Multi-material iron golf club head

Abstract

To provide a tour iron having a golf club head with a faceplate, a body, and an insert.SOLUTION: A sole part, a top rail part, a rear part, and a faceplate enclose a cavity within a body. The cavity can house the insert. The insert can comprise a low-density material, allowing weight to be concentrated around the peripheral edge of a golf club head. The rear part of the golf club head has an inflection seam running from a heel to a toe. The golf club head has an upper portion, above the inflection seam and a lower portion below the inflection seam. The lower portion can have a depth greater that the upper portion depth. The faceplate, the body, and the insert can be formed of different materials having different densities. The golf club head has a comparatively high moment of inertia and a low center of gravity. Other embodiments and methods are described herein.SELECTED DRAWING: None

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority to U.S. Provisional Patent Application No. 62 / 635,020, filed February 26, 2018, U.S. Provisional Patent Application No. 62 / 713,424, filed August 1, 2018, and U.S. Provisional Patent Application No. 62 / 768,543, filed November 16, 2018, the contents of all of which are incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to golf equipment, and more particularly to multi-material iron golf club heads and methods of manufacturing said golf club heads. [Background technology]

[0003] Iron-type golf club heads typically include various styles, such as muscle back, cavity back, or tour irons. Skilled golfers with low handicaps prefer compact, aesthetically sleek tour irons. Tour irons have high lofts, low centers of gravity (CGs), short shaft lengths, small profiles, and thin toplines. Tour irons generally have a beautiful, classic appearance and a pleasing sound. Forged tour irons, in particular, are considered to offer improved "feel" and aesthetic appeal over other types of irons, such as cast irons. Low-handicap golfers, such as tour players, generally desire iron-type club heads with low CGs and closer to the club face. Tour irons have a smaller sweet spot for straighter flight, allowing these golfers to control the area of ​​the club face that impacts the golf ball for better shot control. While difficult for high-handicap golfers to use effectively, tour irons fulfill a niche demand for highly skilled, often low-handicap golfers.

[0004] On the other hand, Game Improvement irons are typically designed to accommodate high-handicap golfers who desire increased iron forgiveness and loft. High-handicap golfers tend to play iron-type clubheads with higher moments of inertia (MOI), which provide more forgiveness to the clubhead. Game Improvement irons, such as deep cavity back, muscle back, or hollow-body irons, allow for perimeter weighting, which increases the clubhead's forgiveness and allows the face to flex, resulting in greater distance. However, Game Improvement irons naturally do not "feel" like solid-body tour irons and may feel impure to golfers accustomed to traditional solid-body irons. Game Improvement irons have large profiles, resulting in a bulky feel. Such Game Improvement irons may also have thick toplines or other shape features that many golfers consider less aesthetically pleasing. The golf club heads described herein satisfy the desires of golfers who want a club that shares the benefits of both game improvement irons and tour irons.

[0005] There is a need in the art for a club head that can be used by mid to low handicap players and has 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 traditional game improvement iron. [Brief explanation of the drawings]

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

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

[0008] [Figure 3] 2 shows a rear view of the golf club head of FIG. 1.

[0009] [Figure 4] 2 shows a toe side view of the golf club head of FIG. 1.

[0010] [Figure 5] 4 shows a toe-side cross-sectional view of the golf club head of FIG. 1 taken along line VV of FIG. 3.

[0011] [Figure 6] 4 shows a toe-side cross-sectional view of the golf club head of FIG. 1 taken along line VV of FIG. 3 according to a first embodiment with a multi-material insert.

[0012] [Figure 7] 4 shows a toe-side cross-sectional view of the golf club head of FIG. 1 taken along line VV of FIG. 3 according to a second embodiment with a multi-material insert.

[0013] [Figure 8] 1 along line VV of FIG. 3 according to a third embodiment with a multi-material insert.

[0014] [Figure 9] 4 shows a toe-side cross-sectional view of the golf club head of FIG. 3 taken along line VV of FIG. 3 according to a fourth embodiment with a multi-material insert.

[0015] [Figure 10] 1 illustrates a toe-side cross-sectional view of a golf club head according to an embodiment having a rear shelf.

[0016] [Figure 11] 1 illustrates a toe-side cross-sectional view of a golf club head according to an embodiment having a rear shelf at a 90 degree angle from the loft plane.

[0017] [Figure 12]4 shows a toe-side cross-sectional view of the golf club head of FIG. 1 taken along line VV of FIG. 3, including a tape layer.

[0018] [Figure 13] 2 shows a rear perspective view of the golf club head of FIG. 1, including an exploded view of the toe cavity and toe weight.

[0019] [Figure 14] 1 shows an exploded view of a golf club head according to a second embodiment.

[0020] [Figure 15] 15 shows a rear view of the golf club head of FIG. 14.

[0021] [Figure 16] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15.

[0022] [Figure 17] 15 shows a front perspective view of the main body of the golf club head of FIG. 14.

[0023] [Figure 18] 15 shows a rear perspective view of the golf club head of FIG. 14.

[0024] [Figure 19] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15.

[0025] [Figure 20] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15 according to a first embodiment having a partial fill insert.

[0026] [Figure 21] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15 according to a second embodiment having a partial fill insert.

[0027] [Figure 22] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15 according to a third embodiment having a partial fill insert.

[0028] [Figure 23] 16 shows a heel-side cross-sectional view of the golf club head of FIG. 14 taken along line XVI-XVI of FIG. 15 according to a fourth embodiment having a partial fill insert.

[0029] [Figure 24] 2 shows a method for manufacturing the golf club head of FIG. 1.

[0030] [Figure 25] 15 shows a method for manufacturing the golf club head of FIG. 14. DETAILED DESCRIPTION OF THE INVENTION

[0031] It is well understood by those knowledgeable in golf that tour irons are visually distinct from game improvement irons by both their size and appearance. Accordingly, tour irons have different design requirements than game improvement irons. The golf clubs described herein satisfy the market demand for tour-style irons while retaining the functional advantages of game improvement irons.

[0032] Specifically, the golf club heads described herein combine the aesthetically appealing features of tour irons (e.g., compact size, forged, solid feel) with the performance advantages of game improvement irons (e.g., perimeter weighting and high forgiveness). Golf club heads are described herein having a body forming a cavity, an insert can fit within the cavity, and the cavity is surrounded by a cap on the rear of the body or by the face plate of the body. Thus, the golf club heads provide golfers with a tour-style iron club while maintaining the level of forgiveness necessary for intermediate or beginner skill golfers to make the most accurate shots possible for their skill level. Generally, tour irons are designed for highly skilled golfers or low- to medium-handicap players, while game improvement irons are designed for low- to medium-skill golfers who also have a high handicap (over 10). The golf club heads of the present description provide an option for golfers who lack the skills to use traditional tour irons but who wish to play with a range of tour irons.

[0033] Furthermore, the golf club heads provide highly skilled golfers with options for increasing shot accuracy through high MOI designs. The golf club heads described herein may have a lower MOI than certain game improvement or standard irons, but the club heads nevertheless have a higher MOI than other golf club heads within the same category, i.e., tour or miniature irons. Furthermore, the disclosed golf club heads provide a low CG, which is desirable for highly skilled golfers. The golf club heads described herein may be exemplified by, but are not limited to, these embodiments.

[0034] The golf club head can be manufactured by a method that includes swedging (swagging) a face plate onto the body of the golf club head. In a surface fusion process, the interface between the swaged face plate and the body can be laser welded. The insert is not damaged by the swedging or laser welding.

[0035] For simplicity and clarity of explanation, the drawings show general construction methods, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Further, elements in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements in the drawings may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numbers in different drawings refer to the same elements.

[0036] Described herein are golf clubs having hollow golf club heads or partially / almost hollow golf club heads, each of which includes a low-density insert (the hollow golf club heads or partially / almost hollow golf club heads are hereinafter referred to as "golf club heads"). The golf club includes a golf club head, a shaft, and a grip. The golf club head includes a body including a hosel, a front portion, a rear portion, a top rail portion, and a sole portion. The body may include a cavity. The face plate, the sole portion, the rear portion, and the top rail portion surround the cavity. In some embodiments, the cavity of the golf club head may be surrounded from the front portion by the face plate. In some embodiments, the cavity may be open at the rear portion of the club, partially exposing the cavity. The insert may fit within the cavity. The front portion of the golf club head may further include a face plate that surrounds the cavity from the front portion.

[0037] One embodiment of a golf club head described herein includes a body defining 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 can be cast or forged. The cavity can receive and accommodate the low-density insert.

[0038] The golf club head has a low-density center, a high-density perimeter, and, as previously mentioned, a low-density insert to shift weight to the perimeter, thereby improving overall forgiveness. The insert comprises a low-density material, such as aluminum, titanium, or a composite. Filling the cavity with a solid insert improves the sound and feel of the golf club head over other similar hollow-body irons. In some embodiments, adhesives and / or tape are used to further secure the insert within the cavity and prevent rattle.

[0039] The face plate surrounds the front opening of the golf club head and forms a cavity. The face plate is secured using swaging, press fitting, or other low-temperature methods. TIG welding is not used. In some embodiments, the face plate can be further secured to the body by laser welding because laser welding is very precise and does not create a significant heat-affected zone (hereinafter referred to as "HAZ") that affects the insert, tape, and / or adhesive. If the face plate were TIG welded to the front of the golf club head body, the insert, tape, and / or adhesive would be exposed to high temperatures and damaged, thereby impairing the weight distribution of the insert and compromising the material properties of the tape and / or adhesive.

[0040] The high density perimeter 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 can further include a toe cavity. The toe weight can be mounted within the toe cavity. The toe weight can include a high density material, such as tungsten. Additionally, in some embodiments, the golf club head can include a toe screw weight for swing weighting.

[0041] In a second embodiment of the golf club head, the cavity in the body is exposed through an opening in the top of the rear section. Similar to the first embodiment, the golf club head of the second embodiment includes a body and a low-density insert. The body can be cast or forged. The body includes a rear opening in the top of the body. The low-density insert is housed within the cavity in the body. In this embodiment, the insert includes a material that can be injected into the cavity, such as a thermoplastic composite, a foam, or other filler damping material.

[0042] The golf club head further includes a face plate that forms a forward boundary of the cavity. The injection molding process can form a low-density insert within the cavity of the body. The golf club head can further include a toe weight within the toe cavity of the body and / or a tip weight within the hosel for perimeter weighting. Additionally, the golf club head can include a toe screw weight for swing weighting.

[0043] In the description and claims, the terms "first," "second," "third," "fourth," etc., if any, are used to distinguish between similar elements and not necessarily to describe a particular sequence or chronological order. Terms so used are interchangeable under appropriate circumstances; for example, it is understood that the embodiments described herein may operate in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprise," "have," and any variations thereof are intended to non-exclusively encompass processes, methods, systems, articles, devices, or apparatuses, etc., that comprise a list of elements, but are not necessarily limited to those elements, and may include other elements not expressly listed or inherent to such processes, methods, articles, systems, and apparatuses.

[0044] The terms "front," "back," "rear," "top," "bottom," etc. in the specification and claims, if any, are used for descriptive purposes and not necessarily to describe permanent relative positions. It should be understood that such terms, when used, are interchangeable under appropriate circumstances, such that the device, method, and / or article embodiments described herein can operate in other orientations other than those illustrated or otherwise described herein, for example.

[0045] The term "couple" 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 coupled but not electrically or otherwise coupled. The coupling may be for any length of time, e.g., permanently or semi-permanently, or may be only momentarily.

[0046] The term MOI, as used herein, can be a quantity that describes a 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 the axis of rotation. A higher MOI makes the club head more forgiving; that is, golfers will notice more consistent shots, even when the golf ball is struck on a portion of the striking face that is off-center. MOI is increased by shifting weight away from the center of the golf club head and toward the periphery of the golf club head. To increase MOI, the center of the golf club head must contain either a cavity or a material that is lighter than the main golf club head to maintain a desired overall golf club head weight.

[0047] The golf club configurations described herein may be applied to one or more golf clubs in a set of irons. In some embodiments, the 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 the set of irons may be conventionally numbered with a number ranging from 1 to 10. Most commonly, sets are numbered 3 to 9. Additionally, the set of irons may include one or more wedges having a higher loft angle than the numbered irons.

[0048] 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.

[0049] In many embodiments, the loft angle of the golf club head is less than about 64 degrees, less than about 63 degrees, less than about 62 degrees, less than about 61 degrees, less than about 60 degrees, less than about 59 degrees, less than about 58 degrees, less than about 57 degrees, less than about 56 degrees, less than about 55 degrees, or less than about 54 degrees. Additionally, in many embodiments, the loft angle of the golf club head is greater than about 46 degrees, greater than about 47 degrees, greater than about 48 degrees, greater than about 49 degrees, greater than about 50 degrees, greater than about 51 degrees, or greater than about 52 degrees.

[0050] In many embodiments, the golf club head can have a total volume ranging from 1.9 cubic inches to 2.7 cubic inches. In some embodiments, the total volume of the golf club head can range from 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 can 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.

[0051] In many embodiments, the golf club head can include a total mass in the range of 200 grams to 300 grams. In some embodiments, the golf club head can range from 200 grams to 210 grams, 210 grams to 220 grams, 220 grams to 230 grams, 230 grams to 240 grams, 240 grams to 250 grams, 250 grams to 260 grams, 255 grams to 260 grams, 260 grams to 270 grams, 265 grams to 275 grams, 270 grams to 280 grams, 275 grams to 280 grams, or 250 grams to 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.

[0052] The golf club heads described herein can be viewed from various perspectives while in the address position, including, but not limited to, a front view, a back view, a toe-side view, a heel-side view, a top view, a sole-side view, and various perspective views. For example, the front view of the golf club head 100 views the club head from a direction forward of the loft plane 20 parallel to the ground plane 10. The back view of the golf club head 100 views the club head from a direction behind the rear 103 parallel to the ground plane 10. The toe-side view of the golf club head 100 views the club head from a toe-to-heel direction parallel to the ground plane 10. The heel-side view of the golf club head 100 views the club head from a heel-to-toe direction parallel to the ground plane 10. The sole-side view of the golf club head 100 views the club head from a sole-to-top direction perpendicular to the ground plane 10. The top view of the golf club head 100 is a view of the club head from the direction from the top to the sole, perpendicular to the ground plane 10 .

[0053] I. Golf club head having an insert and a surrounding face plate Here, a golf club head 100 will be described. As described above, the golf club head 100 may be a tour-style golf club head with forgiveness. The golf club head 100 may include a body having a cavity for accommodating an insert. The golf club head includes a face plate, a body, and an insert. The body includes an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion. The rear portion may further include a flex joint. The flex joint is the boundary between the upper and lower portions of the golf club head. The face plate and a portion of the body define the striking surface of the golf club head. The face plate, sole portion, rear portion, and top rail portion surround the cavity.

[0054] The body cavity opens toward the front of the golf club head and is surrounded by a face plate. The face plate can be crimped or laser welded to the body. The club head is a tour iron club head and has a volume ranging from 1.8 cubic inches to 2.7 cubic inches (30 cubic centimeters (cc) to 45 cc). The golf club head body can be cast or forged from a metal material.

[0055] The insert comprises 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 additional mass to be concentrated at its periphery to increase 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 allows the lower portion to have more mass concentrated at the periphery, at the heel end, toe end, and sole end. Lowering the mass of the body lowers the CG, which increases launch angle and reduces spin. As explained above, there is a need in the art for an iron that combines tour iron sizing with a relatively high moment of inertia from perimeter weighting and a low CG resulting from a low location of mass. In some embodiments, a tip weight located in the hosel and / or a toe weight located in the toe cavity of the body provides additional perimeter weighting.

[0056] 1-13 , as described above, the golf club head 100 includes a face plate 155, a body 110, and an insert 140. The body 110 may further include an upper portion 108, a lower portion 109, a sole portion 107, a rear portion 103, a toe portion 101, a heel portion 102, and a top rail portion 106. The face plate 155 and a portion of the body may define a striking surface 111. The face plate 155, the sole portion 107, the rear portion 103, and the top rail portion 106 enclose a cavity 120. The upper portion 108 is bounded by the top rail portion 106. The lower portion 109 is bounded by the sole portion 107. The rear portion 103 may include a flex joint 130. The flex joint 130 may extend from the toe portion 101 to the heel portion 102 of the golf club head. Flex joint 130 borders upper portion 108 from top rail portion 106. Flex joint 130 borders lower portion 109 from sole portion 107. Flex joint 130, as described below, marks the end of uniform upper depth 116. As shown in FIGS. 4-12, flex joint 130 is depicted as a bending point in any cross section taken from the top rail portion toward the sole portion in a toe side view.

[0057] As shown in FIGS. 2 and 3, the ground plane 10 serves as a reference for the ground when the golf club is in the address position. As shown in FIG. 4, the loft plane 20 is parallel to the striking surface 111. As shown in FIG. 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 striking surface 111. As shown in FIGS. 2 and 4, the golf club head 100 may have a coordinate system centered on the center point 60 of the golf club head 100. A golf club head 600, described below, may have similar coordinate axes. The reference axis of the x-axis 30 extends from the toe portion toward the heel portion through the center point 60. The x-axis 30 is parallel to the striking surface 111. The reference axis of the y-axis 40 extends from the top rail toward the sole portion through the center point 60. The y-axis 40 is perpendicular to the ground plane 10 when the golf club head 100 is in the address position. The z-axis 50 reference axis extends from front to rear through the CG 60. The z-axis 50 is parallel to the ground plane 10 and perpendicular to the x-axis 30 and y-axis 40. Additionally, the hosel axis 70 reference axis extends through the concentric center of the hosel 105. The leading edge axis 35 is parallel to the ground plane 10, extends in the heel-to-toe direction, and coincides with the lowest point on the generally planar striking face 111 along the center of the striking face 111. The leading edge plane is coincident with the leading edge axis 35 and is parallel to the ground plane 10.

[0058] 1) The top and bottom of the golf club head As shown in FIGS. 4 and 5 , the golf club head 100 includes 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 joint 130. The upper portion 108 of the rear portion 103 can have a uniform depth 116. The rear portion 103 includes an upper wall 131 and a lower wall 132. By remaining substantially parallel to the loft plane 20, the upper wall 131 of the rear portion 103 enables the uniform depth 116 in the upper portion 108 of the golf club head 100. At the flex joint 130, the rear profile transitions between the upper and lower portions 108, 109 of the golf club head 100, resulting in a change in 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 described below. The greater depth of the lower portion 109 is beneficial for lowering the CG of the golf club head 100 and improving launch characteristics.

[0059] This configuration of the rear portion 103 of the golf club head 100 allows mass to be located lower in the golf club head 100 than golf club heads having a flat rear design. By lowering the mass within the club head, the CG is lowered. This allows for improved ball launch and spin characteristics of the golf ball upon impact with the golf club head 100. The full benefit of the CG location is best understood by comparison with a golf club head having a flat rear portion, as provided in Example 3 below. In some embodiments, the golf club head 100 can include a CG that is in the range of 0.030 inches to 0.050 inches lower than the CG of a comparable flat-back golf club head. In some embodiments, the CG decreases in the range of 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.

[0060] The rear profile can vary among embodiments to allow the upper and lower sections 108, 109 to have different depths, volumes, or masses. As shown in the cross-sectional views of FIGS. 10 and 11 , in some embodiments, the lower wall 132 of the rear section 103 can include a shelf 139 immediately below the flex joint 130. The shelf 139 can be between the upper wall 131 and the remainder of the lower wall 132. In these embodiments, the shelf 139 extends rearward and / or downward from the flex joint 130. In one embodiment, shown in FIG. 11 , the shelf 139 is approximately perpendicular to the loft plane 20. Varying the rear profile can change the depth, volume, or mass of the upper and lower sections 108, 109, which affects the location of the CG and the MOI value.

[0061] 2) Top and bottom height 4 and 5, the golf club head 100 includes an upper portion 108 and a lower portion 109, separated by the flex joint 130. The upper portion 108 has a height 188 measured from the top rail portion 106 to the flex joint 130 along the center plane 45 in a direction parallel to the loft plane 20. The upper height 188 may range from 0.60 inches to 0.90 inches. In some embodiments, the upper height 188 may range from 0.60 inches to 0.65 inches, 0.65 inches to 0.70 inches, 0.70 inches to 0.75 inches, 0.75 inches to 0.80 inches, 0.80 inches to 0.85 inches, 0.85 inches to 0.90 inches, 0.60 inches to 0.70 inches, 0.70 inches to 0.80 inches, or 0.80 inches to 0.90 inches.

[0062] The lower portion 109 has a height 189 measured along the center plane 45 from the sole portion 107 to the flex seam 130 in a direction parallel to the loft plane 20. The lower portion height 189 can range from 0.80 inches to 1.10 inches. In some embodiments, the lower portion height 189 can range from 0.80 inches to 0.85 inches, 0.85 inches to 0.90 inches, 0.90 inches to 0.95 inches, 0.95 inches to 1.0 inches, 1.0 inches to 1.05 inches, 1.05 inches to 1.10 inches, 0.9 inches to 1.0 inches, or 1.0 inches to 1.1 inches.

[0063] The ratio of the upper height 188 to the lower height 189 can range from 9:8 (54:48) to 6:11 (54:99). In some embodiments, the ratio of the upper height 188 to the lower height 189 can range from 9:8 (54:48) to 6:8 (54:72), 6:8 (54:72) to 9:11 (54:66), or 9:11 (54:66) to 6:11 (54:99). A higher ratio of the upper height 188 to the lower height 189 can result in a lower CG because the lower height 109 has greater depth and mass, as described below. A lower CG improves launch and spin characteristics by reducing the torque imparted to the golf club head 100 upon impact with a golf ball. A lower CG can also increase ball speed and improve the feel of the golf club head 100.

[0064] 3) Depth of the top and bottom of the golf club head 4 and 5, the top 108 of the golf club head 100 may have a uniform depth. The top depth 116 of the club head 100 may range from 0.200 inches to 0.250 inches. In some embodiments, the top depth 116 may range from 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.

[0065] The lower portion 109 includes a depth 118 measured perpendicular to the loft plane 20 along the center plane 45 from the striking face 111 to the outer surface of the rear portion 103. The lower depth 118 may vary from the top rail toward the sole and / or from the heel toward the toe. The lower depth 118 is equal to or greater than the upper depth 116 of the golf club head 100. The lower depth 118 may range from 0.270 inches to 0.780 inches. In other embodiments, the lower depth 118 is between 0.270 inches and 0.320 inches, between 0.320 inches and 0.380 inches, between 0.380 inches and 0.430 inches, between 0.430 inches and 0.480 inches, between 0.480 inches and 0.530 inches, between 0.530 inches and 0.580 inches, between 0.580 inches and 0.630 inches, between 0.630 inches and 0.680 inches, and between 0.680 inches and 0.680 inches. The thickness may range from 0.730 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, 0.520 inches to 0.720 inches, and 0.570 inches to 0.770 inches.

[0066] In the toe region 101 and heel region 102 of the club head 100, the lower depth 118 can be different from the lower depth 118 at the center plane 45. The minimum lower depth 118 in the toe region 101 can be in the range of 0.300 inches to 0.460 inches. In other embodiments, the lower depth 118 in the toe region 101 can be in the range of 0.300 inches to 0.320 inches, 0.320 inches to 0.330 inches, 0.330 inches to 0.340 inches, 0.340 inches to 0.360 inches, 0.360 inches to 0.380 inches, 0.380 inches to 0.400 inches, 0.400 inches to 0.420 inches, 0.420 inches to 0.440 inches, or 0.440 inches to 0.460 inches.

[0067] The lower depth 118 in the heel region 102 can likewise differ from the lower depth at the center plane 45. The minimum lower depth 118 in the heel region 102 can range from 0.270 inches to 0.315 inches. In other embodiments, the lower depth 118 of the heel region 102 can be in the range of 0.270 inches to 0.280 inches, 0.280 inches to 0.290 inches, 0.290 inches to 0.300 inches, 0.300 inches to 0.310 inches, 0.310 inches to 0.320 inches, 0.320 inches to 0.340 inches, 0.340 inches to 0.360 inches, 0.360 inches to 0.380 inches, 0.380 inches to 0.400 inches, 0.400 inches to 0.420 inches, 0.420 inches to 0.440 inches, or 0.440 inches to 0.460 inches.

[0068] 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 striking face 111 to the outer surface of the rear portion 103. The maximum depth may range from 0.670 inches to 0.770 inches. In other embodiments, the maximum depth may range from 0.670 inches to 0.690 inches, 0.690 inches to 0.710 inches, 0.710 inches to 0.730 inches, 0.730 inches to 0.750 inches, or 0.750 inches to 0.770 inches.

[0069] In some embodiments, the ratio between the upper depth 116 and the lower depth 118 can range from 1:3 to 4:5. In some embodiments, the ratio between the upper depth 116 and the lower depth 118 can range from 1:3 to 1:2, 1:2 to 2:3, or 2:3 to 4:5.

[0070] 4) Volume above and below the golf club head 4 and 5, the upper portion 108 and lower portion 109 of the golf club head 100 can include a volume. The volume is measured from a plane adjacent the heel portion 102 and coincident with the edge / periphery of the face plate 155 to the toe portion 101. The volume of the upper portion 108 can be in the range of 0.20 cubic inches to 0.60 cubic inches. In some embodiments, the volume of the upper portion 108 can be in the range of 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 volume of the upper portion 108 is 0.48 cubic inches.

[0071] As shown in FIG. 5 , the upper portion 108 and the lower portion 109 together form the body 110, which defines a cavity 120. The portion of the cavity 120 within the upper portion 108 of the body 110 can have a volume in the range 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 can be in the range of 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 in the upper portion 108 is 0.17 cubic inches.

[0072] To position the CG appropriately 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 measured similarly to the upper portion 108 (i.e., measured from a plane adjacent the heel portion 102 and coinciding with the edge / periphery of the face plate 155 to the toe). The volume of the lower portion 109 can range from 1.15 cubic inches to 1.55 cubic inches. In some embodiments, the volume of the lower portion 109 can range from 1.15 cubic inches to 1.35 cubic inches, 1.25 cubic inches to 1.45 cubic inches, 1.35 cubic inches to 1.55 cubic inches, 1.20 cubic inches to 1.30 cubic inches, 1.30 cubic inches to 1.40 cubic inches, or 1.40 cubic inches to 1.50 cubic inches. In some embodiments, the volume of the upper portion is 1.36 cubic inches.

[0073] A portion of the cavity 120 in the lower portion 109 can have a volume in the range of 0.15 cubic inches to 0.60 cubic inches (2.46 cc to 9.83 cc). In some embodiments, the cavity volume in the lower portion 109 can be in the range of 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 in the lower portion 109 is 0.37 cubic inches.

[0074] 5) Total volume of the cavity 1 , the golf club head 100 may include a body 110 that includes a cavity 120 in a 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, which is affected by the volume of the cavity 120. A larger cavity will remove 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.

[0075] Cavity 120 can have a volume ranging from 0.2 cubic inches to 0.8 cubic inches (3.28 cc to 13.11 cc). In some embodiments, the volume of cavity 120 is 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 0.40 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 0.50 cubic inches. cubic inch, 0.50 cubic inch to 0.60 cubic inch, 0.50 cubic inch to 0.55 cubic inch, 0.55 cubic inch to 0.60 cubic inch, 0.60 cubic inch to 0.70 cubic inch, 0.60 cubic inch to 0.65 cubic inch, 0.65 cubic inch to 0.70 cubic inch, 0.70 cubic inch to 0.80 cubic inch, 0.70 cubic inch to 0.75 cubic inch, or 0.75 cubic inch to 0.80 cubic inch. In other embodiments, the cavity 120 may be 0.20 cubic inches, 0.22 cubic inches, 0.24 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, 0.5 The container may have a volume of 0 cubic inches, 0.52 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 cubic inches, 0.78 cubic inches, or 0.80 cubic inches.

[0076] Cavity 120, as described above, can have a volume between 5% and 60% of the total club head volume. In some embodiments, cavity 120 can have a volume in the range 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 club head volume. In one embodiment, the volume of cavity 120 is in the range of 17% to 32% of the club head volume.

[0077] Increasing the volume of cavity 120 removes weight from the central region of body 110. This removed weight can be redistributed around the periphery of golf club head 100, making golf club head 100 more forgiving.

[0078] The height, depth, and volume of the upper and lower portions 108, 109 of the body 110 provide the club head 100 with a lowered CG 60. Accordingly, the golf club head 100 has a lower CG than a golf club head having a flat rear portion, as illustrated in Example 3 below. As discussed above, the golf club head 100 can have a CG 60 that is lower than the CG of a comparable flat-back golf club head by a range of 0.030 inches to 0.050 inches. The lower the CG 60, the golf club head 100 will have better launch characteristics, better spin characteristics, and higher ball speeds than a flat-back golf club head.

[0079] 6) Golf club head thickness profile The thickness of the rear portion 103 of the body 110 also affects the weight of the golf club head 100 and, therefore, the center of gravity (CG) position. This thickness is measured from the outer surface of the rear portion 103 to the inner surface of the rear portion 103 within the cavity 120. In some embodiments, the rear portion 103 of the body 110 is thicker adjacent the sole portion 107 of the body 110. Due to the density of the body 110 material, the greater thickness adjacent the sole portion 107 shifts mass downward compared to a golf club head body having a uniform rear portion thickness. As shown in the cross-sectional view of FIG. 5 , the rear portion 103 of the body 110 can have a thickness 113. The rear portion thickness 113 can 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 may be constant across the rear portion 103. In some embodiments, the rear thickness 113 varies across the rear portion 103 from the heel to the toe and / or from the top rail to the sole. Varying the thickness 113 of the rear portion 103 may aid in shifting mass toward the sole portion 107 and rear portion 103 of the golf club head 100. Shifting mass toward the sole portion 107 and rear portion 103 lowers the CG, which may improve launch characteristics, improve spin characteristics, and increase ball speed.

[0080] 7) Cavity of the main body 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 perimeter of the cavity 120. The inner perimeter 127 internally bounds the top rail portion 106, the sole portion 107, the toe portion 101, and the heel portion 102. The inner perimeter 127 may follow the contour of the outer edge of the golf club head 100. The inner 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 of the low-density insert 140 and its weighting benefits are also maximized.

[0081] In some embodiments, although not depicted, the inner periphery 127 is gently tapered such that, in a cross-section of the golf club head 100 taken in a front-to-rear direction, the cavity 120 covers a larger area closer to the front portion 104 and a smaller area closer to the rear portion 103. In these embodiments, this tapering allows the larger area adjacent the front portion 104 to incorporate more surface area of ​​the low-density insert, thereby locating it closer to the front portion 104. The smaller interior cavity area left for the low-density insert leaves more high-density material in the rear portion 103 of the golf club head 100. Thus, molding the cavity 120 allows for more mass to be located adjacent the rear portion 103 and sole portion 107 of the golf club head 100, which can move the center of gravity (CG) downward and rearward.

[0082] 8) Depressions in the cavity of the golf club head 1 and 5, the front portion 104 of the body 110 further includes an indentation 142 for receiving a face plate 155. The indentation 142 connects to the forward opening of the cavity 120 but is not considered part of the cavity 120. The indentation 142 includes a perimeter 143 that generally follows the contours of the golf club head 100, including but not limited to the top rail portion 106, the edges of the body in the toe portion 101, the sole portion 107, and the generally vertical parting line adjacent the heel portion 102. The perimeter 143 of the indentation 142 is offset from the inner perimeter 127 that defines the cavity 120. The area of ​​the indentation 142, as bounded by the perimeter 143, is greater than the area circumscribed by the inner perimeter 127 at the front portion of the cavity 120. The recess 142 has a depth approximately equal to the thickness of the face plate 155, as will be described later.

[0083] A face plate 155 is positioned within the cavity 120, coincident with the recess 142, and rests on the recess 142. An insert 140 (described below) fits within the cavity up to a volume that is flush with the recess 142. The remaining volume of the cavity 120 is filled by the face plate 155, which rests on the recess 142. Together, the insert 140 and the face plate 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 rests on the same plane as the recess 142. This allows the insert 140 to not interfere with the face plate 155, which rests on the recess 142.

[0084] In other embodiments described below, the insert 140 does not fill the volume of the cavity 120 up to the recess 142, but only partially. These embodiments also involve the insert 140 not interfering with the faceplate 155 located above the recess 142.

[0085] B. Golf club head insert In contrast to conventional single-material tour irons, the golf club head 100 includes a low-density insert 140 that fits within the cavity 120 of the body 110. As shown in FIG. 1 , the insert 140 is molded to fit within the cavity 120. The insert 140 may completely fill or partially fill the cavity 120, as described above. In some embodiments, the insert 140 shares a wall shape with the cavity 120. The shape of the insert 140 can be identical or nearly identical to the shape of the cavity 120. In embodiments in which the insert substantially fills the cavity 120, the volume and other dimensions of the insert 140 generally correspond to the respective volumes and other dimensions of the cavity 120. As explained 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.

[0086] 1) Multi-material (multi-density) insert In some embodiments, a multi-material insert 440 is used in place of the insert 140. The multi-material insert 440 can have dimensions and volumes similar to those of the insert 140. The multi-material insert 440 can include a first portion 450 and a second portion 460 made of different materials having different densities. In some embodiments, the first portion 450 is a low-density portion, and the second portion 460 is a weight. Adding weight to the lower portion of the insert 440 lowers the CG 60 of the golf club head 100, thereby improving launch characteristics and increasing ball speed. Adding weight to lower the CG 60 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 can 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.

[0087] As mentioned above, the insert 440 can be formed with the first portion 450 and the second portion 460 in any orientation or combination relative to one another, so 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. The first portion 450 can be separate from the second portion 460 or can be integrally formed into a single multi-material insert 440. Various embodiments of the multi-material inserts 440, 440B, 440C, and 440D are shown in Figures 6-9 and described below.

[0088] Referring to FIG. 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 of FIG. 6 is taken along the center plane 45 of the golf club head 100. The first portion 450 of the insert 440 is adjacent to the face plate 155 and includes a first material. The second portion 460 of the insert 440 is adjacent to the rear portion 103 of the body 110 and includes a second material. The first portion 450 overlaps the second portion 460. The first portion 450 of the insert 440 includes a front surface that abuts the rear surface 128 of the face plate 155. The second portion 460 does not engage the face plate 155. The second portion 460 includes a front surface that engages the rear surface of the first portion 450. The second portion 460 is enclosed within a portion of the cavity 120 within the lower portion 109 of the golf club head 100 .

[0089] In some embodiments, the mating surfaces of one or both of the first and second portions 450, 460 include small features (not shown) extending outward from the generally flat surfaces to increase the mating surface area. These small features may include protrusions, lips, ribs, hooks, or any other suitable features. These features allow the first portion 450 to be secured onto the second portion 460 through a molding or co-molding process.

[0090] 7-9, three additional exemplary embodiments of a multi-material insert are depicted in cross-sectional views of the club head 100 taken along the central plane 45. A second embodiment of a multi-material insert 440B includes a first portion 450B and a second portion 460B arranged as shown in FIG. 7. In this embodiment, the first portion 450B forms the upper portion of the insert 440B, and the second portion 460B forms the lower portion of the insert 440B. Both the first portion 450B and the second portion 460B are in contact with the face plate 155. The first portion 450B fills a portion of the cavity 120 within the upper portion 108 of the body 110. The second portion 460B fills a portion of the cavity 120 within the lower portion 109 of the body 110. The second portion 460B is in contact with the entire inner sole wall of the cavity 120.

[0091] A third embodiment of the multi-material insert 440C includes a first portion 450C and a second portion 460C arranged as shown in FIG. 8 . In this embodiment, the first portion 450C comprises a majority of the volume of the insert 440C. The first portion 450C extends partially into the rear end of the insert 440C. The second portion 460C is located entirely rearward of the first portion 450C. The first portion 450C contacts the face plate 155 from the top rail portion 106 to the sole portion 107 within the cavity of the golf club head 100. The second portion 460C does not engage the face plate 155. The second portion 460C partially fills and is fully seated within a portion of the cavity 120 within the lower portion 109 of the body 110. The second portion 460C engages a portion of the inner sole wall and rear back wall of the cavity 120. In some embodiments, the second portion 460C is formed from a high density material.

[0092] A fourth embodiment of the multi-material insert 440D includes a first portion 450D and a second portion 460D arranged as shown in FIG. 9 . In this embodiment, the first portion 450D extends partially into the rear end of the insert 440D. The first portion 450D engages with the second portion 460D along a plane angled relative to the loft face 20. Additionally, the first portion 450D is wider adjacent the bottom of the insert 440D than adjacent the top of the insert 440D. With respect to the golf club head 100, the first portion 450D is wider adjacent the sole portion 107 than adjacent the top rail portion 106. The first portion 450D abuts the face plate 155 from the top rail portion 106 to the sole portion 107 within the cavity 120 of the golf club head 100. The second portion 460D does not engage the face plate 155. The second portion 460D partially fills and is completely disposed within a portion of the cavity 120 within the lower portion 109 of the body 110. The second portion 460D engages a rear back wall of the cavity 120. In some embodiments, the second portion 460D is formed from a high-density material. The golf club head 100 with the multi-material insert 440 provides improved feel and sound compared to tour irons without the insert.

[0093] In yet another embodiment of the golf club head 100 having a multi-material insert, although not shown, a second portion similar to second portions 460, 460B, 460C, and 460D can be located primarily in the toe portion 101 of the golf club head 100. This provides a toe weight effect, acting similarly to toe weight 161, described below. Embodiments having the second portion of the insert acting as a toe weight do not require an external toe weight. This allows for improved aesthetics and simplified manufacturing by eliminating the need for welding at the toe weight.

[0094] 2) The volume of the cavity filled with the insert in the golf club head 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 a volume of the cavity 120 in the range of 80% to 100%. In some embodiments, the insert 140 can fill a volume of the cavity 120 in the range of 80% to 85%, 85% to 90%, 90% to 95%, 95% to 100%, 80% to 90%, or 90% to 100%. In embodiments having a multi-material insert such as insert 440, the first portion 450 can fill a majority 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 a range of 20% to 90% of the cavity volume. In some embodiments, the first portion 450 can fill a range of 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 a range of 10% to 80% of the cavity 120 volume. In some embodiments, the second portion 460 can fill a range of 10% to 20%, 20% to 30%, 30% to 40%, or 40% to 50%.

[0095] Because the first and second portions 450, 460 are formed from different materials having different densities, as described in more detail below, the volumes of the first and second portions 450, 460 affect the overall weight of the golf club head 100. Many design parameters must be considered together in the design of a golf club head. By forming the insert from multiple materials, mass placement can be controlled to increase perimeter weight and lower CG, leading to improved launch characteristics and faster ball speeds.

[0096] 3) A tape layer combined with an insert in a golf club head In some embodiments, tape layer 150 is disposed in cavity 120 between insert 140 and striking face 111. As seen in FIG. 12 , tape layer 150 is sandwiched between insert 140 and face plate 155. Golf club head embodiments having a multi-material insert, such as insert 440, may similarly include tape layer 150 between first portion 450 and face plate 155 or between first portion 450 of insert 440 and body 110. Within golf club head 100, insert 140 fits within body 110, tape layer 150 may optionally rest on insert 140, and face plate 155 covers tape layer 150 and fills recess 142 in body 110.

[0097] In some embodiments not shown, the second tape layer can be located flush with the inner surface of the rear portion 103 of the body 110 within the cavity 120. The second tape layer can be sandwiched between the rear portion 103 of the body 110 and the insert 140. In some embodiments, the third tape layer can be located flush with the bottom of the cavity 120. The third tape layer can be sandwiched between the sole portion 107 of the body 110 and the insert 140. The golf club head 100 can include one or more of the first tape layer 150, the second tape layer, and the third tape layer.

[0098] The tape layer 150, the second tape layer, or the third tape layer can include a material such as very high bond (hereinafter, "VHB") tape. VHB tape is compressible such that the original thickness (measured perpendicular to the striking face 111) of the tape layer 150 when initially applied is greater than the thickness of the compressed tape layer in the assembled golf club head 100. The second and third tape layers may be similarly compressible. The compressible nature of the tape layer(s) reduces the possibility of rattle caused by manufacturing tolerances between the body 110 and the insert 140. Additionally, the tape layer(s) can provide vibration damping as well as positively affect the feel and sound of the golf club head 100.

[0099] C. Golf club head face plate The complete golf club head 100 is formed by the combination of the body 110, the insert 140, and the face plate 155. The body 110 has an opening to a cavity 120 in the front portion 104 of the golf club head 100. The opening is covered by the face plate 155 to completely enclose 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 within the cavity 120. By hiding the insert 140 within the golf club head 100, the appearance of the golf club head 100 can resemble that of a traditional tour iron.

[0100] Thus, a portion of the front portion 104 of the body 110 and the face plate 155 form a striking face 111. The striking face 111 can cover between 70% and 95% of the surface area of ​​the front portion 104 of the golf club head 100. In some embodiments, the striking face 111 can cover between 70% and 80%, 75% and 85%, 80% and 90%, or 85% and 95% of the surface area of ​​the front portion of the golf club head 100. Additionally, the front surface of the striking face 111 may include one or more grooves. In some embodiments, the grooves extend beyond the edge of the face plate 155 onto a portion of the body 110.

[0101] The face plate 155 can comprise a different material than the body 110, as described below. In some embodiments, the material of the face plate 155 is stronger than the material of the body 110. To take advantage of the benefits of the face plate 155 material, a majority of the striking face 111 is formed by the face plate 155. The face plate 155 can form between 50% and 95% of the surface area of ​​the front portion 104 of the golf club head 100. In some embodiments, the face plate 155 can form between 50% and 60%, 60% and 70%, 70% and 80%, 80% and 90%, or 85% and 95% of the surface area of ​​the striking face 111. Because the insert 140 provides firm support for the face plate 155, both the face plate 155 and the body 110 portion of the striking face 111 provide a solid feel despite being made of different materials. The body 110 , insert 140 , and face plate 155 can all contribute to a consistent feel and sound of the golf club head 100 when the golf club head 100 impacts a golf ball on various areas of the face plate 155 .

[0102] 1) Other characteristics of the faceplate The support provided to the face plate 155 by the insert 140 allows a thin face plate 155 to be used in the golf club head 100. As shown in FIG. 5 , the face plate 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 face plate thickness 112 can 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 face plate thickness 112 can be constant across the face plate 155. In some embodiments, the face plate thickness 112 can vary from the heel to the toe or from the top rail to the sole. In some embodiments, the face plate thickness 112 can vary radially from the center of the face plate 155.

[0103] In other embodiments, faceplate 155 can further comprise a variable thickness region. In some embodiments, a central region of faceplate 155 can be thicker than a peripheral region of faceplate 155. In some embodiments, the thickened central region can have an elliptical shape. The thickness of faceplate 155 can taper from the center toward the periphery of faceplate 155.

[0104] D. Other perimeter weighting of the golf club head (tip weight, toe weight) In addition to the perimeter weighting and swing characteristics provided by the insert 140 and the body 110, the golf club head 100 can further include other perimeter-type weightings. In some embodiments, the golf club head 100 can further include a tip weight 160. The tip weight 160 is a weight that fits at the junction between the hosel 105 and the golf club shaft. The tip weight 160 provides additional perimeter weighting to the club head 100. As shown in FIG. 13 , the tip weight 160 fits within the hosel 105 of the body 110. The tip weight 160 can be cylindrical, spherical, cubic, or any other suitable shape. The tip weight 160 can be located higher or lower within the hosel 105 than shown in FIG. 13 .

[0105] As shown in FIGS. 1 and 13 , the body 110 of the golf club head 100 may further include 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. FIG. 3 shows the toe cavity 114 with the toe weight 161 installed. FIG. 13 shows the toe weight 161 removed from the toe cavity 114. In some embodiments, the toe cavity 114 is located partially within the sole portion 107 and partially within the toe portion 101. In some embodiments, the toe cavity 114 is located completely within the toe portion 101 of the golf club head 100 and adjacent to the sole portion 107. In some embodiments, the toe cavity 114 is located completely within the sole portion 107 and adjacent to the toe portion 101. In some embodiments, the toe cavity 114 is located entirely within the toe portion 101. In some embodiments, the toe cavity 114 is located in the center of the toe portion 101, approximately halfway between the top rail portion 106 and the sole portion 107.

[0106] In some embodiments, the toe cavity 114 is visible from a rear view of the body 110 of the club head 100. In other embodiments, the toe cavity 114 is not visible from a rear view of the body 110. In some embodiments, the toe cavity 114 is visible from a toe side view of the body 110. In other embodiments, the toe cavity 114 is not visible from a toe side view of the body 110. In some embodiments, the toe cavity 114 is visible from a sole side view of the body 110. In other embodiments, the toe cavity 114 is not visible from a sole side view of the body 110. In the embodiments of Figures 1-13, the toe cavity 114 is visible from the rear view, the sole side view, and the toe side view.

[0107] The toe weight 161 is shaped to match the contours of the toe cavity 114 of the body 110. The outer wall of the toe weight 161 is designed to follow the curves of the body 110 of the golf club head. In some embodiments, the mass of the toe weight 161 can be in the range of 5% to 45% of the mass of the body 110. In some embodiments, the mass of the toe weight 161 can be in the range of 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.

[0108] In some embodiments, the body 110 of the golf club head 100 may further include a toe screw weight port in the toe portion 101, although this is not shown. 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 weight ranging from 2 grams to 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 may be replaced with a different screw weight having a different weight value.

[0109] In some embodiments, there are combinations of the above weights, including inserts, toe weights, tip weights, and toe screw weights. Other embodiments may include a multi-material insert combined with one or more of the toe weights, tip weights, and toe screw weights.

[0110] E. Material The materials forming the body 110, insert 140, and face plate 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 golf club head 100 with the necessary strength and flexibility. The golf club head 100 may include 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.

[0111] In some embodiments, faceplate 155 can include a first material having a first density. Body 110 can include a second material having a second density. Insert 140 can include a third material having a third density. The third density can be less than the first density and / or the second density. In some embodiments, faceplate 155 can be the same material (and therefore the same density) as body 110. As mentioned above, in some embodiments, insert 440 can include two or more materials that are different from each other and can be different or the same across the materials of faceplate 155 and / or body 110.

[0112] 1) Body material The body 110 can include a material such as steel, a steel alloy, or any other suitable material. In some embodiments, the body 110 can include materials with different densities across the faceplate 155 and the insert 140. The material can include a material selected from the group consisting of a steel-based material and a steel alloy. In some embodiments, the body material can be 8620 carbon steel, which includes iron, approximately 0.17-0.23% by weight carbon, approximately 0.15-0.35% by weight silicon, approximately 0.60-0.90% by weight manganese, approximately 0.15-0.30% by weight molybdenum, approximately 0.40-0.70% by weight nickel, approximately 0.40-0.65% by weight chromium, approximately 0.040% by weight phosphorus, and trace amounts of other elements. In some embodiments, the body material can be 300-grade steel, containing iron, approximately 18-19% nickel, approximately 8.5-9.5% cobalt, approximately 4.6-5.2% molybdenum, approximately 0.5-0.8% titanium, approximately 0.05-0.15% aluminum, and trace amounts of other elements. In some embodiments, the body material can be maraging steel, containing iron, approximately 17-19% nickel, approximately 8-12.5% ​​cobalt, approximately 3.0-5.2% molybdenum, approximately 0.15-1.6% titanium, approximately 0.05-0.15% aluminum, and trace amounts of other elements. The density of the body 110 material can range from 7.70 to 8.10 grams per cubic centimeter (hereinafter "g / cc"). In some embodiments, the density of the body material can 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.

[0113] 2) Insert material The insert 140 may comprise a material such as titanium, a titanium alloy, aluminum, an aluminum alloy, an elastomer, a polymer matrix composite, any other suitable low-density material, or any other suitable density material that is lower in density 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 a Kevlar® (aramid) fiber-reinforced polymer, a carbon fiber-reinforced polymer, or any other elastomer matrix composite that is any combination of a suitable resin and suitable reinforcing fibers. 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 base material can be 17-4PH stainless steel, 431, 455, 457, 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 Ti-15-3-3-3. The titanium alloy can be an alpha-beta titanium alloy.

[0114] The insert 140 may include materials with different densities across 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 having a metal insert material, the density of the insert 140 material may range from 2.4 g / cc to 5.0 g / cc. In some embodiments, the density of the insert 140 material can 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, or 5.0 g / cc. In one embodiment, the insert 140 material 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 about 4.5 g / cc.

[0115] In some embodiments, particularly those having a polymer matrix composite material, the density of the insert 140 can range from 1.0 g / cc to 12.0 g / cc. In preferred embodiments of a polymer matrix composite material, the density of the insert 140 can range from 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 insert 140 can lighten the central portion of the club head that houses the insert 140, allowing weight to be redistributed to the periphery of the club head. The redistributed weight increases the MOI.

[0116] In some embodiments of the golf club head 100, the insert 440 includes separate portions formed from different materials and different densities. In some embodiments, the first and second portions 450, 460 of the insert 440 can each be formed from any of the materials described above for the single-material insert. In some embodiments, the first portion 450 of the insert 440 is formed from an elastomer or polymer matrix composite material having a density ranging from 0.8 g / cc to 1.4 g / cc, and the second portion 460 of the insert 440 is formed from aluminum or an aluminum alloy having a density ranging from 1.5 g / cc to 3.0 g / cc.

[0117] In some embodiments of the golf club head 100, the first portion 450 of the insert 440 can include any of the materials described above having a density ranging from 1.0 g / cc to 12.0 g / cc. In some embodiments, the second portion 460 of the insert 440 can include a material having a density higher than the density of the body material. In some embodiments, the second portion 460 of the insert 440 can include any of the materials described below for the toe weight 161, resulting in a weight portion having a density ranging from 14.0 g / cc to 19.6 g / cc. In some of these embodiments, the toe weight 161 is not necessary, as the second portion 460 of the insert 440 serves a similar purpose.

[0118] The weight of the insert 140 or 440 can range from 10 grams to 50 grams. In some embodiments, the weight of the insert 140 can 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 comprises a material similar to that of the toe weight 161 described below, the weight of the insert 140 or 440 may range from 10 grams to 70 grams. In some embodiments, the weight of the multi-material insert 140 or 440 may range from 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.

[0119] Additionally, inserts 140 and 440 provide structural support to striking face 111. In embodiments having a metal insert material, insert 140 or 440, or a portion of insert 140 or 440, can include a Rockwell B hardness ranging from 30 HRB to 100 HRB. In some embodiments, insert 140 or 440, or a portion of insert 140 or 440, can have a Rockwell B hardness ranging from 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, or 90 HRB to 100 HRB. In other embodiments, the insert 140 or a portion of the insert 140 may be 30HRB, 31HRB, 32HRB, 33HRB, 34HRB, 35HRB, 36HRB, 37HRB, 38HRB, 39HRB, 40HRB, 41HRB, 42HRB, 43HRB, 44HRB, 45HRB, 46HRB, 47HRB, 48HRB, 49HRB, 50HRB, 51HRB, 52HRB, 53HRB, 54HRB, 55HRB, 56HRB, 57HRB, 58HRB, 59HRB, 60HRB, 61HRB, 62HRB, 63HRB, The hardness may be 64 HRB, 65 HRB, 66 HRB, 67 HRB, 68 HRB, 69 HRB, 70 HRB, 71 HRB, 72 HRB, 73 HRB, 74 HRB, 75 HRB, 76 HRB, 77 HRB, 78 HRB, 79 HRB, 80 HRB, 81 HRB, 82 HRB, 83 HRB, 84 HRB, 85 HRB, 86 HRB, 87 HRB, 88 HRB, 89 HRB, 90 HRB, 91 HRB, 92 HRB, 93 HRB, 94 HRB, 95 HRB, 96 HRB, 97 HRB, 98 HRB, 99 HRB, or 1000 HRB. In other embodiments having a metal insert, the insert 140 or 440, or a portion of the insert 140 or 440, may include a Rockwell C hardness ranging from 30 HRC to 60 HRC. In some embodiments, the insert 140 or 440 may have a hardness ranging from 30HRC to 40HRC, 35HRC to 45HRC, 40HRC to 50HRC, 45HRC to 50HRC, or 50HRC to 60HRC.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 some embodiments including titanium or titanium alloy inserts 140 or 440, the insert hardness is 44HRC.

[0120] 3) Faceplate material 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 a different material than the body material. In some embodiments, the faceplate 155 can include different densities of material across the body 110 and the insert 140.

[0121] The faceplate material can be a steel-based material, a titanium-based material, a titanium alloy, or any combination thereof. The steel-based material can be carbon steel, 17-4PH stainless steel, 431, 455, 475, C300, maraging steel, or other types of stainless steel. The titanium alloy can be Ti-7S+ (ST721), Ti-9S, Ti-6-4, Ti-15-3-3-3, or any other suitable titanium alloy. The titanium alloy can be an alpha-beta titanium alloy. In embodiments in which 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 range from 2.6 g / cc to 8.7 g / cc. In some embodiments, the density of the faceplate material can be in the range of 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 faceplate 155 is a steel-based material, the density of the faceplate material may range from 7.7 g / cc to 8.1 g / cc.

[0122] 4) Tip weight material The tip weight 160 may comprise a material different from the materials of the body 110, the face plate 155, and the insert 140 or 440. The tip weight 160 comprises a high density material, such as tungsten or any other suitable metal or metal alloy material. The density of the tip weight 160 may range from 1.1 g / cc to 19.6 g / cc. In some embodiments, the density of the tip weight 160 material is 1.1 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, 5.0 g / cc, 5.5 g / cc, 6.0 g / cc, 6.5 g / cc, 7.0 g / cc, 7.5 g / cc, 8.0 g / cc, 8.5 g / cc, 9.0 g / cc, 9.5 g / cc, 10.0 g / cc, 10.5 g / cc, 11.0 g / cc, 11.5 g / cc, 12.0 g / cc, 12.5 g / cc, 13.0 g / cc, 13.5 g / cc, 14.0 g / cc, 14.5 g / cc, 15.0 g / cc, 15.5 g / cc, 16.0 g / cc, 16.5 g / cc, 17.0 g / cc, 17.5 g / cc, 18.0 g / cc, 18.5 g / cc, 19.0 g / cc, 19.5 g / cc, 20.0 g / cc, 20.5 g / cc, 21.0 g / cc, 21.5 g / cc, 22.0 g / cc, 22.5 g / cc, 23.0 g / cc, 23.0 g / cc, 24.0 g / cc, 24.5 g / cc, 25.0 g / cc, 26.0 g / cc, 27.0 g / cc, 27.5 g / cc, 28.0 g / cc, 28.5 g / cc, 29.0 g / cc, 29.5 g / cc, 30.0 g / cc, The tip weight 160 may have a weight in the range of 0.5 g / cc, 14.0 g / cc, 14.5 g / cc, 15.0 g / cc, 15.5 g / cc, 15.8 g / cc, 16.0 g / cc, 16.2 g / cc, 16.4 g / cc, 16.6 g / cc, 16.8 g / cc, 17.0 g / cc, 17.2 g / cc, 17.4 g / cc, 17.6 g / cc, 17.8 g / cc, 18.0 g / cc, 18.2 g / cc, 18.4 g / cc, 18.6 g / cc, 18.8 g / cc, 19.0 g / cc, 19.2 g / cc, 19.4 g / cc, or 19.6 g / cc. The tip weight 160 may have a weight in the range of 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 ranges from 0 grams to 9 grams.

[0123] 5) Toe weight material The toe weight 161 can comprise a material that is different from the materials of the body 110, face plate 155, tip weight 160, and insert 140 or 440. The toe weight 161 comprises a high density material, such as tungsten or any other suitable metal or metal alloy material. The density of the toe weight 161 material can range from 14.0 g / cc to 19.6 g / cc. In some embodiments, the density of the toe weight 161 material can range from 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, 16.6 g / cc, 16.8 g / cc, 16.9 ... c, 16.8 g / cc, 17.0 g / cc, 17.2 g / cc, 17.4 g / cc, 17.6 g / cc, 17.8 g / cc, 18.0 g / cc, 18.2 g / cc, 18.4 g / cc, 18.6 g / cc, 18.8 g / cc, 19.0 g / cc, 19.2 g / cc, 19.4 g / cc, or 19.6 g / cc. The weight of the toe weight 161 may range from 10 grams to 40 grams. In some embodiments, the weight of the toe weight 161 can 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, and 40 grams. In some embodiments, the weight of the toe weight 161 can range from 12 grams to 26.5 grams.

[0124] 6) Toe screw weight material The toe screw weight (swing weight) can include any high-density material similar to the high-density material of the tip weight or toe weight. The density of the toe screw material can be similar to the density of the tip weight material. The weight of the toe screw weight can be similar to the weight of the tip weight described above.

[0125] II. Golf club head with rear opening Here, a golf club head 600 will be described. Similar to the golf club head 100, the golf club head 600 may be a tour-style golf club head with the forgiveness described above. The golf club head 600 may include a body 610 having a cavity 620 that receives an insert 640. The golf club head 600 includes a face plate 655, the body 610, and the insert 640. The body 610 includes an upper portion 608, a lower portion 609, a sole portion 607, a rear portion 603, and a top rail portion 606. The rear portion 603 may further include a flex joint 630. The flex joint 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 a portion of the body define a striking face 611 (striking surface) of the golf club head. The face plate 655 , the sole portion 607 , the rear portion 603 , and the top rail portion 606 enclose a cavity 620 .

[0126] 14-23 show a golf club head 600 similar to golf club head 100. Golf club head 600 includes a body 610 forming a cavity 620, a face plate 655, a rear opening 680, and a low-density insert 640 within the cavity. Body 610 includes an upper portion 608, a lower portion 609, a sole portion 607, a rear portion 603, and a top rail portion 606. Rear portion 603 may further include a flex joint 630. Flex joint 630 is the boundary between upper portion 608 and lower portion 609 of golf club head 600. Face plate 655 and a portion of body 610 define a striking face 611 (hitting surface) of golf club head 600.

[0127] Body 610 is similar to body 110. Face plate 655, sole portion 607, and rear portion 603 form a cavity 620 with a rear opening 680 in a top portion 608 of golf club head 600. Rear opening 680 in body 610 partially exposes cavity 620. After assembly, insert 640 is visible through opening 680 in rear portion 603. Body 610 further includes a recess 642 in front portion 604 of body 610 for receiving face plate 655, similar to recess 142 described above for club head 100.

[0128] An insert 640 is housed within the cavity 620. The insert 640 may comprise a non-metallic or polymer-based material. The insert material may be injected into the cavity 620 of the golf club head 600 through the rear opening to form the insert 640 within the cavity 620. In other embodiments, the insert 640 may comprise a metallic material similar to the insert 140 described above. A face plate 655 surrounds the cavity 620 at the front portion 604 of the golf club head 600. The face plate 655 and the front portion 604 of the body 610 together define a striking face 611.

[0129] The golf club head 600 is a tour iron club head and has a volume of 1.8 to 2.7 cubic inches (30 to 45 cc) cubic centimeters (cc). The body 610 of the golf club head 600 can be cast or forged from a metal material.

[0130] The insert 640 comprises a low-density material and fills the cavity 620 formed by the body 610 of the golf club head 600. Reducing the mass at the center of the golf club head 600 allows for additional mass to be concentrated at its periphery to increase the moment of inertia value of the golf club head 600. As described above, the golf club head 600 comprises a lower portion 609 and an upper portion 608. The lower portion 609 has a greater depth than the upper portion 608. This allows the lower portion 609 to have more mass concentrated at the periphery in the heel portion 602, toe portion 601, and sole portion 607. Lowering the mass of the body 610 results in a lower CG 60, which increases launch angle, reduces spin, and increases ball speed. As discussed above, there is a need in the art for an iron that combines tour iron sizing with a relatively high moment of inertia from perimeter weighting and a low CG resulting from a low location of mass. In some embodiments, a tip weight 660 located in the hosel and / or a toe weight 661 located in the toe cavity 614 of the body 610 provides additional perimeter weighting. In some embodiments, a toe screw weight 662 (swing weight) located in the toe screw weight cavity 663 (swing weight cavity) of the body 610 provides additional perimeter weighting.

[0131] Golf club head 600 can be described in terms of the same reference planes and axes as golf club head 100. The definitions of ground plane 10, loft plane 20, center plane 45, center point 80, leading edge axis 35, leading plane, x-axis 30, y-axis 40, z-axis 50, and hosel axis 70 remain the same for golf club head 600 as they were for golf club head 100.

[0132] A. Golf club head part 15 and 16, the body 610 includes at least an upper portion 608, a lower portion 609, a sole portion 607, a top rail portion 606, a rear portion 603, a front portion 604, a toe portion 601, a heel portion 602, and a hosel 605, each of which is similar to the upper portion 108, the lower portion 109, the sole portion 107, the top rail portion 106, the rear portion 103, the front portion 104, the toe portion 101, the heel portion 102, and the hosel 105 of the golf club head 100. In some embodiments, a face plate 655 is welded or crimped across the front opening of the body 610.

[0133] The body 610 includes a flex seam 630 and a rear profile similar to the flex seam 130 and rear profile of the golf club head 100. The height of the upper and lower portions 608, 609, the depth of the upper and lower portions 608, 609, and the thickness of the rear portion 603 are similar to the height of the upper and lower portions 108, 109, the depth of the upper and lower portions 108, 109, and the thickness of the rear portion 103 of the golf club head 100.

[0134] The body 610 further includes an aperture wall 682 at the rear of the body 610. The aperture wall 682 defines a rear aperture 680. The rear aperture 680 of the body 610 is located in the upper portion 608 of the club head 600, above the flex joint 630. The uniform depth of the upper portion 608, coupled with the location of the rear aperture 680 within the entire upper portion 608, allows for a flat surface surrounding the aperture 680. On all sides of the aperture wall 682 (rear aperture 680) of the body 610, the exterior surface of the golf club head 600 is flat. This flat surface is necessary to provide a seal around the rear aperture 680 during injection of insert material into the cavity 620 during manufacturing, as described further below.

[0135] To identify the size of the rear opening 680, one can take the projected area of ​​the rear portion 603 (not including the hosel 605 or sole portion 607) parallel to the loft plane 20. The projected area of ​​the rear portion 603 can be compared to the projected area circumscribed by the opening walls 682. The opening walls 682 circumscribe (cover) an area in the range of 25% to 50% of the projected area of ​​the rear portion 603 of the club head 600. In some embodiments, the opening walls 682 can enclose a percentage of the rear region in the range of 25% to 30%, 25% to 35%, 30% to 40%, 35% to 45%, 40% to 50%, or 45% to 50%. In other embodiments, the opening wall 682 can enclose 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% of the rear area.

[0136] In some embodiments, the insert 640 is visible through the rear opening 680. In some embodiments, between 10% and 60% of the insert is visible through the rear opening 680. In some embodiments, between 10% and 20%, 15% and 25%, 20% and 30%, 25% and 35%, 30% and 40%, 35% and 45%, 40% and 50%, 45% and 55%, or 50% and 60% of the insert 640 is visible through the rear opening 680. Although not shown, in some embodiments, a badge is positioned over the rear opening 680. In these embodiments, the badge may cover between 10% and 60% of the insert. In some embodiments, the badge may cover between 10% and 20%, 15% and 25%, 20% and 30%, 25% and 35%, 30% and 40%, 35% and 45%, 40% and 50%, 45% and 55%, or 50% and 60% of the insert 640.

[0137] The rear portion 603, including the opening wall 682 that defines the rear opening 680, contributes to the low mass of the upper portion 608. Filling the rear opening 680 with a material having a density lower than that of 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 perimeter weight distribution to improve the forgiveness of the golf club head. Various design parameters can contribute to the low mass of the upper portion. As discussed above for the golf club head 100, maintaining a uniform upper depth also contributes to the low mass of the upper portion 608.

[0138] Because the material used to form the body 610 generally has a higher density than the material of the insert 640, replacing the portion of the rear body 610 surrounded by the aperture wall 682 with the insert material can reduce the mass of the upper portion 608. Compared to a similar golf club head having a solid rear portion formed solely from body material, the golf club head 600 has a lower CG due to the rear aperture 680. The percentage projected area of ​​the aperture 680 and the density of the insert material can reduce the mass of the upper portion 608 by a range of 1 to 17 grams. In some embodiments, the mass of the upper portion 608 can be reduced by a range of 1 to 3 grams, 3 to 5 grams, 5 to 7 grams, 7 to 9 grams, 9 to 11 grams, 11 to 13 grams, 13 to 15 grams, or 15 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 mass of the upper portion 108 of the body 610 assists in lowering CG, improving launch and spin characteristics, and increasing ball speed.

[0139] The body 610 of the golf club head 600 defines a cavity 620. The cavity 620 of the body 610 can be configured to receive a low-density insert 640 that increases the MOI of the golf club head 600 without sacrificing the preferred stiff feel of a tour iron. The area, volume, and contour of the cavity 620 are similar to the area, volume, and contour of the cavity 120. Adjacent to the front opening of the cavity 620, the body 610 includes an inner periphery 627 similar to the inner periphery 127 of the golf club head 100. The sole portion 607, the top rail portion 606, the rear portion 603, the inner periphery 627, and the face plate 655 define the cavity 620. The cavity 620 connects to a rear opening 680 of the body 610 and is bounded by the front portion 604 of the body 610 by the face plate 655. The cavity 620 is exposed through a rear opening 680 in the rear portion 603 of the body 610 .

[0140] B. Golf club head insert Insert 640 is configured to fit within cavity 620 of body 610 to increase the MOI and maintain a solid feel of golf club head 600. The volume of insert 640 may be similar to the volume of insert 140 of golf club head 100. In some embodiments, insert 640 extends beyond cavity 620 into rear opening 680, so the volume of insert 640 may be greater than the volume of cavity 620.

[0141] The insert 640 may completely fill or partially fill the cavity 620, as described above for the golf club head 100. The insert 640 may fill a percent volume of the cavity 620, as described above for the golf club head 100. In some embodiments, as shown in FIG. 19, the insert 640 may fill 100% of the cavity 620 and extend into the rear opening 680. As shown in FIG. 20, the insert 640 may fill 60% of the cavity 620. As shown in FIG. 21, the insert 640 may fill 70% of the cavity 620 and extend partially into the rear opening 680. As shown in FIG. 22, the insert 640 may fill 80% of the cavity 620 and extend partially into the rear opening 680. As shown in FIG. 23, the insert 640 may fill 90% of the cavity 620 and extend partially into the rear opening 680. Although not shown, in some embodiments, insert 640 may fill only cavity 620 and not rear opening 680. In some embodiments, insert 640 may comprise a metallic material and may fill only cavity 620. In this exemplary embodiment, although not shown, opening wall 682 of body 610 may be tapered to blend into insert 640, providing a less defined boundary for rear opening 680.

[0142] 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 through which the insert 640 is injected into the cavity 620, as described below.

[0143] C. Body cavity The front surface of the body cavity 620 may be surrounded by a face plate 655. The face plate 655 and the striking surface 611 may be similar to the face plate 155 and the striking surface 611 of the golf club head 100. However, in some embodiments, the striking surface 611 may be integrally formed with the body 610. The striking surface 611 includes a thickness 612 similar to the thickness 112 of the striking surface 111 of the golf club head 100.

[0144] Body 610 is partially or completely filled with insert 640, which is secured within golf club head 600 by face plate 655. In some embodiments, cavity 620 further accommodates tape layer 150 and / or adhesive, similar to tape layer 150 and / or adhesive of golf club head 100.

[0145] In some embodiments, the golf club head 600 further includes 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 includes 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. The golf club head 600 may further include a toe screw cavity 663 and a toe screw weight 662 for adjusting the swing weight, as shown in FIGS. 17 and 18 . The toe screw weight may have a weight ranging from 2 grams to 15 grams, as described for any of the toe screw weights of the golf club head 100. The toe screw weight 662 may be removed and replaced with a different screw weight 662 having a different weight value to customize the golf club head 600 to suit a golfer's swing.

[0146] D. Rear-opening clubhead body material The materials used to form the components of golf club head 600 may be similar to the materials used to form the components of golf club head 100, as described above. In particular, body 610 may include the same body material as body 110. Insert 640 may include the same insert material as insert 140. Face plate 655 may include the same face plate material as face plate 155. 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 golf club head 100.

[0147] III. Golf Club Head Characteristics A. Golf club head measurement The golf club heads 100, 600 can be tour irons. The golf club heads 100, 600 described herein can be tour iron heads with the blade length, hosel-X length, offset distance, and top depth characteristics of a tour iron.

[0148] 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 in the heel region 102 to the edge of the club head 100 in the toe region 101. The blade length of a typical tour iron may 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 may range from 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.

[0149] As shown in FIG. 2 , hosel-X length 174 is measured from center plane 45 to the intersection of hosel axis 70 and leading edge axis 35. The hosel-X length of tour irons is typically less than 1.5 inches, while the hosel-X length of game improvement irons is typically greater than 1.5 inches. The hosel-X length of golf club head 100 is less than 1.5 inches, as is characteristic of tour irons. In some embodiments, hosel-X length 174 can range from 1.30 inches to 1.50 inches, 1.30 inches to 1.40 inches, or 1.40 inches to 1.50 inches.

[0150] As shown in FIG. 4 , the offset distance 173 is measured from the leading edge of the hosel 105 to the forward-most point of the golf club head 100. Typically, the forward-most point is located at the bottom of the striking face 111, adjacent to the sole 107. The offset distance 172 can vary between golf club heads within the same set due to different loft angles. Therefore, to compare sets of irons, the average offset distance 173 of 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 that includes golf club heads similar to the club head 100 is less than 0.140 inches. The offset distance 172 of a single golf club head 100 can range from 0.100 inches to 0.160 inches. In some embodiments, the offset distance can range from 0.100 inches to 0.110 inches, 0.110 inches to 0.120 inches, 0.120 inches to 0.130 inches, 0.130 inches to 0.140 inches, 0.140 inches to 0.150 inches, or 0.150 inches to 0.160 inches.

[0151] Top depth 116 is measured adjacent top rail portion 106 and perpendicular to striking face 111 from front portion 104 to rear portion 103, as shown in FIG. 4. The average top depth of tour irons is generally less than 0.290 inches. The average top depth of game improvement irons is generally greater than 0.290 inches. A set of golf clubs that includes golf club heads similar to golf club head 100 will have an average top depth of less than 0.290 inches, as is characteristic of a set of tour irons.

[0152] A similar parameter between game improvement irons and tour irons is the height of the golf club head. As shown in FIG. 2 , each golf club head 100 can have a maximum height 175 measured along the loft plane 20 from the leading edge axis 35 to the highest point on the top rail portion 106. The golf club head 600 can have a similar height to the golf club head 100. The maximum height 175 can be in the range of 2.0 inches to 2.5 inches. In some embodiments, the maximum height 175 can be in the range of 2.0 inches to 2.1 inches, 2.1 inches to 2.2 inches, 2.2 inches to 2.3 inches, 2.3 inches to 2.4 inches, and 2.4 inches to 2.5 inches.

[0153] Table I below compares the blade length, hosel-X length, average offset distance, average top depth, and maximum height of the Game Improvement irons and Tour irons.

[0154] [Table I]

[0155] B. CG and MOI of the golf club head To truly understand the benefits of perimeter weighting of the golf club head 100, one must consider both the MOI and CG characteristics of the golf club head 100 and the tour size of the golf club head 100. Game improvement irons are known for their high MOI values, but lack other characteristics unique to tour irons. The golf clubs described herein combine the benefits of game improvement irons with the tour iron style.

[0156] In some embodiments, the CG 60 of the golf club head 100, 600 has been moved downward and rearward as compared to a flat-back tour iron. The CG 60 location of the golf club head 100 can also be measured from the leading face.

[0157] The CG 60 of the golf club head 100, 600 can be located above the leading plane in a range of 0.380 inches to 0.670 inches. In some embodiments, the CG 60 of the golf club head 100, 600 can be located above the leading plane in a range 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 0.52 The recess may be located above the leading edge surface by 0 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, or 0.660 inches to 0.670 inches. In other embodiments, CG 60 can be positioned above the leading surface by 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.

[0158] As mentioned above, the golf club heads 100 and 600 described herein may include lightweight inserts 140, 440, and 640 in the center of the golf club head. These weights may be added to the perimeter of the golf club head 100 and 600, allowing for movement of the CG 60 and an increase in the MOI without significantly changing the overall weight of the golf club head 100 and 600. This perimeter weighting may be in the form of toe weights, tip weights, or additional body material added around the perimeter. The compact nature of the golf club heads 100 and 600 results in material properties that play a greater role in MOI enhancement than structural properties. As mentioned above, the MOI, Ixx, around the CG 60 and about the x-axis 30 may range from 78 grams squared to 120 grams squared. The MOI, Iyy, around the CG 60 and about the y-axis 40 may range from 310 grams squared to 466 grams squared. These MOI values ​​may be applicable to the golf club heads 100 and 600. These MOI values ​​may also apply to any embodiment having insert 140, 640, or multi-material insert 440.

[0159] IV. Method 24 , a method 500 of manufacturing a golf club head 100 is described herein. The method includes step 510 of providing each component, step 520 of placing an insert into the body, step 530 of crimping the face plate onto the body, step 540 of laser welding the interface between the face plate and the body, and step 550 of cleaning the final product through grinding and polishing. In some embodiments of method 500, method 500 can consist of steps 510, 520, 530, 540, and 550.

[0160] Step 510 may include providing at least the body 110, the insert 140 or multi-material insert 440, and the face plate 155 as components of the golf club head 100. In some embodiments, providing the body 110 may include one or more of forging, casting, molding by additive manufacturing, machining, or any other suitable method for forming the body 110. Step 510 may include forming the body 110 as a unitary piece.

[0161] In some embodiments, providing insert 140 may include one or more of forging, casting, additive manufacturing molding, machining, or any other suitable method for forming insert 140. In some embodiments, insert 140 or a portion of multi-material insert 440 is molded by pouring resin into a fiber-reinforced structure to form an elastomeric matrix composite. Insert 140 may be formed as a single piece having a uniform density or as multiple pieces having different densities. In some embodiments having a multi-material insert 440, insert 440 may be formed as a single unit or may be placed into cavity 120 in two separate pieces.

[0162] In some embodiments, providing the multi-material insert 440 includes (1) providing a first portion 450 of the insert 440, (2) providing a second portion 460 of the insert 440, and (3) joining the first and second portions 450, 460 of the insert 440. Providing the first portion 450 of the insert 440 may include molding the first portion 450. Providing the second portion 460 of the insert 440 may include casting, forging, stamping, die casting, or other means of providing the second portion 460. In some embodiments, if the first portion 450 is molded and joined to the second portion 460, the substeps of (1) providing the second portion 460 and (2) joining the first portion 450 and the second portion 460 are combined. In some embodiments, the insert 440 may be sanded, ground, or polished before being inserted into the cavity 120 of the golf club head 100.

[0163] In some embodiments, forming faceplate 155 can include forging, casting, machining, forming by additive manufacturing, or otherwise forming faceplate 155. In some embodiments, forming faceplate 155 can include machining, casting, or forging variable thickness geometries into faceplate 155.

[0164] In some embodiments, step 510 of method 500 may further include providing a toe weight, a tip weight, and / or a toe screw weight. In these embodiments, step 510 may further include welding a toe weight 161 to the toe cavity 114 of the body 110. In other embodiments, the toe weight 161 may be swaged, glued, or otherwise secured onto the body 610. In embodiments of the golf club head 100 that further include a toe screw weight, the toe screw weight may be threaded into the golf club head at steps 510, 520, 530, or 550.

[0165] Step 520 of method 500 includes placing the insert 140 within the cavity 120 of the body 110. The insert 140 is inserted through a front opening of the cavity 120 at the front portion 104 of the body 110. In some embodiments, this step 520 includes applying an adhesive, such as epoxy, 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 placing the insert 140 within the cavity. The one or more tape layers, such as tape layer 150, can form a strong and durable bond between the insert 140 and the cavity 120 of the body 110. Additionally, the use of tape can reduce the possibility of rattles and other undesirable quality issues. In some embodiments, various other methods of securing the insert 140 to the body 110 are combined for maximum security. Not all embodiments of the method 500 require the insert 140 to be glued or otherwise secured within the cavity 120 .

[0166] Step 530 of method 500 includes securing face plate 155 onto body 110. Face plate 155 is positioned within recess 142. By placing face plate 155 within recess 142, face plate 155 is positioned to cover insert 140 and cavity 120 of body 110. Step 530 may further include swaging face plate 155 onto body 110 such that face plate 155 is embedded within recess 142 on front portion 104 of body 110. In this manner, insert 140 is retained within golf club head 100 and completely isolated from the exterior of golf club head 100. In other embodiments, face plate 155 is glued, press-fit, or otherwise secured to the body.

[0167] Some golf club heads are manufactured by methods including co-forging (also known as integral forging) and joining individual cast components using high temperatures and applied pressures. 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 ranging from 700°C to 1000°C. The melting points of some aluminum alloys fall in the range of 650°C to 680°C. Therefore, in the case of aluminum inserts, co-forging would compromise the integrity of the aluminum material. The inserts 140, 440, body 110, and face plate 155 are not co-forged together because co-forging can lead to high temperatures that could damage the inserts 140, 440.

[0168] Furthermore, TIG welding the face plate to the golf club head also exposes the golf club head to high temperatures, which can damage the insert. The possible materials for the low-density center of an iron-type golf club head are significantly limited by conventional manufacturing processes. The golf club head 100 can be manufactured with a wide variety of insert materials because the manufacturing process does not subject final assembly to high temperatures. Furthermore, some insert materials described herein, such as thermoplastic composites, simply cannot be co-forged with the metal body material. The manufacturing method 500 described herein allows the insert 140, 440 to be formed from any suitable material without requiring the material to be co-forged with the body 110.

[0169] Steps 530 and 540, described below, both employ low-heat methods of securing the faceplate 155 to encapsulate the insert 140 within the cavity 120. Crimping, laser welding, and other low-temperature methods of securing the faceplate 155 allow the insert 140 or 440 to include a wide variety of materials to fine-tune the acoustic properties, feel, and weighting. The low-head methods of steps 530 and 540 allow for additional design flexibility, such as using adhesives and / or tape around the cavity 120 to reduce unwanted rattle and vibration.

[0170] Step 540 includes laser welding the interface between the face plate 155 and the body 110. The process of step 540 is also referred to as a surface fusion process. After the face plate 155 is crimped onto the body 110 in step 530, the overlapping area or interface between the face plate 155 and the body 110 is laser welded. This laser welding process fuses the metallic materials of the face plate 155 and the body 110 together without creating a deep heat-affected zone (hereinafter referred to as a "HAZ"). Laser welding the interface eliminates any cracks or seams between the face plate 155 and the body 110. In some embodiments, the golf club head 100 is finished with a coating in step 550, as described below. If there are microcracks or seams at the interface, the coating can penetrate the seam and cause quality issues. Laser welding the interface in step 540 eliminates this manufacturing issue.

[0171] Step 540 described above can be performed without compromising the integrity of the material within cavity 120 because the HAZ depth can range from 0.03 inches to 0.08 inches and be less than the thickness 112 of face plate 155. 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 HAZ depth can be 0.03 inches, 0.04 inches, 0.05 inches, 0.06 inches, 0.07 inches, or 0.08 inches. Laser welding heats the insert and other cavity filler materials, such as tape layers, to a temperature below the melting temperature of the insert material. The heat applied to golf club head 100 during step 540 does not compromise any of the materials sealed within cavity 120.

[0172] In step 550 of method 500, the golf club head 100 is cleaned through grinding and polishing. Grinding is used to create a smooth surface on the striking face 111 of the golf club head 100. Additionally, this step 550 may include polishing the surface of the golf club head 100 after grinding. In some embodiments, grooves are ground into the striking face 111 of the face plate 155, and then the striking face 111 is polished. No step in manufacturing method 500 involves co-forging with a different material.

[0173] As shown in FIG. 25 , similar to golf club head 100, a method 700 of manufacturing a golf club head includes providing at least a body 610, an insert material, and a face plate 655, welding or crimping the face plate 655 to the body 610, injecting the insert material into cavity 620 of the body 610, and polishing and cleaning the golf club head 600.

[0174] In step 710, the body 610 can be formed by forging, casting, or additive manufacturing. The face plate 655 can be formed by forging, casting, or additive manufacturing. In one variation of manufacturing process 700, the face plate 655 is integrally formed as part of the body 610 and welded or swaged to the front opening of the body 610, rather than being formed separately as the face plate 655. In some embodiments, step 710 of method 700 further includes providing a toe weight 661, a tip weight 660, and / or a toe screw weight 662. In these embodiments, step 710 further includes welding the toe weight 661 to the toe cavity 614 of the body 610. In other embodiments, the toe weight 661 can be swaged, glued, or otherwise secured onto the body 610. In embodiments of the golf club head 600 further comprising a toe screw weight 662 , the toe screw weight 662 may be threaded into the golf club head at steps 710 , 720 , 730 , or 750 .

[0175] Further, in step 710 of method 700, the aperture walls 682 defining the rear aperture 680 may be formed in the body 610 or may be cut into the rear portion 603 of the body 610 after the body 610 is formed. Step 710 may further include polishing or finishing the aperture walls 682 of the rear portion 603.

[0176] Step 720 includes placing a faceplate 655 within the body recess 642. The faceplate 655 is welded, swaged, or otherwise secured to the body 610. The body 610 and faceplate 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 for the embodiment in FIGS. 14-23. In some embodiments, step 720 of method 700 can further include a laser welding or surface fusion process similar to that described for step 540 of method 500 above.

[0177] In step 730, the insert material is injected in liquid form into the cavity 620 through the rear opening 680. The cavity 620 of the body 610 acts 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 seal the mouth of the rear opening 680. The planar surface surrounding the rear opening 680 in the top 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 seal off a portion of the cavity 620 to prevent the material from filling the entire cavity 620.

[0178] In step 740 of method 700, the golf club head 600 is cleaned by grinding and polishing. Grinding is used to create a smooth surface on the striking face 611 of the golf club head 600. Additionally, this step 740 may include polishing the surface of the golf club head 600 after grinding. In some embodiments, grooves are ground into the striking face 611 of the face plate 655, and then the striking face 611 is polished.

[0179] The method of manufacturing some embodiments of golf club head 600 is more similar to method 500 than to method 700 described above. In some embodiments, the method of forming golf club head 600, where golf club head 600 includes metal insert 640, involves placing insert 640 in cavity 620 before swaging onto face plate 655.

[0180] V. Example Example 1: Measuring a golf club head The golf club head 100 was measured using several different parameters, as described above, including blade length 173, hosel-X length 174, offset distance 172, top depth 116, and maximum height 175. These values ​​were compared to a Game Improvement iron and are both shown in Table II below. The measured golf club head 100 and the Game Improvement iron were both 7 irons and had approximately the same loft angle.

[0181] [Table II]

[0182] Example 2: Moment of Inertia (MOI) Comparison and Center of Gravity (CG) Comparison A test was conducted to compare the MOI of a conventional tour iron head with the golf club head 100 described above. The conventional tour iron head used in this comparison test was identical in size and head weight to the sample golf club head. Therefore, this test isolated MOI as a variable to provide an accurate comparison of the sample's performance relative to the conventional tour iron head. This test produced an Ixx value of approximately 108 grams squared for the sample club head and an Ixx value of approximately 103 grams squared for the conventional tour iron head. Therefore, the MOI about the x-axis 30 is approximately 4.8% higher for the sample club head. This test produced an Iyy value of approximately 413 grams squared for the sample club head and an Iyy value of approximately 398 grams squared for the conventional tour iron head. Therefore, the MOI about the y-axis 40 is approximately 3.7% higher for the sample club head. This test demonstrates that a lightweight insert for the golf club head 100 provides an MOI improvement without changing the size or weight of the golf club head 100.

[0183] Additionally, comparisons were made between five club heads: (1) an iron similar to golf club head 600 with an opening in the rear and an insert formed from TPC; (2) an iron similar to golf club head 600 with an opening in the rear and an insert formed from aluminum; (3) an iron similar to golf club head 100 with a sealed cavity filled with a TPC insert; (4) an iron similar to golf club head 100 with a sealed cavity filled with an aluminum insert; and (5) a solid steel club head with an overall club head volume similar to the golf club head described herein. Measurements were taken 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.

[0184] [Table III]

[0185] Because MOI is a function of distance from the center of gravity and mass, it reflects changes in the overall mass of a golf club head. Therefore, to accurately compare the MOI of club heads, differences in the total mass of the golf club heads must be considered. To show the MOI efficiency across the compared golf club heads, the MOI was divided by the mass of the golf club heads to arrive at an MOI efficiency value. The MOI efficiency values ​​of golf club heads can be compared independent of mass to show how the structure and local weighting of the golf club heads affect the MOI. Therefore, although the MOI values ​​along both the x-axis 30 and y-axis 40 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 efficiencies of the golf club heads (1) to (4). Therefore, the golf club heads (1) through (4) having the low density inserts are more forgiving than golf club heads lacking the low density inserts 140, 440, 460 of the golf club heads 100, 600 described herein.

[0186] As can be seen from Table III, golf club heads (1) through (4) with low density inserts have MOI efficiencies in the x-axis 30 direction that are in the range of 5.9% to 11.2% higher than solid steel golf club head (5). As can be seen from Table III, club heads (1) through (4) with low density inserts have MOI efficiencies in the y-axis 40 direction that are in the range of 8.5% to 15.5% higher than solid steel golf club head (5).

[0187] In addition to increasing the MOI, lowering the CG can also be beneficial to golf club head performance. The golf club heads 100, 600 described herein have a lower CG 60 than comparable solid steel irons having a similar geometry to the golf club heads 100 and 600. A lower CG is desirable in tour irons because it is easier to shape a shot when the CG is lower. In the case of the golf club head 600, the lower CG is due, in part, to the elimination of high-density body material by including the opening 680 in the rear section 603.

[0188] [Table IV]

[0189] Referring to FIG. 1 , CGy is measured upward from the leading edge axis 35 along the y-axis 40 (vertical). CGx is measured horizontally along the leading edge axis 35, with the y-axis 40 as the origin, so that a positive CGx value positions the CG closer to the heel portion 102. CGz is measured rearward from the leading edge axis 35 along the z-axis 50 in a horizontal direction. CGy values ​​are lower for golf club heads (1) and (2) than for golf club heads (3) through (5). This indicates that golf club heads with openings in the rear of the body (similar to golf club head 600 described above) have a desirable lower CG. CG is 2.06% lower for club head (2) than for steel club head (5). CG is 2.84% lower for golf club head (1) than for steel golf club head (5), indicating that the low-density TPC insert provides much better CG placement than its aluminum insert counterpart (golf club head (2)).

[0190] The comparative data in Tables III and IV further demonstrate the strengths of the closed cavity and rear-opening embodiments. While all embodiments of the present invention (comparative golf club heads (1) through (4)) demonstrate improvements over solid club head (5), both the closed cavity embodiment (comparative golf club heads (3) and (4)) and the rear-opening embodiment (comparative golf club heads (1) and (2)) offer unique advantages. The comparative data demonstrates that the MOI efficiencies in both the x-axis 30 and y-axis 40 directions are higher for closed cavity club heads (3) and (4) than for club heads (1), (2), and (5), as shown in the MOI efficiencies in Table III. This suggests that closed cavity embodiments, similar to golf club head 100 described herein or comparative club heads (3) and (4), are more forgiving than embodiments with rear openings, such as golf club head 600 or comparative club heads (1) and (2). However, the embodiment with the rear opening 680 in the body 610 has a lower CG value than the embodiment with the sealed cavity, as shown in the CGy column of Table IV.

[0191] Example 3: Center of Gravity Flat Back vs. Flex Seam Comparison In addition to MOI and feel, the location of the CG of a golf club head affects performance. In particular, CG location affects the amount of torque imparted to the golf club head upon impact with a golf ball. By lowering the CG, the arm between the force applied by the golf ball and the CG is reduced, since the golf ball is typically struck lower on the striking face. This shortened arm between the applied force and the CG results in lower torque and improved launch characteristics upon impact with the golf ball. Therefore, to provide the golfer with the best possible experience, the golf club heads described herein feature a low CG.

[0192] To demonstrate how the uniform depth of the upper portions 108, 608 of golf club heads 100, 600 translates to a lower CG 60, a comparison was made between golf club heads similar to golf club heads 100 and 600 and comparative golf club heads having varying depths from their top rails to their soles. The comparative golf club heads have a flat rear section extending from their top rails to their soles. To provide an accurate depiction, both the comparative golf club heads and golf club heads similar to 100 and 600 were modeled with the same total mass. The results of the comparison are set forth in Table V below.

[0193] [Table V]

[0194] As shown in Table V, the CGy values ​​measured along the vertical y-axis 40 are significantly lower for golf club heads similar to 100 and 600. Specifically, golf club heads similar to 100 and 600 have CGy values ​​that are 0.039 inches lower than the comparative golf club heads. This indicates that the uniform depth of the upper portions 108, 608 above the flex seams 130, 630 lowers the CG, providing better launch and spin characteristics and higher ball speeds.

[0195] Additionally, the CGz value is measured along the z-axis 50, with the CG 60 behind being negative and the CG 60 ahead being positive. Golf club heads similar to the 100 and 600 have CG 60 closer to the front of the golf club head.

[0196] Example 4: Touch and Sound Part of the appeal of tour irons is their compact contours 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, as perceived by the golfer, plays a large role in the golfer's performance. "Feel" is generally affected by weight, materials, acoustics, and the thickness of the striking surface. Many golfers agree that tour irons offer a solid feel that is lacking in many other types of irons. The golf club heads described herein exhibit solid feel and acoustic qualities equal to, if not exceeding, existing tour irons.

[0197] A survey was conducted to quantify the feel of a sample tour iron having a golf club head similar to the golf club head 100 described herein. Twenty golfers participated in the survey and compared their experience with the sample iron to their experience with a conventional tour iron. After using both the sample iron and the conventional iron, survey participants were asked the following question for each iron: "How satisfied are you with the impact experience (feel / sound) this iron provides?" The majority of players preferred the impact experience of the sample tour iron over the conventional tour iron.

[0198] Finally, the quality and durability of the irons are crucial to their continued performance. The striking faces 111 and 611 alone are designed to withstand the stresses placed upon them by striking a golf ball. However, the inclusion of a thermoplastic composite insert 140, 640, a full metal insert 140, 640, or a multi-material insert 440 can provide an additional solid feel to the golf club head and improve the acoustic quality of the golf club head over a similar hollow-body golf club head. The face plate 155, 655 can improve the quality and durability of the golf club head by ensuring that the insert 140, 640 remains secured inside the golf club head at all times.

[0199] By combining and balancing CG placement, perimeter weighting for MOI, and tour iron look and feel, the golf club heads 100, 600 described herein fulfill a need in the art for an iron-type club head that combines the reliability of a game improvement iron with the elegance of a tour iron.

[0200] The golf club heads 100 and 600 described herein function as tour-type golf club heads. They provide a high MOI while remaining smaller than typical game improvement irons. These multi-material golf club heads 100 and 600 provide a very forgiving, compact product.

[0201] 1-23 illustrate particular embodiments of golf club heads, the disclosure of the embodiments is intended to illustrate, but not limit, the scope of the present disclosure, which is intended to be limited to the extent required by the appended claims.

[0202] Because the Rules of golf are subject to change (e.g., new Rules may be adopted, or old Rules may be eliminated or modified by golf standards organizations and / or governing bodies), golf equipment related to the methods, apparatus, and / or products described herein may or may not conform to the Rules of golf in a particular era. Accordingly, golf equipment related 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.

[0203] The substitution of one or more claimed elements constitutes a rearrangement, not a repair. Additionally, advantages, other benefits, and solutions to problems have been described with respect to particular embodiments. However, the advantages, benefits, solutions to problems, and any one or more elements that can cause or make more pronounced any advantage, benefit, or solution should not be construed as a critical, necessary, or essential feature or element of any or all of the claims, unless such advantage, benefit, solution, or element is recited in such claim.

[0204] Furthermore, embodiments and limitations disclosed herein are not claimed to the public under the doctrine of contribution if the embodiment and / or limitation (1) is not expressly recited in the claim and (2) is or could be equivalent to the phraseology and / or limitations in the claim under the doctrine of equivalents.

[0205] Item 1: A golf club head, A face plate and a main body having an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion; The insert and Equipped with the face plate and a portion of the body define a striking surface of the golf club head; The face plate, sole, rear, and top rail surround a cavity. The rear section has a flex joint, The sole comes into contact with the ground surface, The loft plane is tangent to the face plate and intersects the ground plane; The center plane is perpendicular to the ground plane, perpendicular to the loft plane, and coincides with the center point of the hitting surface; the upper portion is bounded by a top rail portion and a flex joint; The upper part includes a height measured along the center plane from the top rail to the flex joint in a direction parallel to the loft plane; The lower portion includes a height measured along the center plane from the sole portion to the flex joint in a direction parallel to the loft plane; The ratio of the top height to the bottom height is in the range of 9:8 to 6:11; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to the outer surface of the rear portion along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; The sole, rear, top rail, and face plate surround the cavity. The insert is received within the cavity, the insert occupying more than 90% of the cavity; the faceplate includes a first material having a first density; the body includes a second material having a second density; the insert includes a third material having a third density; the third density is less than the first density and the second density; Golf club head.

[0206] Item 2: The golf club head further comprises: A heel portion and Toe part and an x-axis extending from the heel to the toe, parallel to the striking face, and coincident with the center of gravity of the club head; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The moment of inertia Ixx measured about the x-axis ranges from 78 grams squared to 120 grams squared, The moment of inertia Iyy measured about the y-axis ranges from 310 grams squared to 466 grams squared. Item 1. The golf club head according to item 1.

[0207] Item 3: The third density ranges from 2.4 g / cc to 5.0 g / cc. Item 1. The golf club head according to item 1.

[0208] Item 4: the third material comprises a material selected from the group consisting of aluminum and titanium; Item 3. The golf club head according to item 3.

[0209] Item 5: The first density is in the range of 2.6 g / cc to 8.7 g / cc, and the second density is in the range of 7.7 g / cc to 8.1 g / cc. Item 1. The golf club head according to item 1.

[0210] Item 6: the first material comprises a material selected from the group consisting of a steel-based material, a titanium-based material, an aluminum alloy, and a titanium alloy; the second material comprises a material selected from the group consisting of a steel-based material and a steel alloy; Item 5. The golf club head according to item 5.

[0211] Item 7: The golf club head further comprises: The total mass, Toe weight and Equipped with The body further comprises a toe cavity; The toe cavity accepts the toe weights. The toe weight comprises a mass ranging from 5% to 45% of the total mass of the club head. Item 1. The golf club head according to item 1.

[0212] Item 8: the ratio of the first depth to the maximum second depth is in the range of 1:3 to 4:5; Item 1. The golf club head according to item 1.

[0213] Item 9: The golf club head further comprises: The center of gravity and a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking surface; a leading surface parallel to the ground plane and coincident with the leading axis; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The center of gravity of the golf club head is located above the leading edge plane within a range of 0.380 inches to 0.670 inches. Item 1. The golf club head according to item 1.

[0214] Item 10: The golf club head further comprises: A heel portion and Toe part and A cylindrical hosel integrated into the main body, Equipped with The cylindrical hosel is When viewed from the toe side, a hosel reference plane is parallel to the front edge of the cylindrical hosel; a hosel axis defined as the central axis of a cylindrical hosel; a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking face; a hosel-X distance, as measured from the intersection of the leading edge axis and the center plane to the intersection of the leading edge axis and the hosel axis, when viewed from the front, that is less than 1.5 inches; an offset distance measured as the smallest distance between the leading edge axis and the hosel reference plane, the offset distance being in the range of 0.05 inches to 0.27 inches; Equipped with Item 1. The golf club head according to item 1.

[0215] Item 11: The golf club head further comprises: A heel portion and Toe part and a blade length measured in a heel-to-toe direction from the edge of the striking face at the heel to the outermost point at the toe; Equipped with The blade length is less than 2.8 inches, Item 1. The golf club head according to item 1.

[0216] Item 12: The golf club head includes a high-density tape disposed between the insert and the face plate. Item 1. The golf club head according to item 1.

[0217] Item 13: the body further comprises a recess; The recess abuts the periphery of the cavity; a region of the rear surface of the faceplate contacting the insert; The remaining area of ​​the rear surface of the faceplate contacts the recess. Item 1. The golf club head according to item 1.

[0218] Item 14: A method for manufacturing a golf club, comprising: (1) providing a faceplate including a first material having a first density; (2) providing a body comprising a second material having a second density, an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion; the face plate and a portion of the body define a striking surface of the golf club head; The rear section has a flex joint, The sole comes into contact with the ground surface, The loft plane is tangent to the face plate and intersects the ground plane; the central plane is perpendicular to the ground surface, extends in a direction from the top rail portion to the sole portion, and coincides with the center point of the striking surface; the upper portion is bounded by a top rail portion and a flex joint; The upper part includes a height measured along the center plane from the top rail to the flex joint in a direction parallel to the loft plane; The lower part includes a height measured along the center plane from the sole part to the flex joint in a direction parallel to the loft plane; The ratio of the top height to the bottom height is in the range of 9:8 to 6:11; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to the outer surface of the rear face along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; the sole portion, the rear portion, and the top rail portion define a cavity; The manufacturing method further comprises: (3) providing an insert including a third material having a third density less than the first density and the second density; (4) placing an insert into the cavity, the insert occupying 90% or more of the cavity; (5) securing a faceplate to the body, the faceplate further defining a cavity; Including, A method for manufacturing a golf club head.

[0219] Item 15: (5) Fixing the faceplate to the main body swedging the faceplate onto the body; laser welding the boundary between the face plate and the body; Including, Item 15. A method for manufacturing a golf club head according to item 14.

[0220] Item 16: Laser welding the boundary between the faceplate and the body producing a heat affected zone having a depth of less than 0.070 inches; Item 16. A method for manufacturing a golf club head according to item 15.

[0221] Item 17: The golf club head further comprises: A heel portion and Toe part and an x-axis extending in a heel-to-toe direction, parallel to the striking face, and coincident with the center of gravity of the club head; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The moment of inertia Ixx measured about the x-axis ranges from 78 grams squared to 120 grams squared, The moment of inertia Iyy measured about the y-axis ranges from 310 grams squared to 466 grams squared. Item 16. A method for manufacturing a golf club head according to item 15.

[0222] Item 18: The manufacturing method further comprises: and disposing a layer of tape on the insert between (4) and (5); The tape layer is sandwiched between the insert and the faceplate upon completion of (5). Item 15. A method for manufacturing a golf club head according to item 14.

[0223] Item 19: The manufacturing method further comprises: forming an integral cylindrical hosel on the body; The golf club head further comprises: A heel portion and Toe part and Equipped with The cylindrical hosel is When viewed from the toe side, a hosel reference plane is parallel to the front edge of the cylindrical hosel; a hosel axis defined as the central axis of a cylindrical hosel; a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking face; a hosel-X distance, as measured from the intersection of the leading edge axis and the center plane to the intersection of the leading edge axis and the hosel axis, when viewed from the front, that is less than 1.5 inches; an offset distance measured as the smallest distance between the leading edge axis and the hosel reference plane, the offset distance being in the range of 0.05 inches to 0.27 inches; Equipped with Item 15. A method for manufacturing a golf club head according to item 14.

[0224] Item 20: The golf club head has a total mass, The body further comprises a toe cavity; The manufacturing method further comprises: forming a toe weight, the toe weight comprising a mass in the range of 5% to 45% of the total mass of the golf club head; securing a toe weight within the toe cavity; Including, Item 15. A method for manufacturing a golf club head according to item 14.

[0225] Item 21: The golf club head A face plate and a body having an upper portion, a lower portion, a sole portion, a rear portion, and a top rail; The insert and Equipped with the face plate and a portion of the body define a striking surface of the golf club head; The face plate, sole, rear, and top rail surround a cavity. The rear section has a flex joint, The sole comes into contact with the ground surface, The loft plane is tangent to the face plate and intersects the ground plane; The center plane is perpendicular to the ground plane, perpendicular to the loft plane, and coincides with the center point of the hitting surface; the upper portion is bounded by a top rail portion and a flex joint; the upper portion includes a height measured along the center plane from the top rail portion to the flex joint in a direction parallel to the loft plane; The lower portion includes a height measured along the center plane from the sole portion to the flex joint in a direction parallel to the loft plane; The ratio of the top height to the bottom height is in the range of 9:8 to 6:11; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to the outer surface of the rear portion along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; The sole, rear, top rail, and face plate surround the cavity. The insert is received within the cavity, the insert occupying more than 90% of the cavity; the insert comprises a first portion and a second portion; the faceplate includes a first material having a first density; the body includes a second material having a second density; the first portion of the insert includes a third material having a third density; a second portion of the insert including a fourth material having a fourth density; the third density is less than the first density, the second density, and the fourth density; Golf club head.

[0226] Item 22: The second portion of the insert does not contact the faceplate. Item 22. The golf club head according to item 21.

[0227] Item 23: The second part of the insert is located completely in the lower part of the body, Item 23. The golf club head according to item 22.

[0228] Item 24: the fourth density is greater than the first and second densities; Item 22. The golf club head according to item 21.

[0229] Item 25: the ratio of the first depth to the maximum second depth is in the range of 1:3 to 4:5; Item 22. The golf club head according to item 21.

[0230] Item 26: The golf club head further comprises: The center of gravity and a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking face; a leading surface parallel to the ground plane and coincident with the leading axis; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The center of gravity of the golf club head is located above the leading edge plane within a range of 0.380 inches to 0.670 inches. Item 22. The golf club head according to item 21.

[0231] Item 27: The golf club head further comprises: A heel portion and Toe part and A cylindrical hosel integrated into the main body, Equipped with The cylindrical hosel is When viewed from the toe side, a hosel reference plane is parallel to the front edge of the cylindrical hosel; a hosel axis defined as the central axis of a cylindrical hosel; a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking face; a hosel-X distance, as measured from the intersection of the leading edge axis and the center plane to the intersection of the leading edge axis and the hosel axis, when viewed from the front, that is less than 1.5 inches; an offset distance measured as the smallest distance between the leading edge axis and the hosel reference plane, the offset distance being in the range of 0.05 inches to 0.27 inches; Equipped with Item 22. The golf club head according to item 21.

[0232] Item 28: The golf club head further comprises: A heel portion and Toe part and a blade length measured in a heel-to-toe direction from the edge of the striking face at the heel to the outermost point at the toe; Equipped with The blade length is less than 2.8 inches. Item 22. The golf club head according to item 21.

[0233] Item 29: The golf club head further comprises a high-density tape disposed between the insert and the face plate. Item 22. The golf club head according to item 21.

[0234] Item 30: The first depth is less than 0.290 inches, Item 22. The golf club head according to item 21.

[0235] Item 31: The third density ranges from 2.4 g / cc to 5.0 g / cc. Item 22. The golf club head according to item 21.

[0236] Item 32: the third material comprises a material selected from the group consisting of aluminum and titanium; The fourth material includes tungsten. Item 32. The golf club head according to item 31.

[0237] Item 33: The golf club head further comprises: The total mass, Toe weight and Equipped with The body further comprises a toe cavity; The toe cavity accepts the toe weights. The toe weight comprises a mass ranging from 5% to 45% of the total mass of the club head. Item 22. The golf club head according to item 21.

[0238] Item 34: The golf club head further comprises: A heel portion and Toe part and an x-axis extending in a heel-to-toe direction, parallel to the striking face, and coincident with the center of gravity of the club head; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The moment of inertia Ixx measured about the x-axis ranges from 78 grams squared to 120 grams squared, The moment of inertia Iyy measured about the y-axis ranges from 310 grams squared to 466 grams squared. Item 22. The golf club head according to item 21.

[0239] Item 35: A method for manufacturing a golf club head, comprising: (1) providing a faceplate including a first material having a first density; (2) providing a body comprising a second material having a second density, an upper portion, a lower portion, a sole portion, a rear portion, and a top rail; the face plate and a portion of the body define a striking surface of the golf club head; The rear section has a flex joint, The sole comes into contact with the ground surface, The loft plane is tangent to the face plate and intersects the ground plane; the central plane is perpendicular to the ground surface, extends in a direction from the top rail portion to the sole portion, and coincides with the center point of the striking surface; The upper portion is bounded by a top rail and a flex joint; The upper part includes a height measured along the center plane from the top rail to the flex joint in a direction parallel to the loft plane; The lower portion includes a height measured along the center plane from the sole portion to the flex joint in a direction parallel to the loft plane; the ratio of the upper height to the lower height is in the range of 1:1 to 2:1; the upper height includes a first depth and the lower height includes a second depth, the depths being measured from the striking face to the outer surface of the rear section along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; the sole portion, the rear portion, and the top rail portion define a cavity; The manufacturing method further comprises: (3) providing an insert including a first portion and a second portion, the first portion including a third material having a third density, the second portion including a fourth material having a fourth density, the third density being less than the first density, the second density, and the fourth density; (4) Fixing an insert in the cavity, the insert occupying more than 90% of the cavity; (5) securing a faceplate to the body, the faceplate further defining a cavity; Including, A method for manufacturing a golf club head.

[0240] Item 36: (5) Fixing the faceplate to the main body swedging the faceplate onto the body; Heat treating (or laser welding) the boundary between the face plate and the main body; Including, Item 35. A method for manufacturing a golf club head according to item 35.

[0241] Item 37: Laser welding the boundary between the faceplate and the body producing a heat affected zone having a depth of less than 0.070 inches; Item 35. A method for manufacturing a golf club head according to item 35.

[0242] Item 38: The golf club head further comprises: A heel portion and Toe part and an x-axis extending in a heel-to-toe direction, parallel to the striking face, and coincident with the center of gravity of the club head; The y-axis is perpendicular to the ground plane and coincides with the center of gravity. Equipped with The moment of inertia Ixx measured about the x-axis ranges from 78 grams squared to 120 grams squared, The moment of inertia Iyy measured about the y-axis ranges from 310 grams squared to 466 grams squared. Item 35. A method for manufacturing a golf club head according to item 35.

[0243] Item 39: The manufacturing method further comprises: and disposing a layer of tape on the insert between (4) and (5); The tape layer is sandwiched between the insert and the faceplate upon completion of (5). Item 35. A method for manufacturing a golf club head according to item 35.

[0244] Item 40: The first and second portions of the insert are integrally formed prior to (4). Item 35. A method for manufacturing a golf club head according to item 35.

[0245] Item 41: A golf club head, A face plate and a main body having an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion; The insert and Equipped with the face plate and a portion of the body define a striking surface of the golf club head; The face plate, sole, rear, and top rail surround a cavity. the rear portion includes a flex joint and a wall defining an opening; the opening wall is above the bend joint and includes a top wall adjacent to the top rail portion, a bottom wall adjacent to the bend joint, a toe wall, and a heel wall; The sole comes into contact with the ground surface, The loft plane is tangent to the face plate and intersects the ground plane; The center plane is perpendicular to the loft plane, perpendicular to the ground plane, and coincides with the center point of the hitting surface; The projected area of ​​the opening parallel to the loft plane is 25% to 50% of the total projected area of ​​the rear section; the upper portion is bounded by a top rail portion and a flex joint; The upper part includes a height measured along the center plane from the top rail to the flex joint in a direction parallel to the loft plane; The lower portion includes a height measured along the center plane from the sole portion to the flex joint in a direction parallel to the loft plane; the ratio of the upper height to the lower height is in the range of 1:1 to 2:1; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to the outer surface of the rear portion along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; The sole, rear, top rail, and face plate surround the cavity. The insert is received within the cavity, the insert occupying no more than 90% of the cavity; the faceplate includes a first material having a first density; the body includes a second material having a second density; the insert includes a third material having a third density; the third density is less than the first and second densities; Golf club head.

Claims

1. A golf club head, A face plate and a main body having an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion; a tape layer; The insert and Equipped with the face plate and a portion of the body define a striking surface of the golf club head; the face plate, the sole portion, the rear portion, and the top rail portion surround a cavity; the rear portion includes a flex joint; The sole portion contacts the ground surface, a loft plane tangent to the face plate and intersecting the ground plane; a center plane perpendicular to the loft plane and coincident with the center of the striking face; the upper portion is bounded by the top rail portion and the flex joint; the lower portion is bounded by the flex seam and the sole portion; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to an outer surface of the rear portion along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; the cavity comprises a cavity volume; the cavity volume at the lower portion is larger than the cavity volume at the upper portion; the insert is received within the cavity, the insert occupying 90% or more of the cavity; the insert includes a first portion and a second portion; the tape layer is combined with the insert such that the tape layer is positioned between the insert and the rear portion or the sole portion of the body; the faceplate includes a first material having a first density; the body includes a second material having a second density; the first portion of the insert includes a third material having a third density; the second portion of the insert includes a fourth material having a fourth density; the third density is less than the first density, the second density, and the fourth density; the third density is in the range of 2.4 g / cc to 5.0 g / cc (2.4 g / cubic centimeter to 5.0 g / cubic centimeter); Golf club head.

2. the upper portion includes a height measured along the central plane from the top rail portion to the flex joint in a direction parallel to the loft plane; the lower portion includes a height measured along the central plane from the sole portion to the flex joint in a direction parallel to the loft plane; the height of the upper portion and the height of the lower portion have a ratio in the range of 9:8 to 6:11; The golf club head according to claim 1 .

3. The golf club head of claim 1 , wherein the second portion of the insert does not contact the face plate.

4. The golf club head of claim 3 , wherein the second portion of the insert is located entirely within the lower portion of the body.

5. The golf club head of claim 1 , wherein the fourth density is greater than the first density and the second density.

6. The golf club head of claim 1 , wherein a ratio of the maximum value of the first depth to the maximum value of the second depth is in the range of 1:3 to 4:

5.

7. The golf club head further comprises: The center of gravity and a leading edge axis that is parallel to the ground plane, extends in a heel-to-toe direction, and coincides with a point on the center plane that is lowest on the striking surface; a leading surface parallel to the ground plane and coincident with the leading axis; a y-axis that is perpendicular to the ground plane and coincides with the center of gravity; Equipped with 10. The golf club head of claim 1, wherein the center of gravity of the golf club head is located between 0.380 and 0.670 inches (0.965 and 1.70 centimeters) above the leading surface.

8. The golf club head further comprises: A heel portion and Toe part and a cylindrical hosel integral with the body; Equipped with The cylindrical hosel a hosel reference plane parallel to a front edge of the cylindrical hosel when viewed from a toe side; a hosel axis defined as a central axis of the cylindrical hosel; a leading edge axis that is parallel to the ground plane, extends in a direction from the heel to the toe, and coincides with a point on the center plane that is lowest on the striking surface; a hosel-X distance, measured from the intersection of the leading edge axis and the center plane to the intersection of the leading edge axis and the hosel axis when viewed from the front, that is less than 1.5 inches (3.8 centimeters); an offset distance, measured as the smallest distance between the leading edge axis and the hosel reference plane, the offset distance ranging from 0.05 to 0.27 inches (0.13 to 0.69 centimeters); Equipped with The golf club head according to claim 1 .

9. The golf club head of claim 1 , wherein the first depth is less than 0.290 inches (0.74 centimeters).

10. The golf club head of claim 1 , wherein the third density ranges from 2.4 g / cc to 3.0 g / cc (2.4 g / cubic centimeter to 3.0 g / cubic centimeter).

11. the third material comprises a material selected from the group consisting of aluminum and titanium; the fourth material includes tungsten; The golf club head according to claim 1 .

12. The golf club head further comprises: The total mass and Toe weight and Equipped with the body further comprising a tow cavity; the toe cavity receives the toe weight; The golf club head of claim 1 , wherein the toe weight comprises a mass in the range of 5% to 45% of the total mass of the body.

13. The golf club head further comprises: A heel portion and Toe part and an x-axis extending from the heel portion toward the toe portion, parallel to the striking face, and coincident with the center of gravity of the golf club head; a y-axis that is perpendicular to the ground plane and coincides with the center of gravity; Equipped with a moment of inertia Ixx measured about the x-axis in the range of 78 to 120 grams squared inches (503 to 774 grams squared centimeters); the moment of inertia Iyy measured about the y-axis is in the range of 310 to 466 grams squared inches (2000 to 3006 grams squared centimeters); The golf club head according to claim 1 .

14. A method for manufacturing a golf club head, comprising: (1) providing a faceplate including a first material having a first density; (2) providing a body including a second material having a second density, an upper portion, a lower portion, a sole portion, a rear portion, and a top rail portion; the face plate and a portion of the body define a striking surface of the golf club head; the rear portion includes a flex joint; The sole portion contacts the ground surface, a loft plane tangent to the face plate and intersecting the ground plane; a center plane extending in a direction from the top rail portion to the sole portion and coinciding with a center point of the striking face; the upper portion is bounded by the top rail portion and the flex joint; the lower portion is bounded by the flex seam and the sole portion; the upper portion includes a height measured along the central plane from the top rail portion to the flex joint in a direction parallel to the loft plane; the lower portion includes a height measured along the central plane from the sole portion to the flex joint in a direction parallel to the loft plane; the height of the upper portion and the height of the lower portion have a ratio in a range of 1:1 to 2:1; the upper portion includes a first depth and the lower portion includes a second depth, the depths being measured from the striking face to an outer surface of the rear portion along the center plane and perpendicular to the loft plane; the first depth is constant and less than the second depth; the sole portion, the rear portion, and the top rail portion define a cavity; The manufacturing method further comprises: (3) providing an insert including a first portion and a second portion, the first portion including a third material having a third density, the second portion including a fourth material having a fourth density, the third density being less than the first density, the second density, and the fourth density, and the third density being in the range of 2.4 g / cc to 5.0 g / cc (2.4 g / cubic centimeter to 5.0 g / cubic centimeter); (4) providing a tape made of a vibration damping material; (5) placing the tape on the insert so as to contact the rear portion or the sole portion of the body; (6) placing the insert in the cavity, the insert filling 90% or more of the cavity; (7) securing the faceplate to the body, the faceplate further defining the cavity; Including, A method for manufacturing a golf club head.

15. The fixing of the face plate to the main body in (7) above is swaging the faceplate to the body; heat treating or laser welding the interface between the face plate and the body; Including, The method for manufacturing a golf club head according to claim 14.

16. Laser welding the interface between the faceplate and the body includes: producing a heat affected zone comprising a depth of less than 0.070 inches (0.178 centimeters); The method for manufacturing a golf club head according to claim 15.

17. The golf club head further comprises: A heel portion and Toe part and an x-axis extending from the heel portion toward the toe portion, parallel to the striking face, and coincident with the center of gravity of the golf club head; a y-axis that is perpendicular to the ground plane and coincides with the center of gravity; Equipped with a moment of inertia Ixx measured about the x-axis in the range of 78 to 120 grams squared inches (503 to 774 grams squared centimeters); the moment of inertia Iyy measured about the y-axis is in the range of 310 to 466 grams squared inches (2000 to 3006 grams squared centimeters); The method for manufacturing a golf club head according to claim 14.

18. The method of manufacturing a golf club head according to claim 14 , wherein, prior to step (4), the first portion and the second portion of the insert are integrally formed.

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