173 of the golf club head 100 is less than 2.8 inches, as is characteristic of a tour iron. In some embodiments, the blade length 173 of the golf club head 100 can be 2.2 inches to 2.8 inches, 2.2 inches to 2.4 inches, 2.4 inches to 2.6 inches, or 2.6 inches to 2.8 inches.

[0223] As shown in FIG. 2, the hosel-X length 174 is measured from the center plane 45 to the intersection of the hosel axis 70 and the leading edge axis 35. The hosel-X length of a tour iron is generally less than 1.5 inches, and the hosel-X length of a game improvement iron is generally greater than 1.5 inches. The hosel-X length of the golf club head 100 is less than 1.5 inches, as is characteristic of a tour iron. In some embodiments, the hosel-X length 174 can be 1.30 inches to 1.50 inches, 1.30 inches to 1.40 inches, or 1.40 inches to 1.50 inches.

[0224] As shown in FIG. 4, the offset distance 173 is measured between the front edge of the hosel 105 and the most forward point of the golf club head 100. Typically, the most forward point is located at the bottom of the strike face 111 and adjacent to the sole 107. The offset distance 172 can vary among golf club heads within the same set due to different loft angles. Thus, to compare sets of irons, the average of the offset distances 173 for all golf clubs in the set is taken. The average offset of a tour iron set is generally less than 0.140 inches. The average offset of a game improvement iron set is generally greater than 0.140 inches. The average offset of a set of golf clubs including a golf club head similar to the club head 100 is less than 0.140 inches. The offset distance 172 of a single golf club head 100 can be between 0.100 inches and 0.160 inches. In some embodiments, the offset distance where the offset distance 172 is 0.100 inches can be between 0.100 inches and 0.110 inches, 0.110 inches and 0.120 inches, 0.120 inches and 0.130 inches, 0.130 inches and 0.140 inches, 0.140 inches and 0.150 inches, or 0.150 inches and 0.160 inches.

[0225] The depth 116 of the upper portion is measured from the front 104 to the rear 103 adjacent to the top rail 106 and orthogonal to the strike face 111, as shown in FIG. 4. The average depth of the upper portion of a tour iron is generally less than 0.290 inches. The average depth of the upper portion of a game improvement iron is generally greater than 0.290 inches. The average depth of the upper portion of a set of golf clubs including a golf club head similar to the club head 100 is less than 0.290 inches, as is characteristic of a set of tour irons.

[0226] A parameter similar between game improvements and tour irons is the height of the golf club head. As shown in Figure 2, each golf club head 100 can have a maximum height 175 measured along the loft plane 20 from the lead edge axis 35 to the highest point on the top rail 106. Golf club heads 600 can have similar heights to golf club heads 100. The maximum height 175 can be between 2.0 inches and 2.5 inches. In some embodiments, the maximum height 175 can be between 2.0 inches and 2.1 inches, 2.1 inches and 2.2 inches, 2.2 inches and 2.3 inches, 2.3 inches and 2.4 inches, and 2.4 inches and 2.5 inches.

[0227] Table I below compares the blade length, hosel X, average offset, average upper section depth, and maximum height of the Tour irons to those of the Game Improved irons. [Table 1] B. CG and MOI of the golf club head

[0228] To accurately understand the advantages of perimeter weighting in 100, 300, and 600 golf club heads, both the MOI and CG characteristics of 100, 300, and 600 golf club heads, as well as the tour size of 100, 300, and 600 golf club heads, must be considered. Game-improving irons are known for their high MOI values ​​but lack other characteristics specific to tour irons. The golf clubs described herein combine the advantages of game-improving irons with the style of tour irons.

[0229] In some embodiments, the CG60 of golf club heads 100, 300, and 600 is shifted downward and backward compared to flat-back tour irons. The CG60 position of golf club heads 100, 300, and 600 can also be measured from the lead edge surface.

[0230] The CG60 for golf club heads 100 and 600 can be positioned between 0.380 inches and 0.670 inches above the lead edge surface. In some embodiments, the golf club heads 100 and 600 have a lead edge surface with a length of 0.400 inches to 0.650 inches, 0.380 inches to 0.400 inches, 0.400 inches to 0.420 inches, 0.420 inches to 0.440 inches, 0.440 inches to 0.460 inches, 0.460 inches to 0.480 inches, 0.480 inches to 0.500 inches, 0.500 inches to 0.520 inches, 0.520 inches to 0.540 inches, 0.540 inches to 0.560 inches, 0.560 inches to 0.580 inches, 0.580 inches to 0.600 inches, 0.600 inches to 0.620 inches, 0.620 inches to 0.640 inches, 0.640 inches to 0.660 inches, and 0.660 inches to 0.670 inches. It can be positioned in inches. In other embodiments, CG60 can be positioned only 0.380 inches, 0.390 inches, 0.400 inches, 0.410 inches, 0.420 inches, 0.430 inches, 0.440 inches, 0.450 inches, 0.460 inches, 0.470 inches, 0.480 inches, 0.490 inches, 0.500 inches, 0.510 inches, 0.520 inches, 0.530 inches, 0.540 inches, 0.550 inches, 0.560 inches, 0.570 inches, 0.580 inches, 0.590 inches, 0.600 inches, 0.610 inches, 0.620 inches, 0.630 inches, 0.640 inches, 0.650 inches, 0.660 inches, or 0.670 inches above the lead edge surface.

[0231] As described above, the golf club heads 100, 300, and 600 described herein may be equipped with a lightweight insert 140, 440, 240, 270, and / or 640 at the center of the golf club head. The saved weight can be added around the golf club heads 100, 300, and 600 without significantly changing the overall weight of the golf club heads 100, 300, and 600, but will allow for a shift in CG60 and an increase in MOI. This periphery weighting may be done by toe weights, tip weights, or body material added around the periphery. The compact nature of the golf club heads 100, 300, and 600 means that material properties will play a greater role in MOI improvement than structural size. Ixx, which is the MOI around CG60 and around the x-axis 30, may range from 70 to 140 grams per square inch. Iyy, which is the MOI around CG60 and around the y-axis 40, may range from 310 to 500 grams per square inch. These MOI values ​​can be applied to golf club heads 100, 300, and 600. These MOI values ​​can be further applied to any embodiment having inserts 140, 640, multi-material inserts 440, or lightweight inserts 240 or 270. V. Method

[0232] As shown in Figure 54, a method 500 for manufacturing a golf club head 100 is described herein. This method includes the steps of preparing each component 510, positioning an insert within a body 520, swaging a face plate onto a body 530, laser welding the boundary between the face plate and the body 540, and cleaning the final product by grinding and polishing. In some embodiments of method 500, method 500 may consist of steps 510, 520, 530, and 550.

[0233] Step 510 may include preparing at least a body 110, an insert 140 or a multi-material insert 440, and a face plate 155 as components of the golf club head 100. In some embodiments, preparing the body 110 may consist of one or more of forging, casting, forming by additive manufacturing, machining, or any other suitable method for forming the body 110. Step 510 may also include forming the body 110 as a single piece.

[0234] In some embodiments, preparing the insert 140 can consist of one or more of forging, casting, additive manufacturing, machining, or any other suitable method for forming the body 140. In some embodiments, the insert 140 or a portion of the multi-material insert 440 is formed by pouring resin into a fiber-reinforced structure to form an elastomer matrix composite. The insert 140 can be formed as a single piece with uniform density or as multiple pieces with different densities. In some embodiments, since there is a multi-material insert 440, the insert 440 can be formed as a single unit or arranged in the cavity 120 as two separate parts.

[0235] In some embodiments, preparing a multi-material insert 440 includes (1) preparing a first portion 450 of the insert 440, (2) preparing a second portion 460 of the insert 440, and (3) joining the first and second portions 450, 460 of the insert 440. Preparing the first portion 450 of the insert 440 may include molding the first portion 440. Preparing the second portion 460 of the insert 440 may include casting, forging, stamping, die casting, or other means for preparing the second portion 460. In some embodiments, (1) preparing the second portion 460 and (2) joining the first portion 450 and the second portion 460 are combined when the first portion 450 is molded and joined to the second portion 460. In some embodiments, the insert 440 may be ground or polished before being inserted into the cavity 120 of the golf club head 100.

[0236] In some embodiments, forming the faceplate 155 may consist of forging, casting, machining, additive manufacturing, or other methods for forming the faceplate 155. In some embodiments, forming the faceplate 155 may include machining, casting, or forging a variable-thickness geometry within the faceplate 155.

[0237] In some embodiments, step 510 of method 500 may further include preparing a toe weight, a tip weight, and / or a toe screw weight. In these embodiments, step 510 further includes welding the toe weight 161 to the toe cavity 114 of the body 110. In other embodiments, the toe weight 161 may be fixed onto the body 610 by swaging, bonding, or other means. In embodiments of the golf club head 100 further including a toe screw weight, the toe screw weight may be screwed into the golf club head in steps 510, 520, 530, or 550.

[0238] Step 520 of Method 500 includes positioning the insert 140 within the cavity 120 of the body 110. The insert 140 is inserted through the front opening of the cavity 120 at the front 104 of the body 110. In some embodiments, this step 520 includes applying an adhesive, such as epoxy resin, to the cavity 120 of the body 110 and the insert 140 to secure the insert 140 within the body 110. In some embodiments, this step 520 includes applying one or more tape layers, such as tape layer 150, to the cavity 120 before positioning the insert 140 within the cavity. One or more tape layers, such as tape layer 150, can form a strong and durable connection between the insert 140 and the cavity 120 of the body 110. Furthermore, the use of tape can reduce the possibility of rattle and other undesirable quality issues. In some embodiments, various other methods for securing the insert 140 to the body 110 are combined for maximum security. Not all embodiments of Method 500 require the insert 140 to be bonded or fixed within the cavity 120.

[0239] Step 530 of Method 500 includes securing the faceplate 155 onto the body 110. The faceplate 155 is positioned within the recess 142. By positioning the faceplate 155 within the recess 142, the faceplate 155 is positioned to cover the insert 140 and the cavity 120 of the body 110. Step 530 may further include swaging the faceplate 155 onto the body 110 so that it is embedded in the recess 142 on the front 104 of the body 110. In this way, the insert 140 is held within the golf club head 100 and completely isolated from the outside of the golf club head 100. In other embodiments, the faceplate 155 is bonded to the body, press-fitted, or otherwise secured.

[0240] Some golf club heads are manufactured using methods that include co-forging (also called integrated forging) and joining individual cast parts at high temperatures and high applied pressure. These methods apply high temperatures that affect multiple components of the golf club head, including any inserts. For example, the co-forging process occurs at temperatures of 700-1000°C. The melting point of some aluminum alloys drops to 650-680°C. Therefore, in the case of aluminum inserts, co-forging would compromise the integrity of the aluminum material. Inserts 140, 440, body 110, and faceplate 155 are not co-forged together because co-forging could result in temperatures high enough to potentially damage inserts 140, 440.

[0241] Furthermore, TIG welding the faceplate to the golf club head also applies high temperatures to the golf club head, which can damage the insert. The possible materials for the low-density core of an iron-type golf club head are significantly limited due to conventional manufacturing processes. The golf club head 100 can be manufactured from a wide variety of insert materials because the manufacturing process does not place the final product under high temperatures. Moreover, some insert materials described herein, such as thermoplastic composites, cannot simply be co-forged with the metal body material. The manufacturing method 500 described herein allows the inserts 140, 440 to be formed from any suitable material without requiring the material to be co-forged with the body 110.

[0242] Steps 530 and 540, described later, both employ low-temperature methods to secure the faceplate 155 and enclose the insert 140 within the cavity 120. Swaging, laser welding, and other low-temperature methods for securing the faceplate 155 allow the insert 140 or 440 to contain a wide variety of materials for fine-tuning acoustics, feel, and weight. The low-temperature methods of steps 530 and 540 allow for further design flexibility, such as using adhesive and / or tape around the cavity 120 to reduce undesirable rattle and vibration.

[0243] Step 540 includes laser welding the boundary between the faceplate 155 and the body 110. The process of Step 540 is also called a surface fusion treatment. After the faceplate 155 is swaged onto the body 110 in Step 530, the overlapping region or boundary between the faceplate 155 and the body 110 is laser welded. This laser welding process reconciles the metal materials of the faceplate 155 and the body 110 without creating a deep heat affected zone (hereinafter referred to as "HAZ"). By laser welding the boundary, cracks or seams between the faceplate 155 and the body 110 are removed. In some embodiments, the golf club head 100 is finished by coating in Step 550 as described below. Even a tiny crack or seam at the boundary can allow the coating to penetrate the seam, potentially causing quality problems. By laser welding the boundary in Step 540, this manufacturing problem is resolved.

[0244] The above-described Step 540 has a HAZ depth between 0.03 inches and 0.08 inches, which can be made smaller than the thickness 112 of the faceplate 155, so it can be implemented without compromising the integrity of the material within the cavity 120. In some embodiments, the HAZ depth can be less than 0.08 inches, less than 0.07 inches, less than 0.06 inches, less than 0.05 inches, less than 0.04 inches, or less than 0.03 inches. In some embodiments, the depth of the HAZ can be 0.03 inches, 0.04 inches, 0.05 inches, 0.06 inches, 0.07 inches, or 0.08 inches. Laser welding heats other cavity fillers such as inserts and tape layers to a temperature lower than the melting temperature of the insert material. The heat applied to the golf club head 100 during Step 540 does not damage any of the materials sealed within the cavity 120.

[0245] In step 550 of method 550, the golf club head 100 is cleaned by grinding and polishing. Grinding is used to form a smooth surface on the strike face 111 of the golf club head 100. Furthermore, step 550 may include polishing the surface of the golf club head 100 after grinding. In some embodiments, grooves are formed in the strike face 111 of the face plate 155, and then the strike face 111 is polished. None of the steps in manufacturing method 500 involve co-forging with different materials.

[0246] As shown in Figure 32, a method 700 for manufacturing a golf club head, similar to the golf club head 600, includes the steps of preparing at least a body 610, an insert material, and a face plate 655; welding or swaging the face plate 655 to the body 610; injecting the insert material into the cavity 620 of the body 610; and polishing and cleaning the golf club head 600.

[0247] In step 710, the body 610 may be formed by forging, casting, or additive manufacturing. The faceplate 655 may be formed by forging, casting, or additive manufacturing. In a variation of manufacturing process 700, the strike face 655 is formed integrally as part of the body 610, rather than being formed separately as a faceplate 655 and welded or swaged onto the front opening of the body 610. In some embodiments, step 710 of method 700 further includes preparing a tow weight 661, a tip weight 650, and / or a tow screw weight 662. In these embodiments, step 710 further includes welding the tow weight 661 to the tow cavity 614 of the body 610. In other embodiments, the tow weight 661 may be fixed onto the body 610 by swaging, bonding, or other means. In embodiments of the golf club head 600 further comprising a toe screw weight 662, the toe screw weight 662 may be screwed into the golf club head in steps 710, 720, 730, or 750.

[0248] Furthermore, in step 710 of method 700, the opening wall 782 defining the rear opening 680 may be formed in the body 610, or it may be cut into the rear portion 603 of the body 610 after the body 610 has been formed. Step 710 may further include grinding or finishing the opening wall 782 of the rear 603.

[0249] Step 720 includes positioning the faceplate 655 within the recess 642 of the body. The faceplate 655 is secured to the body 610 by welding, swaging, or other means. The body 610 and the strike plate 655 form a cavity 620. After the faceplate 655 is secured to the body 610, the only opening to the cavity 620 is the rear opening 680 of the body 610, as shown in the embodiments of Figures 14-23. In some embodiments, step 720 of method 700 may further include a laser welding or surface fusion process similar to that described in step 540 of method 500 above.

[0250] Step 720 may further include the step of placing the tow screw weight 662 into the tow screw cavity 663. Since the tow screw cavity 663 is open into the body cavity 620, the tow screw weight 662 can be inserted into the tow screw cavity 663 to prevent the insert material from being ejected through the tow screw cavity 663 during injection molding in step 730. The club head 600 may be further prepared for injection molding by precision machining the back or mouth of the rear opening 680. Golf club heads prepared by casting or forging typically lack a surface smooth enough to seal the surrounding mold. In this embodiment of the manufacturing process, the back or mouth of the rear opening 680 acts as a sealing surface to which the injected material fills during manufacturing. Tight tolerances are required to provide a clean seal to the mold at the sealing surface and prevent flash formation during injection molding. Therefore, the sealing surface (in this embodiment, the back surface or mouth of the rear opening 680) can be precision machined to provide a suitable tight tolerance to the mold.

[0251] In step 730, the insert material is injected in liquid form into the cavity 620 through the rear opening 60. The cavity 620 of the body 610 serves as a mold for the injected material. In some embodiments, the injection molding process bonds the insert material to the surface of the cavity 620. To inject the material into the cavity 620 under pressure, the injection device must be sealed over the opening of the rear opening 680. The flat surface surrounding the rear opening 680 in the upper portion 608 of the golf club head 600 allows for a good seal between the injection device and the body 610 of the golf club head 600. In some embodiments, if the insert 640 only partially fills the cavity 620, the injection device is configured to further form a seal over a portion of the cavity 620 to prevent the material from filling the entire cavity 620.

[0252] In step 740 of method 700, the golf club head 600 is cleaned by grinding and polishing. Grinding is used to form a smooth surface on the strike face 611 of the golf club head 600. Furthermore, step 740 may include polishing the surface of the golf club head 600 after grinding. In some embodiments, grooves are formed in the strike face 611 of the face plate 655, and then the strike face 611 is polished.

[0253] Methods for manufacturing some embodiments of the golf club head 600 are more similar to method 500 than to method 700 described above. In some embodiments, the method for forming the golf club head 600, which includes a metal insert 640, requires placing the insert 640 within the cavity 640 before swaging the face plate 655. VI. Examples Example 1: Measurement of a golf club head Golf club head 100 was measured using several different parameters as described above. These included blade length 173, hosel-X length 174, offset distance 172, upper section depth 116, and maximum height 175. These values ​​were compared to the game-improved irons, both of which are shown in Table II below. Both the measured golf club head 100 and the game-improved irons were 7 irons and had nearly identical loft angles. [Table 2] Example 2: Comparison of Moment of Inertia (MOI) and Center of Censorship (CG)

[0254] A test was conducted to compare the MOI of a conventional tour iron head with that of the aforementioned golf club head 100. The conventional tour iron head used in this comparative test was identical in size and head weight to the sample golf club head. Therefore, this test isolated MOI as a variable and provided an accurate comparison of the sample's performance to that of the conventional tour iron head. The test yielded an Ixx value of approximately 108 grams per square inch for the sample club head and an Ixx value of approximately 103 grams per square inch for the conventional tour iron head. Thus, the MOI around x-axis 30 is approximately 4.8% higher for the sample club head. The test yielded an Iyy value of approximately 413 grams per square inch for the sample club head and an Iyy value of approximately 398 grams per square inch for the conventional tour iron head. Thus, the MOI around y-axis 40 is approximately 3.7% higher for the sample club head. This test demonstrates that a lightweight insert for golf club head 100 provides an improvement in MOI without changing the size or weight of golf club head 100.

[0255] Furthermore, comparisons were made between five club heads: (1) an iron similar to golf club head 600 having an opening at the rear and an insert formed from TPC; (2) an iron similar to golf club head 600 having an opening at the rear and an insert formed from aluminum; (3) an iron similar to golf club head 100 having a sealed cavity filled with a TPC insert; (4) an iron similar to golf club head 100 having a sealed cavity filled with an aluminum insert; and (5) a solid steel club head having a total club head volume similar to the golf club heads described herein. Measurements were performed using computer-aided design (CAD) models of each golf club head. Table III below summarizes the collected MOI data. Table IV below summarizes the collected CG data. [Table 3]

[0256] Since MOI is a function of distance from CG and mass, MOI reflects the change in the total mass of the golf club head. Therefore, to accurately compare club head MOIs, the difference in the total mass of the golf club heads must be taken into account. To show the MOI efficiency across the compared golf club heads, the MOI efficiency value was derived by dividing the MOI by the mass of the golf club head. The MOI efficiency values ​​of the golf club heads can be compared independently of mass to show how the structure and local weights of the golf club heads affect the MOI. Thus, although the MOI values ​​in both the x-axis 30 and y-axis 40 directions were higher for the solid steel golf club head (5) than for the low-density insert golf club heads (1) to (4), the MOI efficiency of the solid steel golf club head (5) was lower than the MOI efficiency of golf club heads (1) to (4). Therefore, golf club heads (1) to (4) having low-density inserts are more forgiving than golf club heads 100, 600 described herein and golf club heads 140, 440, 460 lacking low-density inserts.

[0257] As can be seen from Table III, golf club heads (1) to (4) with low-density inserts have an MOI efficiency in the x-axis direction of 30 degrees that is 5.9% to 11.2% higher than that of a solid steel golf club head (5). As can be seen from Table III, club heads (1) to (4) with low-density inserts have an MOI efficiency in the y-axis direction of 40 degrees that is 8.5% to 15.5% higher than that of a solid steel golf club head (5).

[0258] In addition to increasing MOI, reducing CG can also be beneficial to golf club head performance. The golf club heads 100, 300, and 600 described herein include a CG of 60 lower than that of comparable solid steel irons having a similar shape to the golf club heads 100 and 600. A lower CG is desirable in tour irons because it is easier to form a shot when the CG is lower. In the case of the golf club head 600, the reduction in CG is due in part to the elimination of high-density body material by including an opening 680 in the rear 603. [Table 4]

[0259] Referring to Figure 1, CGy is measured vertically and upward from the lead edge axis 35 in the direction of the y-axis 40. CGx is measured horizontally along the lead edge axis 35 with the origin at the y-axis 40, and a positive CGx value indicates that the CG is closer to the heel 102. CGz is measured backward and horizontally along the z-axis 50 from the lead edge axis 35. The CGy value is lower for golf club heads 1 and 2 than for golf club heads 3-5. This indicates that golf club heads with an opening at the rear of the body (similar to golf club head 600 mentioned above) have a desirable lower CG. The CG is 2.06% lower for club head 2 than for steel club head 5. The CG is 2.84% lower for golf club head 1 than for steel golf club head 5, which indicates that the low-density TPC insert results in an even better CG arrangement than its aluminum insert counterpart (golf club head 2).

[0260] The comparative data in Tables III and IV further demonstrates the strengths of the sealed cavity and rear-opening embodiments. While all embodiments of the present invention (comparative golf club heads (1) to (4)) are improvements over the solid club head (5), both the sealed cavity embodiments (comparative golf club heads (3) and (4)) and the rear-opening embodiments (comparative golf club heads (1) and (2)) offer unique advantages. The comparative data shows that the MOI efficiency in both the x-axis 30 and y-axis 40 directions is higher in the sealed cavity club heads (3) and (4) than in club heads (1), (2), and (5), as shown in the MOI efficiency column of Table II. This suggests that the sealed cavity embodiments, such as golf club head 100 or comparative club heads (3) and (4) described herein, are more forgiving than embodiments with a rear opening, such as golf club head 600 or comparative club heads (1) and (2). However, embodiments having a rear opening 680 in the body 610 have a lower CG value than embodiments having a sealed cavity, as shown in the CGy column of Table IV. Example 3: Comparison of center of gravity flat back vs. flexed seam back

[0261] In addition to MOI and feel, the position of the center of gravity (CG) of the golf club head affects performance. In particular, the CG position affects the amount of torque applied to the golf club head at impact with the golf ball. By lowering the CG, the arm between the force applied by the golf ball and the CG is reduced, as the golf ball is typically struck in the lower part of the strike face. This shortened arm between the applied force and the CG results in lower torque and improves the launch characteristics at impact with the golf ball. Therefore, to provide golfers with the best possible experience, the golf club heads described herein include a low CG.

[0262] To demonstrate how the uniform depth of the upper portions 108 and 608 of golf club heads 100 and 600 leads to a lower CG60, comparisons were made between similar golf club heads to golf club heads 100, 300, and 600 and comparison golf club heads with varying depths from their top rail to their sole. The comparison golf club heads have a flat rear extending from their top rail to their sole. To provide an accurate description, both the comparison golf club heads similar to 100, 300, and 600 and the golf club heads were modeled with the same total mass. The results of the comparison are summarized in Table IV below. [Table 5]

[0263] As shown in Table IV, the CGy values ​​measured along the vertical y-axis 40 are significantly lower for the 100, 300, and 600 similar golf club heads. Specifically, the 100, 300, and 600 similar golf club heads have a CGy that is 0.039 inches lower than the comparison golf club heads. This indicates that the uniform depth of the upper portion 108, 608 above the inflection points 130, 630 lowers the CG, providing better launch and spin characteristics and faster ball speed.

[0264] Furthermore, the CGz value is measured along the z-axis 50, with negative values ​​behind CG60 and positive values ​​in front of CG60. For golf club heads similar to 100, 300, and 600, CG60 is closer to the front of the golf club head. Example 4: Touch and Sound

[0265] Part of the appeal of tour irons lies in their compact profile and sleek aesthetic design. Furthermore, forged golf club heads are perceived by many golfers as superior to cast club heads. Therefore, it is important that tour irons satisfy these expectations. Golfers particularly enjoy the sound and feel of forged tour irons compared to other types of irons. In golf, the "feel" of a golf club head plays a significant role in a golfer's performance, as perceived by the golfer. This "feel" is generally influenced by the weight, material, acoustics, and thickness of the strike face. Many golfers agree that tour irons offer a solid feel that many other types of irons lack. The golf club heads described herein exhibit a solid feel and acoustic quality equal to, if not exceeding, that of existing tour irons.

[0266] The study was conducted to quantify the feel of a sample tour iron with a golf club head similar to the Golf Club Head 100 described herein. Twenty golfers participated in the study and compared their experience with the sample iron to their experience with a traditional tour iron. After using both the sample and traditional irons, participants were asked the following question for each iron: "How satisfied are you with the impact experience (feel / sound) that this iron provides?" The majority of players preferred the impact experience of the sample tour iron over that of the traditional tour iron.

[0267] Finally, the quality and durability of the irons are crucial for sustained performance. Strike Faces 111, 311, and 611 are designed, on their own, to withstand the stress placed upon them by striking a golf ball. However, including thermoplastic composite inserts 140 or 640, all-metal inserts 140 or 640, multi-material inserts 440, or lightweight inserts 240 or 280 adds additional solidity to the golf club head, improving the acoustic quality of the club head compared to similar hollow-body golf club heads. Faceplates 155 and 655 can improve the quality and durability of the golf club head by ensuring that the inserts 140, 340, 440, 240, 280, or 640 always remain fixed inside the golf club head. Example 5: Performance Test

[0268] Tests were conducted to compare a control club, a first test club with an insert having Shore A30 hardness (similar to the golf club head 600 described above), and a second test club with an insert made of TPU (similar to the golf club head 600 described above). Shot data for all three clubs was recorded for 12 golfers. The results showed that both the first test club (Shore A30 insert) and the second test club (TPU insert) exhibited ball speeds similar to the control club (within 0.9 mph). The launch angles and spin rates of the first and second test clubs did not differ significantly from the launch angle of the control club. It was predicted that the control club would outperform the first and second test clubs in terms of ball speed, launch angle, and spin rate due to the insert material. Therefore, it was unexpected when the test results showed that the three clubs were performed under similar ball speeds, launch angles, and spin rates.

[0269] As illustrated in Figure 53, ball speed, launch angle, and spin rate were similar for the three clubs, but the second test club showed greater downline (or carry) and offline consistency. The landing points of each shot were charted and analyzed to determine the statistical plotting area for each club. The statistical plotting area is an elliptical region derived from the test data, within which 90% of future shots are expected to land. The statistical plotting area is determined by first taking the mean standard deviation of the downline distance of the test shots and multiplying it by a coefficient to form the downline radius of the ellipse. The mean standard deviation of the offline distance of the test shots and multiplying it by a coefficient gives the offline radius of the ellipse. The ellipse of the statistical plotting area is centered on the mean downline and offline distances within which 90% of future shots are expected to land.

[0270] The first test club was performed similarly to the control club. The first test club produced a statistical plot area of ​​1246 square yards, while the control club produced a statistical plot area of ​​1183 square yards. However, the second test club (with a TPU insert) produced a statistical plot area that was approximately 42% smaller than that of the control club. The second test club produced a statistical plot area of ​​690 square yards. The smaller statistical plot area of ​​the second test club indicates that this club (with a TPU insert) significantly increases the consistency of the golfer's shots. As plotted in Figure 53, the second test club (with a TPU insert) showed greater consistency in both the downline and offline directions compared to the control and the first test club. This performance test showed that the second golf club (with a TPU insert similar to the golf club head 600) provided higher shot accuracy than the control or the first golf club.

[0271] By combining and balancing CG placement, perimeter weighting for MOI, and the look and feel of a tour iron, the golf club heads 100, 300, and 600 described herein satisfy the need in the art for iron-type club heads that combine the reliability of a game-improving iron with the elegance of a tour iron. The golf club head 600 can also exhibit greater downline and offline consistency than conventional golf club heads.

[0272] The golf club heads 100 and 600 described herein function as tour-type golf club heads. The golf club head 300 can function as a tour-type iron or a game-improvement iron. The golf club heads 100 and 600, and optionally 300, offer a high MOI while remaining smaller than typical game-improvement irons. These multi-material golf club heads 100 and 600, and optionally 300, offer a highly forgiving and compact product.

[0273] Figures 1–52 illustrate specific embodiments of a golf club head, but the disclosure of embodiments is intended to illustrate, not limit, the scope of this disclosure. The scope of this disclosure is intended to be limited to the extent required by the appended claims.

[0274] Because the rules of golf are changed from time to time (for example, new rules may be applied or old rules may be abolished or changed by golf standards organizations and / or governing bodies such as the United States Golf Association (USGA) and the Royal and Advanced Golf Club of St. Louis (R&A)), golf equipment relating to the apparatus, methods and products described herein may or may not conform to the rules of golf at any particular time. Accordingly, golf equipment relating to the methods, apparatus and / or products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The methods, apparatus and / or products described herein are not limited in this respect.

[0275] The replacement of one or more claimed elements constitutes a reconfiguration, not a repair. Furthermore, effects, other advantages, and solutions to problems have been described in relation to specific embodiments. However, advantages, other advantages, and solutions to problems, and any one or more elements that give rise to or make apparent any advantage, advantage, or solution, do not constitute a material, essential, or essential feature or element of any or all elements of the claims unless such advantage, advantage, solution, or element is expressly stated in such claims.

[0276] Furthermore, the embodiments and limitations described herein are not made available to the public under the principle of public disclosure if (1) they are not expressly asserted in the claims, and (2) they are equivalent or potentially equivalent to the expressive elements and / or limitations in the claims under the doctrine of equivalents.

[0277] Article 1: A golf club head comprising a face plate, a body, and an insert, wherein the body comprises an upper portion, a lower portion, a sole, a rear, and a top rail, the sole resting on the ground surface, the loft surface contacting the face plate and intersecting the ground surface, the rear comprising a flex seam, the upper portion being bounded by the top rail and the flex seam, the lower portion being bounded by the flex seam and the sole, the face plate, the rear and the top rail surrounding a cavity, and the insert A golf club head comprising an insert housed within the cavity, an upper insert portion configured to receive the insert within the upper portion of the body, a lower insert portion configured to receive the insert within the lower portion of the body, one or more recesses formed within the lower insert portion, the face plate comprising a first material of first density, the body comprising a second material of second density, and the insert comprising a third material of third density, wherein the third density is less than that of the first and second densities.

[0278] The golf club head according to paragraph 1, wherein the insert comprises a front surface, a rear surface, a perimeter, and an insert flex seam separating the upper portion of the insert from the lower portion of the insert, the upper portion of the insert and the lower portion of the insert are integrally formed in the insert flex seam, the one or more recesses extend inward from the front surface of the insert toward the rear surface but do not penetrate the rear surface of the insert, the perimeter of the insert is flush with the wall of the cavity, and the one or more recesses open only toward the faceplate.

[0279] The golf club head according to paragraph 1, wherein the one or more recesses comprises a plurality of recesses selected from the group consisting of two recesses, three recesses, four recesses, five recesses, and six recesses, and the insert further comprises one or more ribs separating the plurality of recesses.

[0280] Clause 4: The golf club head according to Clause 3, wherein the one or more ribs are perpendicular to the face plate and oriented in a direction parallel to the top rail-sole direction.

[0281] Item 5: The golf club head described in Item 1, wherein the upper portion of the insert is solid.

[0282] Clause 6: The golf club head according to Clause 1, wherein the insert comprises a front surface, a rear surface, a perimeter, and an insert bending seam separating the upper portion of the insert from the lower portion of the insert, the upper portion of the insert further comprises at least one connecting rail forming two or more openings, the perimeter of the insert forms a frame supporting the at least one connecting rail, and the at least one connecting rail may comprise a plurality of rails selected from the group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 rails.

[0283] Clause 7: The golf club head according to Clause 1, wherein the insert is smaller by a mass selected from the group consisting of 5-6 grams, 5.5-6.5 grams, 6-7 grams, 6.5-7.5 grams, 7-8 grams, 7.5-8.5 grams, 8-9 grams, 8.5-9.5 grams, and 9-10 grams than a similar insert lacking one or more recesses.

[0284] Clause 8: The golf club head according to Clause 1, wherein the insert fills a percentage of the cavity volume selected from the group consisting of 80% to 85%, 85% to 90%, 90% to 95%, 95% to 100%, and 80% to 90%.

[0285] Clause 9: The golf club head according to Clause 1, wherein the upper portion of the insert has a height measured from the top rail to the flex seam in a direction parallel to the loft plane, the lower portion of the insert has a height measured from the sole to the flex seam in a direction parallel to the loft plane, the height of the upper portion and the height of the lower portion have a ratio of 9:8 to 6:11, the upper portion has a first depth, and the lower portion has a second depth, the depth measured from the striking surface to the rear outer surface in a direction perpendicular to the loft plane, the first depth is constant and less than the second depth.

[0286] Clause 10: The golf club head as described in Clause 1, further comprising a heel and a toe, an x-axis extending in the heel-toe direction, parallel to the striking surface, and coinciding with the center of gravity of the club head, and a y-axis perpendicular to the ground surface and coinciding with the center of gravity, wherein the moment of inertia Ixx measured around the x-axis is in the range of 78 grams square inches to 120 grams square inches, and the moment of inertia Iyy measured around the y-axis is in the range of 310 grams square inches to 466 grams square inches.

[0287] Item 11: The golf club head described in Item 1, wherein the third density is 2.4 to 5.0 g / cc.

[0288] Clause 12: The golf club head according to Clause 11, wherein the third material comprises a material selected from the group consisting of aluminum and titanium.

[0289] Clause 13: The golf club head described in Clause 1, wherein the first density is 2.6 to 8.7 g / cc and the second density is 7.7 to 8.1 g / cc.

[0290] Clause 14: The golf club head according to Clause 13, wherein the first material comprises a material selected from the group consisting of steel-based materials, titanium-based materials, aluminum alloys, or titanium alloys, and the second material comprises a material selected from the group consisting of steel-based materials or steel alloys.

[0291] Clause 15: The golf club head according to Clause 1, further comprising a total mass and a toe weight, wherein the body further comprises a toe cavity, the toe cavity receiving the toe weight, and the toe weight having a mass between 5% and 45% of the total mass of the club head.

[0292] Clause 16: The golf club head according to Clause 1, further comprising: a center of gravity; a lead edge axis parallel to the ground plane, extending in the heel-toe direction and coinciding with the loft plane; a lead edge plane parallel to the ground plane and coinciding with the lead edge axis; and a y-axis perpendicular to the ground plane and coinciding with the center of gravity, wherein the center of gravity of the golf club head is located between 0.380 inches and 0.670 inches above the lead edge plane.

[0293] Clause 17: The golf club head according to Clause 1, further comprising: a heel and a toe; a central plane perpendicular to the center of the faceplate; a cylindrical hosel integral with the body; a hosel reference plane parallel to the front end of the cylindrical hosel when viewed from the toe side; a hosel axis defined as the central axis of the cylindrical hosel; a lead edge axis parallel to the ground plane, extending in the heel-toe direction and coinciding with the loft plane; a hosel-X distance of less than 1.5 inches, measured from the intersection of the lead edge axis and the central plane to the intersection of the lead edge axis and the hosel axis when viewed from the front; and an offset distance of between 0.05 inches and 0.27 inches, measured as the minimum distance between the lead edge axis and the hosel reference plane.

[0294] Section 18: The golf club head described in Section 1, further comprising a heel and a toe, and a blade length of less than 2.8 inches, measured in the heel-toe direction from the edge of the heel of the striking surface to the outermost point of the toe.

[0295] Clause 19: The golf club head according to Clause 1, further comprising a high-density tape disposed between the insert and the faceplate.

[0296] Clause 20: The golf club head according to Clause 1, wherein the body further comprises a recess, the recess abuts against the periphery of the cavity, the area on the back of the faceplate contacts the insert, and the remaining area on the back of the faceplate contacts the recess.

[0297] Clause 21: A golf club head comprising a body and an insert, the body comprising an upper portion, a lower portion, a sole, a rear, a toe region, a heel region, and a top rail, the sole resting on the ground surface, the loft surface being in contact with the face plate and intersecting the ground surface, the rear comprising a flex seam, the upper portion being bounded by the top rail and the flex seam, the lower portion being bounded by the flex seam and the sole, the sole, the rear and the top rail of the body enclosing a cavity, the body defining a front opening connected to the cavity, the insert being housed in the cavity and the front opening, the insert forming at least a portion of the striking surface, the body comprising a first material of a first density, and the insert comprising a second material of a second density, the second density being less than the first density, the golf club head.

[0298] Clause 22: The golf club head according to Clause 21, wherein the insert comprises an upper insert portion configured to be received in the upper portion of the body, and the insert comprises a lower insert portion configured to be received in the lower portion of the body, and the upper insert portion and the lower insert portion together form at least a portion of the strike face.

[0299] Section 23: The golf club head described in Section 21, wherein the first density of the first material is between 7.70 and 8.10 g / cc.

[0300] Section 24: The golf club head according to Section 21, wherein the second material comprises a polymer resin and reinforcing fibers.

[0301] Clause 25: The golf club head according to Clause 24, wherein the second material is selected from the group consisting of glass-filled elastomers, stainless steel-filled elastomers, tungsten-filled elastomers, thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), Kevlar® (aramid) fiber-reinforced polymers, and carbon fiber-reinforced polymers.

[0302] Item 26: The golf club head according to item 21, wherein the second density of the second material is between 0.8 g / cc and 1.4 g / cc.

[0303] Clause 27: The golf club head according to Clause 21, wherein the body further comprises a rear wall defining a rear opening, the rear opening being opposite to the front opening and located in the upper portion of the body, and the insert further housing in the rear opening.

[0304] Paragraph 28: The golf club head according to Paragraph 27, wherein the mass of the upper portion of the body is 1 gram to 70 grams less than the mass of a golf club head lacking a rear opening and an insert of lower density than the body.

[0305] Clause 29: The golf club head according to Clause 21, wherein the body further comprises one or more fixed features provided within the cavity and extending from one or more of the rear, sole, toe region, and heel region.

[0306] Clause 30: The golf club head according to Clause 29, wherein at least one of the fixed features extends from the rear to the sole within the cavity.

[0307] Clause 31: The golf club head according to Clause 29, wherein at least one of the fixed features comprises a first end and a second end, the first end and the second end together being attached to the sole within the cavity.

[0308] Clause 32: The golf club head according to Clause 29, wherein at least one of the fixed features forms a through hole that is filled by the insert, and the insert is geometrically locked by the at least one of the fixed features.

[0309] Clause 33: The golf club head according to Clause 21, wherein the body further comprises an undercut in the top rail, the undercut forming part of the cavity, and the insert is mechanically locked in the cavity by filling the undercut.

[0310] Clause 34: The golf club head according to Clause 21, wherein the body further comprises an undercut in the sole, the undercut forming part of the cavity, and the insert is mechanically locked within the cavity by filling the undercut.

[0311] Clause 35: The golf club head as described in Clause 21, further comprising an x-axis extending in the heel-toe direction, parallel to the striking surface and coinciding with the center of gravity of the club head, and a y-axis perpendicular to the ground surface and coinciding with the center of gravity, wherein the moment of inertia Ixx measured about the x-axis is in the range of 78 grams square inches to 120 grams square inches, and the moment of inertia Iyy measured about the y-axis is in the range of 310 grams square inches to 466 grams square inches.

[0312] Clause 36: The golf club head according to Clause 21, wherein the first material comprises a material selected from the group consisting of steel-based materials, titanium-based materials, aluminum alloys, and titanium alloys.

[0313] Clause 37: The golf club head according to Clause 21, further comprising a total mass and a toe weight, wherein the body further comprises a toe cavity, and the toe weight has a mass between 5% and 45% of the total mass of the club head.

[0314] Clause 38: The golf club head according to Clause 21, further comprising: a center of gravity; a lead edge axis parallel to the ground plane, extending in the heel-toe direction and coinciding with the loft plane; a lead edge plane parallel to the ground plane and coinciding with the lead edge axis; and a y-axis perpendicular to the ground plane and coinciding with the center of gravity, wherein the center of gravity of the golf club head is located between 0.380 inches and 0.670 inches above the lead edge plane.

[0315] Clause 39: The golf club head according to Clause 21, further comprising: a heel and a toe; a central plane perpendicular to the center of the faceplate; a cylindrical hosel integral with the body; a hosel reference plane parallel to the front end of the cylindrical hosel when viewed from the toe side; a hosel axis defined as the central axis of the cylindrical hosel; a lead edge axis parallel to the ground plane, extending in the heel-toe direction and coinciding with the loft plane; a hosel-X distance of less than 1.5 inches, measured from the intersection of the lead edge axis and the central plane to the intersection of the lead edge axis and the hosel axis when viewed from the front; and an offset distance of between 0.05 inches and 0.27 inches, measured as the minimum distance between the lead edge axis and the hosel reference plane.

[0316] Section 40: The golf club head according to Section 21, further comprising a heel and a toe, and a blade length of less than 2.8 inches, measured in the heel-toe direction from the edge of the heel of the striking surface to the outermost point of the toe.

Claims

1. It is a golf club head, It has a body and an insert, The aforementioned body comprises an upper section, a lower section, a sole, a rear section, a toe area, a heel area, and a top rail. The sole is placed on the ground surface, The loft surface is in contact with the face plate and intersects with the ground surface. The rear section is equipped with a flexible seam, The aforementioned upper portion is demarcated by the top rail and the curved seam, The aforementioned lower portion is demarcated by the flex seam and the sole. The sole, rear, and top rail of the body surround the cavity. The body defines a front opening that connects to the cavity, The insert is housed in the cavity and the front opening, The insert forms at least a portion of the striking surface, The body comprises a first material having a first density, The insert comprises a second material having a second density, A golf club head wherein the second density is less than the first density.

2. The insert comprises an upper insert portion configured to be received in the upper portion of the body, The insert has an insert lower portion configured to be received in the lower portion of the body, The golf club head according to claim 1, wherein both the upper portion of the insert and the lower portion of the insert form at least a part of the strike face.

3. The golf club head according to claim 1, wherein the first density of the first material is between 7.70 and 8.10 g / cc.

4. The golf club head according to claim 1, wherein the second material comprises a polymer resin and reinforcing fibers.

5. The golf club head according to claim 4, wherein the second material is selected from the group consisting of glass-filled elastomer, stainless steel-filled elastomer, tungsten-filled elastomer, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), Kevlar® (aramid) fiber-reinforced polymer, and carbon fiber-reinforced polymer.

6. The golf club head according to claim 1, wherein the second density of the second material is between 0.8 g / cc and 1.4 g / cc.

7. The body further comprises the rear opening wall that defines the rear opening, The rear opening is on the opposite side of the front opening and is located in the upper portion of the body. The golf club head according to claim 1, wherein the insert is further housed in the rear opening.

8. The golf club head according to claim 7, wherein the mass of the upper portion of the body is 1 gram to 70 grams less than the mass of a golf club head lacking a rear opening and an insert of lower density than the body.

9. The golf club head according to claim 1, wherein the body further comprises one or more fixed features provided within the cavity and extending from one or more of the rear, sole, toe region, and heel region.

10. The golf club head according to claim 9, wherein at least one of the fixed features extends from the rear to the sole within the cavity.

11. At least one of the fixed features comprises a first end and a second end, The golf club head according to claim 9, wherein both the first end and the second end are attached to the sole within the cavity.

12. At least one of the fixed features forms a through hole that is filled by the insert, The golf club head according to claim 9, wherein the insert is geometrically locked by the at least one of the fixed features.

13. The body further includes an undercut in the top rail, The undercut forms part of the cavity, The golf club head according to claim 1, wherein the insert is mechanically locked within the cavity by filling the undercut.

14. The body further has an undercut in the sole, The undercut forms part of the cavity, The golf club head according to claim 1, wherein the insert is mechanically locked within the cavity by filling the undercut.

15. It extends in the heel-toe direction, is parallel to the striking surface, and coincides with the center of gravity of the club head along the x-axis, The system further comprises a y-axis that is perpendicular to the ground plane and coincides with the centroid, The moment of inertia Ixx measured around the x-axis is in the range of 78 grams per square inch to 120 grams per square inch. The golf club head according to claim 1, wherein the moment of inertia Iyy measured around the y-axis is in the range of 310 grams per square inch to 466 grams per square inch.

16. The golf club head according to claim 1, wherein the first material comprises a material selected from the group consisting of steel-based materials, titanium-based materials, aluminum alloys, and titanium alloys.

17. Total mass and It also features a toe weight, The aforementioned body further includes a toe cavity, The toe cavity houses the toe weight, The golf club head according to claim 1, wherein the toe weight has a mass between 5% and 45% of the total mass of the club head.

18. Center of gravity and, The lead edge axis is parallel to the ground plane, extends in the heel-toe direction, and coincides with the loft plane, A lead edge surface that is parallel to the ground surface and coincides with the lead edge axis, The system further comprises a y-axis that is perpendicular to the ground plane and coincides with the centroid, The golf club head according to claim 1, wherein the center of gravity of the golf club head is located between 0.380 inches and 0.670 inches above the lead edge surface.

19. Heel and toe, The central surface passing vertically through the center of the faceplate, The aforementioned body includes an integrated cylindrical hosel, When viewed from the side of the toe, the hosel reference plane is parallel to the front end of the cylindrical hosel, The hosel axis is defined as the central axis of the cylindrical hosel, The lead edge axis is parallel to the ground plane, extends in the heel-toe direction, and coincides with the loft plane, When viewed from the front, the hosel-X distance, measured from the intersection of the lead edge axis and the center plane to the intersection of the lead edge axis and the hosel axis, is less than 1.5 inches. The golf club head according to claim 1, further comprising an offset distance between 0.05 inches and 0.27 inches, measured as the minimum distance between the lead edge axis and the hosel reference plane.

20. Heel and toe, The golf club head according to claim 1, further comprising: a blade length of less than 2.8 inches, measured in the heel-toe direction from the edge of the heel of the striking surface to the outermost point of the toe.

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