Golf club head with insert

Abstract

The golf club head disclosed herein includes a metallic body and a non-metallic insert. The insert forms the entire toe end of the golf club head. The insert can include an offset surface disposed behind a strike face of the body. A gap is formed between the insert and the strike face. The offset surface of the insert temporarily limits bending of the center of the strike face during impact with a golf ball. The gap between the strike face and the insert allows the strike face to flex and the backstop prevents the strike face from flexing excessively. In one embodiment, the golf club head can include a body having an enclosed cavity that opens toward the toe end. The insert can form an outermost surface of the toe end and can fill a portion of the cavity.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 144,871, filed February 2, 2021, and U.S. Provisional Patent Application No. 63 / 203,754, filed July 29, 2021. The entire contents of the above disclosure are hereby incorporated by reference in their entirety.

[0002] The present disclosure relates generally to golf equipment, and more particularly to a method of manufacturing an iron-type golf club head. The present disclosure also relates to a multi-material golf club head and a method of manufacturing a multi-material golf club head. [Background technology]

[0003] Typically, iron-type golf clubs are designed to bestow a golfer with a particular skill level. For example, game improvement iron-type golf club heads have very flexible faces to improve potential ball speeds and are highly forgiving to improve the aiming of off-center shots. Cavity back irons are a type of game improvement iron. At the other end of the spectrum, tour irons can be designed for highly skilled golfers. Tour irons typically have a smaller footprint than game improvement irons and often have solid metal construction. Tour irons are not as forgiving but allow skilled golfers to shape their shots.

[0004] Hollow body irons combine the solid aesthetic design of tour irons with the forgiveness of game improvement irons. However, hollow body irons can have unpleasant acoustic characteristics and can be difficult to construct efficiently. There is a need in the art for a golf club head that has simple construction, pleasant acoustic characteristics, high forgiveness through well-positioned weight placement, and performance characteristics that lead to greater shot accuracy. [Brief explanation of the drawings]

[0005] [Figure 1] 1 shows a perspective exploded view of a golf club head with a body and an insert according to a first embodiment.

[0006] [Figure 2] 2 illustrates a perspective exploded view of an insert with the body removed and an internal weight configured to fit within the insert of FIG. 1;

[0007] [Figure 3] 2 shows a rear view of the golf club head of FIG. 1.

[0008] [Figure 4] 2 shows a front view of the golf club head of FIG. 1.

[0009] [Figure 5] 2 shows a rear view of the body of the golf club head of FIG. 1 with the insert removed.

[0010] [Figure 6] 6 shows a rear perspective view of the body of FIG. 5 with the insert removed.

[0011] [Figure 7] 7 shows a cross-sectional view of the body of FIG. 5 taken along line VII-VII of FIG. 5.

[0012] [Figure 8] 8 shows a cross-sectional view of the body of FIG. 5 taken along line VIII-VIII of FIG. 7;

[0013] [Figure 9] 2 shows a front view of the insert of the golf club head of FIG. 1.

[0014] [Figure 10] 10 shows a rear view of the insert of FIG. 9.

[0015] [Figure 11] 2 illustrates a rear view of an internal weight of the golf club head of FIG. 1 in one embodiment.

[0016] [Figure 12] 1 along line XII-XII in FIG. 4.

[0017] [Figure 13] 1 along line XIII-XIII in FIG. 4.

[0018] [Figure 14] 10 shows an exploded view of the rear surface of a golf club head with a body and an insert according to a second embodiment.

[0019] [Figure 15] 15 shows a rear assembly view of the golf club head of FIG. 14.

[0020] [Figure 16] 15 shows a front assembly view of the golf club head of FIG. 14.

[0021] [Figure 17] 15 shows a rear view of the body of the golf club head of FIG. 14 with the insert removed.

[0022] [Figure 18] 18 shows a top view of the body of FIG. 17 with the insert removed.

[0023] [Figure 19] 18 shows a tow view of the body of FIG. 17 with the insert removed.

[0024] [Figure 20] 15 shows a front view of the insert of the golf club head of FIG. 14.

[0025] [Figure 21] 21 shows a rear view of the insert of FIG. 20.

[0026] [Figure 22] 15 shows a cross-sectional view of the golf club head of FIG. 14 taken along line XXII-XXII of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0027] (definition) The terms "comprise" and "have," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that includes a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent in such process, method, system, article, device, or apparatus.

[0028] Terms such as "left," "right," "front," "rear," "top," "bottom," "above," and "below," when used in the detailed description and claims, are used for descriptive purposes and are not necessarily used to describe permanent relative positions. It should be understood that terms so used are interchangeable under appropriate circumstances, and that embodiments of the apparatus, methods, and / or articles of manufacture described herein are capable of operation, for example, in other orientations than those illustrated or otherwise described herein.

[0029] Terms such as "couple," "coupled," "connection," and "coupled" should be understood broadly and refer to the connection of two or more elements, mechanically or otherwise. The connection (mechanical or otherwise) can be for any length of time, for example, permanently or semi-permanently, or only momentarily.

[0030] As used herein, the terms "golf club head," "iron-type golf club head," or "iron" refer to an iron-type golf club head. Specifically, an iron-type golf club head can be a muscle back iron, a cavity back iron, a blade-style iron, a hollow body iron, a cavity back muscle iron, a high moment of inertia iron, a wedge, a cast iron, a forged iron, or any other iron-type golf club head. A standard set of irons can include a 3, a 4, a 5, a 6, a 7, an 8, a 9, and a pitching wedge (PW).

[0031] As used herein, the terms "strike face" and "face panel" refer to the front surface of a golf club head configured to strike a golf ball. The term "strike face" can be used interchangeably with "club face" and "face panel."

[0032] As used herein, the term "strike face perimeter" may refer to the edge of the strike face. The strike face perimeter may be located along the outer edge of the strike face where the curvature deviates from the bulge and / or roll of the strike face.

[0033] As used herein, the terms “geometric center point,” “geometric center,” and “face center” can refer to the geometric center point of the strike face perimeter at the midpoint of the strike face’s club face height. In the same or another example, the geometric center point can be centered relative to an engineered impact zone, which can be defined by the area of ​​grooves on the strike face. In another approach, the strike face’s geometric center point can be located according to a definition by a golf governing body, such as the United States Golf Association (USGA). For example, the strike face’s geometric center point can be determined according to Section 6.1 of the USGA Procedure for Measuring the Flexibility of Golf Club Heads (USGA-TPX3004, Rev. 1.0.0, May 1, 2008) (available at http: / / www.usga.org / equipment / testing / protocols / Procedure-For-Measuring-The-Flexibility-Of-A-Golf-Club-Head / ) (“Flexibility Procedure”).

[0034] As used herein, the term "ground surface" may refer to a reference plane associated with the surface on which the golf ball is positioned. The ground surface may be a horizontal plane tangent to the sole of the golf club head at address position.

[0035] As used herein, the term "loft plane" may refer to a reference plane that is tangent to the geometric center point of the strike face.

[0036] The terms "loft" or "loft angle" of a golf club, as used herein, refer to the angle formed between the strike face and the shaft as measured by any suitable loft and lie machine.

[0037] Irons are less than about 60 degrees, less than about 59 degrees, less than about 58 degrees, less than about 57 degrees, less than about 57 degrees, less than about 56 degrees, less than about 55 degrees, less than about 54 degrees, less than about 53 degrees, less than about 52 degrees, less than about 51 degrees, 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, less than about 40 degrees, less than about 39 degrees The golf club may have a loft angle of less than about 38 degrees, less than about 37 degrees, less than about 36 degrees, less than about 35 degrees, less than about 34 degrees, less than about 33 degrees, less than about 32 degrees, less than about 31 degrees, less than about 30 degrees, less than about 29 degrees, less than about 28 degrees, less than about 27 degrees, less than about 26 degrees, less than about 25 degrees, less than about 24 degrees, less than about 23 degrees, less than about 22 degrees, less than about 21 degrees, less than about 20 degrees, less than about 19 degrees, or less than about 18 degrees.

[0038] In other embodiments, the irons are 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, greater than about 25 degrees, greater than about 26 degrees, greater than about 27 degrees, greater than about 28 degrees, greater than about 29 degrees, greater than about 30 degrees, greater than about 31 degrees, greater than about 32 degrees, greater than about 33 degrees, greater than about 34 degrees, greater than about 35 degrees, greater than about 36 degrees, greater than about 37 degrees, greater than about 38 degrees, or greater than about 39 degrees. , greater than about 39 degrees, greater than about 40 degrees, greater than about 41 degrees, greater than about 42 degrees, greater than about 43 degrees, greater than about 44 degrees, greater than about 45 degrees, 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, greater than about 52 degrees, greater than about 53 degrees, greater than about 54 degrees, greater than about 55 degrees, greater than about 56 degrees, greater than about 57 degrees, greater than about 58 degrees, greater than about 59 degrees, or greater than about 60 degrees.

[0039] As used herein, the "volume" of an iron can be measured as the displaced volume enclosed by the outer surface of the club head. In some embodiments, the volume of the golf club head can be less than about 45 cc, less than about 40 cc, less than about 35 cc, less than about 30 cc, or less than about 25 cc. The total volume of the club head can range from 30 cc to 45 cc, inclusive. In other embodiments, the volume of the club head can be about 31 cc to 38 cc (1.9 cubic inches to 2.3 cubic inches), about 31 cc to 33 cc, about 33 cc to 35 cc, about 35 cc to 37 cc, about 37 cc to 39 cc, or about 35 cc to 45 cc. In one example, the golf club head can be 39 cc (2.4 cubic inches). The volume of the golf club head can range from 25 cc to 35 cc, inclusive. In other embodiments, the volume of the club head 210 can be approximately 25 cc to 30 cc (1.9 cubic inches to 2.3 cubic inches).

[0040] As used herein, the "mass" of an iron can range from 240 grams (g) to 400 grams (g), inclusive. In one example, the mass can be 260 g. In other embodiments, the mass of a golf club head can range from 230 grams (g) to 300 grams (g), inclusive. In another example, the mass can be approximately 250 g.

[0041] (Detailed explanation) Described herein is a golf club head having a multi-material construction and providing high potential ball speed and shot accuracy. The golf club head includes a body and an insert made of a lightweight material, such as a polymer composite. The insert can be a toe insert that forms the outer surface of the club head. The toe insert partially forms the top rail, rear section, sole, and toe end of the club head. The top rail, rear section, and sole can be formed from multiple materials. The toe end or toe of the club head is formed by the toe insert. The toe insert can be exposed on the outer surface of the club head such that the toe insert forms the outermost surface of the toe end. The body does not form the outermost surface of the toe end.

[0042] Additionally, the insert can be spaced a gap distance from the rear surface of the face. The gap distance allows room for the face panel to flex during impact, preserving potential ball speed. However, to balance this potential ball speed benefit with durability, the insert also includes a backstop to prevent excessive flexing of the face panel. Typically, the center of the face is most likely to flex too much at impact, causing structural failure in a thin, unsupported strike face. The backstop on the insert described herein temporarily contacts the center of the strike face, preventing excessive flexing of the strike face and preventing durability issues for the strike face. The backstop also results in a more uniform impact response across the strike face. Other insert features, such as flexure control surfaces, can alter the bending properties of the face to improve potential shot accuracy.

[0043] The golf club head described herein is an iron-type golf club head. The body can be a cast or forged metal part, and the insert can be formed of a low-density material such as a polymer composite. The body can include a thin-walled face panel that forms a strike face. The thin-walled face panel enables high potential ball speeds. The body can partially define a cavity or other geometric shape, such as a passage for receiving or mechanically locking an insert into the body. The insert can form a portion of the periphery of the club head and can fill or cover a central region of the club head. In particular, the insert can form a portion of the toe end and / or top rail, and a portion of the insert can be positioned behind the face panel. A gap can exist between the insert and the rear surface of the face panel. The insert can include a protruding backstop. The backstop is closer to the rear surface of the face panel than the remainder of the insert. The insert gap distance and the backstop gap distance control bending of the face panel during dynamic impact. In this manner, the insert allows for maximum strike face deflection without reaching material failure, thereby preventing durability issues with thin face panels. The positioning and shaping of the backstop can also increase the uniformity of impact response across the strike face.

[0044] I. Toe Insert Embodiments Referring to the drawings, FIGS. 1-13 illustrate a first embodiment of a multi-material golf club head 10 including a body 70 and an insert 140. The club head 10 can be a hollow-body iron. In other words, the club head 10 can be a hollow-body iron including a toe-end insert 140. The toe-end insert 140 can be exposed on the outer surface of the club head 10. The club head 10 includes a toe end 12, a heel end 14 opposite the toe end 12, a hosel 16 connected to the heel end 14, a top rail 18, a sole 20 opposite the top rail 18, a strike face 26, and a rear 28. The toe-end insert 140 partially forms the top rail 18, the sole 20, and the rear 28. The toe-end insert 140 forms the toe end 12 and the outermost surface of the toe end 12 (i.e., the surface of the club head 10 closest to the toe). With reference to FIGS. 4 and 7, the strike face 26 defines a geometric center 50. FIG. 7 illustrates a ground plane 58 that is tangent to the sole when the club head is in the address position. The club head 10 defines a loft plane 60 that is tangent to the geometric center 50 of the strike face 26. A geometric center reference axis 52 extends through the geometric center 50 and is perpendicular to the strike face 26. FIGS. 4 and 5 illustrate a central reference plane 54 that is perpendicular to the ground plane 58 and coincides with the geometric center reference axis 52. A vertical reference plane 56 extends in a front-to-rear direction through the golf club head 10, perpendicular to the ground plane 58. In other words, the vertical reference plane 56 is parallel to the central reference plane 54. The offset of the vertical reference plane 56 from the central reference plane 54 can assist in identifying the location of certain club head features, as described below.

[0045] 3, the club head 10 has a length 40 measured parallel to the ground surface 58 in a direction from the heel end 14 to the toe end 12. The length 40 can range from 3.0 to 4.0 inches. The length 40 can be 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 inches. In one example, the golf club head length 40 is approximately 3.5 inches.

[0046] The body 70 can be formed from a metal. Specifically, the body 70 can be formed from a steel alloy selected from the group consisting of 450 steel, C250 steel, NiMark 250 steel, 475 steel, and 17-4 steel. In other embodiments, the body 70 can include a metal alloy other than a steel alloy. The body 70 has a first density that is greater than the second density of the insert 140. In other words, the second density of the insert 140 is less than the first density of the body 70.

[0047] The insert 140 can be formed from a non-metallic material. Specifically, the insert 140 can be formed from a polymer resin and reinforcing fibers. The insert 140 can be a polymer composite. The polymer resin can be a thermoplastic, such as a thermoplastic elastomer (TPE) or a thermoplastic polyurethane (TPU). The reinforcing fibers can be carbon fiber (sometimes called graphite fiber), fiberglass, aramid fibers such as Kevlar®, or boron fiber. In other embodiments, the reinforcing fibers can be natural fibers, including, but not limited to, fibers from jute, flax, ramie, hemp, sugarcane, coir, sisal, grasses, and abaca. The reinforcing fibers can be short or long fibers. The reinforcing fibers can be randomly oriented within the composite. The insert 140 can be injection molded. In other embodiments, the insert 140 can include a lightweight metal alloy, such as an aluminum alloy or a magnesium alloy.

[0048] (i. body) 1-3 illustrate a golf club head 10 including a cylindrical body 70 configured to receive an insert 140. The body 70 forms the majority of the club head 10. The body 70 defines an interior cavity 124. The body 70 of the golf club head 10 includes a face panel 72, a rear portion 82, a top wall 102, a sole portion 112 including a thick sole portion 114 and a thin sole portion 118, a hosel transition portion 106, and a cylindrical hosel 16. The rear portion 82 is located opposite the face panel 72 and forms part of the rear 28 of the club head 10. The top wall 102 forms part of the top rail 18 of the club head 10. The top wall 102 connects the face panel 72 and the rear portion 82 at the top of the club head 10. The sole portion 112 connects the face panel 72 and the rear portion 82 at the bottom of the club head 10. The face panel 72, rear portion 82, top wall 102, and thicker and thinner sole portions 114, 118, respectively, merge into a hosel transition portion 106. The hosel transition portion 106 connects to the cylindrical hosel 16. The body 70 is configured to receive and support an insert 140, as described in more detail below.

[0049] 5-7 , the body 70 includes a face panel 72 having a front surface 74 and a rear surface 76. The front surface 74 of the face panel 72 may form the entire strike face 26 of the club head 10. The rear surface 76 of the face panel 72 is opposite the front surface 74. The rear surface 76 faces the interior cavity 124 of the club head 10. When the golf club head 10 impacts a golf ball, the rear surface 76 may flex and momentarily contact a portion of the insert 140 disposed behind the rear surface 76.

[0050] Referring to FIG. 7 , the face panel 72 has a thickness 78 measured between the front surface 74 and the rear surface 76. The face panel 72 may have a uniform thickness. The face panel 72 may have a constant thickness. The face panel 72 may have a consistent thickness as measured in the heel-toe and top rail-sole directions across the strike face 26. The face panel thickness 78 may range between 0.055 inches and 0.10 inches. In other embodiments, the face panel thickness 78 may range between 0.055 inches and 0.075 inches, 0.065 inches and 0.085 inches, 0.075 inches and 0.095 inches, or 0.080 inches and 0.1 inches. Also, in other embodiments, the face panel thickness 78 can be less than 0.060 inches, less than 0.065 inches, less than 0.070 inches, less than 0.08 inches, less than 0.09 inches, or less than 0.10 inches. For example, the face panel thickness 78 can be 0.055, 0.06, 0.061, 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, or 0.10 inches. In one example, the face panel thickness 78 can be approximately 0.055 inches. In another example, the face panel thickness 78 can be approximately 0.065 inches. A thin face panel 72 promotes face flexion, thereby increasing ball speed.

[0051] Referring to FIG. 4 , the face panel front surface 74 may include grooves to improve grip of a golf ball striking the face panel 72 during impact. The grooves may extend in a heel-to-toe direction. The face panel front surface 74 may include 5 to 20 grooves. In some embodiments, the face panel front surface 74 may include 15 to 18 grooves. The face panel 72 may be integrally formed with the body 70. In other embodiments, the face panel 72 may be a separate face plate welded onto the body 70.

[0052] With reference to FIG. 6 , the body 70 can be generally cylindrical and define an inner cavity 124. The cylindrical body 70 defines a hollow structure with the inner cavity 124. The cylindrical body 70 can be bounded by the face panel 72, the heel end 14, the rear 28, the sole 20, and the top rail 18. In other words, the cylindrical body 70 can be a hollow shell bounded by the face panel 72, the heel end 14, the rear 28, the sole 20, and the top rail 18. However, as illustrated in FIG. 5 , the face panel 72 can extend further toward the toe end 12 than any other portion of the body 70. The body 70 does not form any portion of the outermost surface of the toe end 12. With reference to FIGS. 1 and 5-7 , the inner cavity 124 is open toward the toe end 12 of the club head 10. FIG. 6 illustrates the mouth 126 of the inner cavity 124. FIG. 5 illustrates the mouth of the inner cavity 124 positioned in the vertical reference plane 56. The cavity mouth 126 points toward the toe end 12 of the club head 10. The cavity mouth 126 can be an entrance to the inner cavity 124. The cavity mouth 126 can be an access to the inner cavity 124. The cavity mouth 126 is not directly visible from one or more of the rear view, the front view, the sole view, and the top view. The cavity mouth 126 is never visible from the heel view. The body 70 can be shaped so that the inner cavity 124 has a cross-sectional area taken parallel to the vertical reference plane 56 that is greatest at the mouth 126. In some embodiments, the body 70 can be shaped so that the cavity 124 has a cross-sectional area that gradually decreases toward the heel end 14. This cavity shaping allows the insert to be pre-formed and then smoothly slid into the cavity 124. Additionally, in some embodiments, the heel boundary of the inner cavity 124 can be positioned approximately 0.9 inches to 1.5 inches away from the central reference plane 54 toward the heel end 14.For example, the heel boundary of the inner cavity 124 can be located approximately 0.9 inches to 1 inch, 1 inch to 1.1 inch, 1.1 inches to 1.2 inches, 1.2 inches to 1.3 inches, 1.3 inches to 1.4 inches, or 1.4 inches to 1.5 inches from the central reference plane 54 toward the heel end 14. In some embodiments, the heel boundary of the inner cavity 124 can be located approximately 1.1 inches from the central reference plane 54 toward the heel end 14. The volume and length of the inner cavity 124 are important to the positioning of the insert 140 behind the strike face 26.

[0053] The face panel rear surface 76, the rear portion 82, the top wall 102, and the sole portion 112 together define (bound) an inner cavity 124. The face panel rear surface 76 may form a forward boundary of the inner cavity 124. The rear portion 82 may form a rear boundary of the cavity 124. The top wall 102 may form a ceiling of the cavity 124. The thicker and thinner sole portions may form a bottom boundary of the cavity 124. In some embodiments, the hosel transition portion 106 may define a heel boundary of the cavity 124. In some embodiments, the cavity 124 extends partially into the hosel transition portion 106.

[0054] The inner cavity 124 may have a volume. The cavity volume may range between 0.65 cubic inches and 0.90 cubic inches. For example, the cavity volume may be 0.86 cubic inches. In some embodiments, the cavity volume may range between 25% and 40% of the total volume of the club head 10. In some embodiments, the cavity volume may range between 25% and 30%, 30% and 35%, or 35% and 40% of the total club head volume. For example, the cavity volume may be 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, or 40% of the total club head volume.

[0055] FIG. 3 illustrates an upper rear surface 30 and a lower rear surface 34 separated by a fold 38 (also referred to as a cross-sectional inflection point or bend line). The fold 38 extends from the toe end 12 to the heel end 14 and is located between the upper rail 18 and the sole 20. The fold 38 allows the rear 28 to flex when the club head 10 impacts a golf ball. The upper rear surface 30 may have a height 32 measured perpendicular to a ground surface 58. The upper rear surface height 32 may be greater than the lower rear surface height 36. The upper rear surface height 32 may increase from near the heel end 14 to near the toe end 12. The lower rear surface height 36 may increase from near the heel end to near the toe end 12. The fold 38 may be closer to the ground surface 58 near the heel end 14 than near the toe end 12 when the golf club head 10 is addressed.

[0056] 5 and 6 , the face panel 72 may extend further toward the toe end 12 of the club head 10 than the remainder of the body 70. The top wall 102, the rear portion 82, and the sole portion 112 extend toward the toe end 12 and do not extend farther than the vertical reference plane 56. The vertical reference plane 56 may be offset from the central reference plane 54 toward the toe end 12 of the club head by an offset distance 55. The offset distance 55 may range from 1.0 inches to 1.8 inches. For example, the offset distance 55 may be 1.4 inches. In alternative embodiments, the offset distance 55 may range from 0 inches to 1.8 inches. As a result of the top wall 102, the rear portion 82, and the sole portion 112 terminating at or short of the vertical reference plane 56, the body cavity also terminates on the heel side of the vertical reference plane 56. The offset distance 55 allows the body 70 of the club head 10 to be configured so that the insert 140 and the backstop of the insert 140 are optimally positioned behind the face panel 72, as described below.

[0057] In some embodiments, the top wall 102, rear portion 82, and sole portion 112 of the body 70 do not extend within 0.2 inches, 0.4 inches, 0.6 inches, 0.8 inches, 1.0 inches, 1.2 inches, or 1.4 inches from the outermost point or surface on the club head toe end 12. In contrast, the face panel 72 can extend almost or completely to the toe end 12. The offset of the body 70 from the outermost surface of the toe end 12 allows the insert 140 to form the top wall 102, rear portion 82, sole portion 112, and the remaining portion of the toe end 12.

[0058] Referring to FIG. 7 , the thickness of the top wall 102 and sole portion 112 can affect the ability of the face panel 72 to flex during dynamic impact with a golf ball. The top wall 102 can have a thickness 104 ranging from 0.030 inches to 0.040 inches, inclusive. In some embodiments, the top wall thickness 104 can range from 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, or 0.038 inches to 0.040 inches, inclusive. A thin top wall 102 can facilitate flexing of the strike face. The aforementioned thicknesses of the top wall 102 and sole portion 112 allow for weight reduction and provide the club head 10 with the strength to withstand golf ball impacts.

[0059] Referring to FIG. 8 , the sole portion 112 includes a thicker sole portion 114 and a thinner sole portion 118. The thicker sole portion 114 can be behind the thinner sole portion 118 when the inner cavity 124 is viewed in the front-to-rear direction. The thicker sole portion 114 does not extend entirely across the sole 20. For example, the thicker sole portion 114 can be located primarily on the heel side of the central reference plane 54. The thicker sole portion 114 improves mass properties by distributing more weight downward and further back, and also provides a structure for the interlocking geometry for the insert 140. The thinner sole portion 118 connects to the face panel 72 at the leading edge 22 of the sole 20. Positioning the thinner sole portion 118 directly behind the leading edge 22 promotes flexure of the strike face 26. The thinner sole portion 118 promotes greater flexure of the strike face upon impact with a golf ball. The thin sole portion 118 can have a thickness 120 ranging from 0.030 inches to 0.075 inches. In some embodiments, the thin sole portion thickness 120 can range from 0.030 inches to 0.05 inches, or from 0.05 inches to 0.075 inches. In other embodiments, the thin sole portion thickness 120 can range from 0.030 inches to 0.045 inches, from 0.045 inches to 0.06 inches, or from 0.06 inches to 0.075 inches. In one example, the thin sole portion thickness 120 can be approximately 0.035 inches. The thick sole portion 114 can have a thickness 116 that is greater than the thin sole portion thickness 120. The thick sole portion thickness 116 can range from 0.040 inches to 0.100 inches. In some embodiments, the thickened sole portion thickness 116 ranges from 0.040 inches to 0.050 inches, 0.050 inches to 0.060 inches, 0.060 inches to 0.070 inches, 0.070 inches to 0.080 inches, 0.080 inches to 0.090 inches, or 0.090 inches to 0.100 inches. In one example, the thickened sole portion thickness 116 can be approximately 0.075 inches.

[0060] (ii. Insert) 1-3, the golf club head 10 includes a low-density insert 140 that can temporarily limit the deflection or movement of the face panel 72 during dynamic impact with a golf ball. The insert 140 prevents excessive or potentially breakable deflection of the face panel 72. The insert 140 can slide from the toe end 12 into the inner cavity 124 and form a majority of the toe end 12. Portions of the insert 140 can be exposed at the toe end 12 and at portions of the rear 28, sole 20, and top rail 18. The insert 140 can form the entire outermost surface of the toe end 12.

[0061] FIG. 3 illustrates that the insert 140 replaces or forms a portion of the club head periphery, such as the toe end 12 or the top rail 18. The insert 140 can be configured to mount, couple, and / or slide onto the body 70. As illustrated in FIGS. 9 and 10 , the insert 140 includes an offset surface 144, a back surface 146 opposite the offset surface 144, a top edge 148, and a bottom edge 150. The insert 140 can at least partially fill the interior cavity of the body 70. The insert 140 can form a portion of the rear 28, sole, top rail 18, and toe end 12 of the club head 10. The insert 140 can form an upper portion of the toe end 12, a central portion of the toe end 12, and a bottom portion of the toe end 12. The insert 140 can be partially exposed at the toe end 12. The insert 140 can be externally visible from at least the front, toe, and / or rear views. Figure 9 illustrates that the midplane of the insert 140 can be defined as the halfway point between the heel end 14 and the toe end 12 of the insert 140 along its length 142.

[0062] 12 and 13 , a gap may be formed between the offset surface 144 of the insert 140 and the rear surface 76 of the face panel 72. The gap between the insert 140 and the face panel 72 may provide room for the face panel 72 to flex during golf ball impact. FIG. 12 illustrates that the gap distance 64 between the insert offset surface 144 and the face panel rear surface 76 (hereinafter, “insert gap distance 64”) may range from 0.050 inches to 0.100 inches. In other embodiments, the insert gap distance 64 may range from 0.05 inches to 0.075 inches, or from 0.075 inches to 0.100 inches. In other embodiments, the insert gap distance 64 can range from 0.055 inches to 0.095 inches, 0.055 inches to 0.075 inches, 0.060 inches to 0.090 inches, 0.060 inches to 0.080 inches, or 0.065 inches to 0.075 inches. For example, the insert gap distance 64 can be 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, 0.085, 0.090, 0.095, or 0.100 inches. In one example, the insert gap distance 64 can be approximately 0.075 inches. The insert 140 does not contact the face panel 72 in a static state (i.e., before impact with a golf ball). In other words, the insert 140 is not in intimate contact with the face panel 72 during a rest state. During a golf ball impact, the face panel 72 is in a deformed state under the load of the golf ball, and the insert 140 contacts the rear surface 76 of the face panel 72 to provide support for bending due to the impact of a particular force on the strike face 26, thereby preventing the face panel 72 from deflecting to the point of failure.

[0063] The insert 140 includes an encapsulated portion 174 and an exposed portion 178. The encapsulated portion 174 and the exposed portion 178 of the insert 140 may be integrally formed. The encapsulated portion 174 may be located entirely within the cavity 124. The encapsulated portion 174 of the insert 140 may be at least partially disposed on the heel end side of the vertical reference plane 56 defined above. The encapsulated portion 174 may be the portion of the insert 140 disposed behind the face panel 72.

[0064] The exposed portion 178 may be located entirely outside the cavity 124. The exposed portion 178 of the insert 140 may be located entirely on the toe side of the vertical reference plane 56. The insert exposed portion 178 may form the toe end 12 of the club head 10 and a section of the rear 28 adjacent to the toe end 12. The exposed portion 178 is not positioned directly behind the face panel 72. The insert 140 may fill the cavity 124, completely sealing off the cavity mouth 126. The insert 140 may fill the entrance or access to the cavity 124. The exposed portion 178 of the insert 140 aligns with the outer surface of the body 70 to form the outer surface of the golf club head 10. The insert 140 forms the outermost surface of the toe end 12. The body 70 does not form the toe end of the club head 10 or the outermost surface of the toe end 12 of the club head 10 .

[0065] The encapsulated portion 174 can partially fill the cavity 124 of the body 70. The encapsulated portion 174 of the insert 140 can have at least one surface that is in intimate contact with the interior cavity walls of the body 70, particularly the walls that form the rear 28. However, near the front 24, a gap distance 64 separates the insert 140 from the face panel 72. The encapsulated portion 174 of the insert 140 can be in intimate contact with the periphery of the face panel 72. The insert 140 supports the periphery of the face panel 72, allowing the insert 140 to be spaced apart from the face panel 72 at a central portion of the face panel 72.

[0066] 12 and 13 , the upper edge 148 of the insert 140 can be in close contact with the outer periphery of the face panel 72. The upper edge 148 can contact the outer periphery of the face panel 72 in a heel-to-toe direction along the length of the top rail 18. The insert 140 contacts the outer periphery of the face panel 72, and other portions of the insert 140 do not contact the face panel 72 (e.g., a central area or portion of the face panel 72). The insert 140 supports the outer periphery of the face panel 72, but does not support the central portion of the face panel 72, allowing the face panel 72 to flex during golf ball impact.

[0067] 3, 4, 9, and 10, the exposed portion 178 partially forms the toe end 12 and may have an insert front surface 182 and a front edge 180. The front of the exposed portion 178 may be mostly covered by the body face panel 72. The insert front surface 182 is in intimate contact with and positioned directly behind the toe-side outer periphery of the face panel 72. The front edge 180 hugs or wraps around the toe-side outer periphery of the face panel 72 to form a portion of the outer periphery of the club head 10. The front edge 180 extends around and forward from the insert front surface 182. The front edge 180 may support the periphery of the face panel 72 at the toe end 12. The front edge 180 does not contact a central portion of the face panel 72. Some alternative embodiments may lack the front edge 180 and instead have the face panel 72 extend uninterrupted to the outermost periphery of the toe end 12 .

[0068] 3 and 4, the exposed portion 178 may have an outer surface that is flush with and connects to the outer surface of the body 70. The exposed portion 178 may form less than 50% of the rear 28 of the club head 10. In some embodiments, the insert exposed portion 178 may form more than 5%, more than 10%, more than 15%, more than 20%, or more than 30% of the rear 28. In some embodiments, the insert 140 forms approximately 25% of the rear 28. For example, the insert 140 may form 0.95 square inches of the rear 28, which may have a total surface area of ​​approximately 3.69 square inches.

[0069] The exposed portion 178 can form less than 50% of the sole 20 of the club head 10. In some embodiments, the insert exposed portion 178 can form more than 5%, more than 10%, more than 15%, more than 20%, or more than 30% of the sole. In some embodiments, the insert 140 forms approximately 25% of the sole 20. The exposed portion 178 can also form a portion of the top rail 18. As illustrated in FIG. 3 , the outer surfaces of the top rail 18, sole 20, and rear 28 of the assembled club head 10 can be formed of multiple materials. The assembled club head 10 can further include a material at the toe end 12 or at the outermost surface of the toe end 12. The assembled club head 10 can further include a material on the strike face 26 or the face panel front surface 74. The insert exposed portion 178 can be integrally attached to the toe end of the encapsulation portion 174. The insert 140 may be molded as one component, such that both the encapsulated portion 174 and the exposed portion 178 are molded from the same material.

[0070] Further, less than 35% of the volume of the insert 140 can be disposed outside the cavity 124. In other embodiments, less than 30%, less than 25%, less than 20%, less than 15%, or less than 10% of the volume of the insert 140 can be disposed outside the cavity 124. Further, more than 65% of the volume of the insert 140 can be disposed within the cavity 124. In other embodiments, more than 70%, 75%, 80%, 85%, 90%, or 95% of the volume of the insert 140 can be disposed within the cavity 124.

[0071] 9 , the insert 140 can have a length 142, measured parallel to the ground surface 58 in a direction from the heel end 14 to the toe end 12, that is between 10% and 80% of the golf club head length 40. In some embodiments, the insert 40 can have a length 142 between 10% and 30%, 10% and 50%, 30% and 70%, 30% and 60%, 30% and 50%, 40% and 50%, 20% and 50%, or 50% and 80% of the golf club head length 40. In some embodiments, the insert 140 has a length 142 that is approximately 50% of the golf club head length 40. The length of the insert 140 provides sufficient length to control the location of the backstop 152 behind the face panel 72.

[0072] In some embodiments, the insert 140 can have a volume ranging between 1 cubic inch and 6 cubic inches. In one example, the insert volume can be approximately 5 cubic inches. In some embodiments, the insert 140 can have a mass ranging between 10 g and 20 g, inclusive. In one example, the insert mass can be approximately 15.8 g. The insert 140 can have a specific gravity that is less than the specific gravity of the body 70.

[0073] In some embodiments, the insert 140 can fill a majority of the cavity 124. The insert 140 can fill between 60% and 95% of the cavity 124. In some embodiments, the insert 140 can fill between 70% and 90%, 70% and 80%, 75% and 85%, or 80% and 90% of the cavity 124. For example, the insert 140 can fill approximately 87% of the cavity 124. In some embodiments, the insert encapsulated portion 174 can have a volume ranging between 0.65 cubic inches and 0.86 cubic inches. The volume of the encapsulated portion corresponds to the fill volume of the cavity 124. In other words, the free volume of the cavity 124 can range between approximately 0.1 cubic inches and 0.5 cubic inches.

[0074] (a. Backstops and Deflection Control Surfaces) 9 , the insert may include a backstop 152 protruding from (or disposed on) the insert offset surface 144 and a deflection control surface 162. The backstop 152 and the deflection control surface 162 may be configured to temporarily contact the face panel 72 as the face panel 72 flexes during dynamic impact. The backstop 152 does not contact the face panel 72 when the golf club 10 is at rest. The backstop 152 contacts the face panel rear surface 76 to prevent excessive deflection of the face panel 72 during dynamic impact of the club head 10 with a golf ball. The deflection control surface 162 may not contact the face panel 72 when the golf club 10 is at rest. In other words, the backstop 152 does not contact the rear surface 76 of the face panel 72 in the first configuration (i.e., the static state). In the second configuration (i.e., the deformed state), the backstop 152 contacts the rear surface 76 of the face panel 72. The backstop 152 prevents excessive deflection of the face panel 72 during golf ball impact.

[0075] The encapsulation portion 174 partially fills the inner cavity 124 and may include a backstop 152 and a deflection control surface 162. As described below, the backstop 152 is generally located behind and centrally located relative to the geometric center of the strike face 26. The deflection control surface 162 is peripherally located, with a majority of the surface generally behind the upper toe and heel regions of the strike face 26. Both the backstop 152 and the deflection control surface 162 may be closer to the face panel 72 than the remainder of the insert encapsulation portion 174. In other words, the backstop gap distance 66 and the deflection control gap distance are less than the insert gap distance 64. The backstop gap distance 66 and the deflection control gap distance allow the face panel 72 to flex without excessive deflection (i.e., the backstop 152 and / or the deflection control surface 162 briefly contact the face panel 72 during golf ball impact).

[0076] The encapsulation portion 174 may include the offset surface 144 of the insert 140. The offset surface 144 may further include the backstop 152 and the deflection control surface 162 described above. In other words, both the backstop 152 and the deflection control surface 162 are disposed on the front of the encapsulation portion 174. As described above, the insert gap distance 64, the backstop gap distance 66, and the deflection control gap distance act to control bending of the face panel.

[0077] 12 , the backstop 152 of the insert 140 may be positioned behind and centered on the strike face 26. The backstop 152 may be closer to the face panel 72 than the remainder of the insert offset surface 144. In other words, the backstop 152 may be offset inward from the rear surface 76 of the face panel 72 a lesser distance than the remainder of the insert offset surface 144. The backstop 152 may be offset from the rear surface 76 of the face panel 72 by a backstop gap distance 66 that is less than the insert gap distance 64.

[0078] 12 , the backstop gap distance 66 can range between 0.015 inches and 0.065 inches. In some embodiments, the backstop gap distance 66 can range between 0.015 inches and 0.040 inches, or between 0.040 inches and 0.065 inches. In other embodiments, the backstop gap distance 66 can range between 0.015 inches and 0.035 inches, 0.025 inches and 0.045 inches, 0.035 inches and 0.055 inches, or 0.045 inches and 0.065 inches. For example, the backstop gap distance 66 can be 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, or 0.065 inches. In one example, the backstop gap distance 66 can be approximately 0.025 inches. In another example, the backstop gap distance 66 can be 0.05 inches. The backstop gap distance 66 controls how much the backstop 152 caps or limits face deflection.

[0079] The backstop 152 can prevent excessive flexing of the face panel 72 by limiting the distance the face panel 72 can bend before encountering resistance from the insert 140. The gap between the insert 140 and the face panel 72 encourages flexing of the face without allowing excessive flexing that could result in structural failure. The insert gap distance 64 and the backstop gap distance 66 are important to this balance between face flexibility (which translates to ball speed) and durability.

[0080] The backstop 152 may be positioned behind the geometric center 50 of the strike face 26. The geometric center reference axis 52 may intersect the backstop 152. The backstop 152 protrudes from the remainder of the insert offset surface 144. The backstop 152 may be substantially parallel to the face panel 72 and may include a flat surface 154. The backstop flat surface 154 may have a surface area (also referred to as a backstop surface area) that ranges between 0.05 and 0.20 square inches. In some embodiments, the backstop surface area ranges between 0.05 and 0.10 square inches, 0.10 and 0.15 square inches, or 0.15 and 0.20 square inches. In one example, the backstop surface area may be approximately 0.10 square inches.

[0081] 9 , the backstop 152 may include a top side 156, a toe side 158, and a heel side 160. The top side 156 may be convex, and the toe side 158 and heel side 160 may be concave relative to the geometric central reference axis 52. The toe side 158 and heel side 160 may meet at a rounded point at the bottom of the backstop 152. The toe side 158 and heel side 160 intersect the top side 156 to form wing-like shapes that point toward the toe end 12 and heel end 14, respectively. The shape of the backstop 152 may facilitate temporarily limiting bending at points or regions that make the strike face 26, and specifically the face panel 72, more flexible than desired. The backstop's flat surface 154 may include fillet-welded connections to the backstop's sides (top side, toe side, and heel side). These sides of the backstop may also have fillet welded connections to the rest of the insert 140 .

[0082] 9 illustrates the deflection control surface 162. The deflection control surface 162 can be closer to the face panel 72 than the remainder of the insert offset surface 144. In other words, the deflection control surface 162 can be offset inwardly from the rear surface 76 of the face panel 72 a smaller distance than the remainder of the insert offset surface 144. In some embodiments, the backstop 152 and the deflection control surface 162 are offset inwardly by the same gap distance, while in other embodiments, they are offset by different distances. The deflection control surface 162, like the backstop 152, can prevent excessive deflection of the face panel 72 by limiting the distance the face panel 72 can bend before encountering resistance from the insert 140.

[0083] The distance of the deflection control surface 162 from the face panel rear surface 76 (hereinafter referred to as the "deflection control gap distance") can range from 0 inches to 0.040 inches. In some embodiments, the deflection control gap distance (not illustrated) can range from 0 inches to 0.010 inches, 0.010 inches to 0.020 inches, 0.020 inches to 0.030 inches, or 0.030 inches to 0.040 inches. In some embodiments, there is no gap between the deflection control surface and the rear surface of the face panel (i.e., the deflection control gap distance is zero). The deflection control gap distance controls how much the deflection control surface caps or limits face deflection. In addition to inhibiting bending in areas of the face panel that are not intended to bend, the deflection control surface, and particularly its edges, can alter the impact response of the face panel 72.

[0084] 9 illustrates the flexure control surface 162 of the insert 140. During impact, the flexure control surface 162, and in particular the flexure control edge 164, can provide leverage to the face panel rear surface 76. The leverage can change the bending behavior of the face panel 72 and alter the trajectory of the shot. For example, the higher the golf ball impacts on the strike face 26, the more the flexure control surface 162 can provide significant leverage to the face panel 72, causing areas of the face panel 72 to angle downward or flatten. This can provide some compensation for undesirable high impacts.

[0085] FIG. 9 illustrates the insert 140 in a heel-toe orientation (i.e., the length 142 of the insert 140 is measured in the heel-toe direction). The flexure control surface 162 may be generally disposed behind the upper toe and heel regions of the strike face 26, which rarely experience direct impact from a golf ball. The flexure control surface 162 includes a flexure control edge 164. The flexure control edge 164 may be concave relative to the geometric central axis 52. The flexure control edge 164 arches across the sweet spot of the strike face 26. The flexure control surface 162 protrudes above the flexure control edge 164 from the remainder of the insert offset surface 144. The flexure control surface 162 extends behind the face panel 72 to the upper, upper toe, and upper heel sides of the insert region. The deflection control surface 162 may have a surface area of ​​between approximately 0.3 and 0.9 square inches. For example, the deflection control surface 162 may have a surface area of ​​0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 square inches. In some embodiments, the deflection control surface 162 has a surface area of ​​approximately 0.5 square inches. Conversely, the area of ​​the insert behind the face panel 72 has a recessed surface (i.e., the offset surface 144). The recessed surface corresponds to the majority of the area that experiences most impacts, except for the area corresponding to the center backstop 152 of the strike face 26. The recessed surface may have an area of ​​between approximately 1.5 and 2.5 square inches. For example, the recessed surface can have an area of ​​1.5 square inches, 1.6 square inches, 1.7 square inches, 1.8 square inches, 1.9 square inches, 2.0 square inches, 2.1 square inches, 2.2 square inches, 2.3 square inches, 2.4 square inches, or 2.5 square inches. In some embodiments, the recessed surface can have an area of ​​approximately 2 square inches, and the distance between the recessed surface and the face panel 72 can be equal to the insert gap distance 64 described above.

[0086] The shaping of the flexion-controlling edge 164 determines how the face flexes, which can alter the trajectory of the ball's flight. The flexion-controlling edge 164 can include a straight segment 166, a deep arc segment 168, and a shallow arc segment 170. The straight segment 166 can begin in the lower toe region of the insert and extend upward and slightly inward toward but not quite at the top rail 18. The straight segment 166 connects to the deep arc segment 168, which is concavely curved relative to the geometric central reference axis 52 within the upper toe region of the insert 140. The deep arc segment 168 connects to the shallow arc segment 170 at approximately the mid-plane, assuming a 0.5-inch increase or decrease on either side of the insert 140. The shallow arc segment 170 is also concave relative to the geometric central axis 52. The shallow arc segment 170 extends through the upper heel region of the insert 140 to the upper heel edge. The shallow arc segment 170 has a larger average radius of curvature than the radius of curvature of the deep arc segment 168. The average radius of curvature of the deep arc can range between 0.55 inches and 1 inch, inclusive. The average radius of curvature of the shallow arc can range between 0.75 inches and 2 inches, inclusive. In some embodiments, the radii of curvature of the deep and shallow arcs are variable throughout the lengths of these segments.

[0087] In some embodiments, the deep arc segment 168 and the shallow arc segment 170 of the deflection control edge 164 can together form a single conic section with an rho value of 0.5 inches and an endpoint separation of approximately 1.8 inches. The heel end of the conic section can have a tangent angle of approximately 44 degrees measured from a vertical reference axis. The toe end of the conic section can have a tangent angle of approximately 18 degrees measured from a vertical reference axis.

[0088] The shaping and positioning of the deflection-controlling edge segment contributes to the impact response of the golf club head 10. In the illustrated embodiment of Figures 1-13, the deflection-controlling edge 164 is not symmetrical about the midplane of the insert 140 and is not symmetrical about the central reference plane 54 of the club head 10. The deflection-controlling edge 164 may include an upper fillet at the deflection-controlling surface 162 and / or a lower fillet at the juncture between the edge 164 and the rest of the insert 140.

[0089] (b. Connection between body and insert) The insert 140 and the body 70 may include alignment features to assist in securing these components together. For example, the alignment features may include interlocking channels and rails, interlocking grooves and ledges, one or more recesses and protrusions, interlocking geometries, or any other suitable aligning, interlocking, or snap-fit ​​geometries. In some embodiments, the body 70 includes rails or ledges, and the insert 140 includes channels or grooves for receiving the rails or ledges, as described below. Alternatively, the body 70 may include channels or grooves, and the insert 140 may include rails or ledges. In other embodiments, the golf club head 10 may include other forms of mechanical locking mechanisms, such as pegs, snap features, and / or tabs, for attaching the insert to the body. In other embodiments, the body 70 and the insert 140 may be secured together using a combination of adhesive and mechanical connections.

[0090] 8 and 10, the golf club head 10 includes alignment features in the form of an insert passageway 176 and a body inner rail 84. The rear portion 82 of the body 70 may include the inner rail 84, which extends into a portion of the inner cavity 124. In other words, the inner rail 84 may extend away from the rear 28 of the club head 10 toward the front portion 24. The inner rail 84 may also be referred to as a cantilevered rail, cantilevered portion, rear block, protrusion, or track. The inner rail 84 may function as an alignment or locking mechanism for securing the insert 140 to the body 70.

[0091] 7 and 8 , in some embodiments, the inner rail 84 can be aligned generally in a heel-toe direction. The inner rail 84 connects to the hosel transition portion 106 and extends from the hosel transition portion 106 toward the toe end 12, terminating before reaching the vertical reference plane 56. The inner rail 84 resides entirely within the cavity 124 and does not extend beyond the vertical reference plane 56. In some embodiments, the inner rail 84 does not extend beyond the central reference plane 54. In other words, in these embodiments, the inner rail 84 resides entirely on the heel side of the central reference plane 54. In some embodiments, the inner rail 84 terminates between 0 inches and 0.4 inches, inclusive, on the heel side of the central reference plane 54. The inner rail 84 can be configured to couple to or align the insert 140 within the cavity 124. The inner rail 84 can be integrally formed with the remainder of the body rear section 82.

[0092] 8 , the inner rail 84 may have a length 86 measured parallel to the ground surface 58 in a direction from the heel end 14 toward the toe end 12. The inner rail length 86 may range between 15% and 25% of the golf club head length 40. For example, the inner rail length 86 may be approximately 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, or 25% of the golf club head length 40. In alternative embodiments, the inner rail length 86 may range between 25% and 60% of the golf club head length 40.

[0093] In some embodiments, the inner rail 84 can be aligned generally parallel to the sole 20 and generally parallel to the top rail 18, or can be angled between the two orientations. The inner rail 84 can include a front wall 88, a top wall 90, a bottom wall 92, and a toe side wall 94. The front wall 88 can be spaced from the face panel 72 by a distance of at least 0.030 inches, at least 0.040 inches, at least 0.045 inches, at least 0.050 inches, at least 0.060 inches, at least 0.070 inches, at least 0.080 inches, at least 0.090 inches, or at least 0.1 inches. In some embodiments, the inner rail front wall 88 is spaced from the face panel 72 by a distance of approximately 0.1 inches. The spacing between the inner rail 84 and the face panel 72 allows the face panel 72 to flex during dynamic impact of the club head 10 with a golf ball.

[0094] 7, in some embodiments, inner rail 84 can bound the top of undercut void 128, which is a region of cavity 124. Thickened sole portion 114 can bound the bottom of undercut void 128. Inner rail 84 can connect to thickened sole portion 114 behind undercut void 128. Undercut void 128 can facilitate flexion of sole 20 during impact.

[0095] 2 and 10 , which shows a rear view of the insert 140, in some embodiments, a channel 176 extends in a heel-to-toe direction along the rear surface 146 of the insert 140 (specifically, the encapsulated portion 174). The channel 176 is sized to receive the inner rail 84 of the body 70. The insert channel 176 can slide over the body inner rail 84 when the insert 140 is slid into the body cavity 124. The engagement between the insert channel 176 and the body inner rail 84 helps align and secure the insert 140 in the proper position within the cavity 124. Because a gap may exist between the insert 140 and the face panel rear surface 76, this channel-to-rail alignment connection helps properly orient the insert 140 within the body cavity 124.

[0096] (c. Weight) 2 and 11, the golf club head 10 may include an internal weight 184 encapsulated within the insert 140. The internal weight 184 extends into both the encapsulated portion 174 and the exposed portion 178. The mass distribution of the golf club head 10 may be precisely controlled by the location of the high-density internal weight 184 within the low-density insert 140. In some embodiments, the golf club head 10 may further include a removable toe weight and / or multiple internal weights within the insert 140. The high-density internal weight 184 may be co-molded into the insert 140. FIG. 2 illustrates an exploded view with the high-density weight 184 next to the insert 140 for comparison.

[0097] 12 , the internal weight 184 can be completely encapsulated inside the insert 140. In some embodiments, the internal weight 184 can be partially disposed within the encapsulated portion 174 and partially disposed within the exposed portion 178 of the insert 140. In other embodiments, the internal weight 184 is completely disposed within one of the encapsulated portion 174 or the exposed portion 178.

[0098] 11 , the internal weight 184 can have an integrally connected elongated portion 186 and a lofty toe portion 188. The lofty toe portion 188 can extend closer to the top rail 18 than the elongated portion 186. The lofty toe portion 188 can include a peak portion 190. The peak portion 190 extends significantly higher than the remainder of the lofty toe portion 188. The elongated portion 186 can be positioned lower within the insert 140 and can extend generally in a heel-to-toe direction. In some embodiments, the internal weight 184 can be positioned closer to the rear 28 of the club head 10 than the front 24. The internal weight 184 can be positioned closer to the toe end 12 than the heel end 14.

[0099] 2 and 11 , in some embodiments, the golf club head 10 can further include an internal weight, a toe weight, a hosel tip weight, or other weight placement elements located within the hosel 16 (not shown) to provide a desired mass distribution throughout the club head 10, as needed. FIGS. 2 and 11 illustrate at least one internal weight 184, which can be co-molded into the insert 140. The internal weight 184 can have a density greater than that of the body 70 and greater than that of the insert 140. In some embodiments, the internal weight 184 includes tungsten powder encapsulated in a polymer. The internal weight 184 can be located lower within the club head, closer to the toe end 12 than the heel end 14.

[0100] The internal weight 184 can include a tungsten material. For example, the internal weight 184 can include tungsten powder encapsulated in or impregnated with a polymer. The polymer can be thermoplastic urethane (TPU), styrene isoprene styrene (SIS) rubber, or any other suitable material. The durometer of the internal weight 184 can be varied depending on the type of polymer used. For example, an SIS polymer forms a softer internal weight than a TPU. The density of the internal weight 184 can be selected by the ratio of tungsten powder to polymer.

[0101] The internal weight 184 may have a mass ranging between 79 g and 130 g. For example, the internal weight 184 may have a mass of approximately 110 g. The internal weight 184 may have a specific gravity ranging between 12 and 17. For example, the internal weight 184 may have a specific gravity of 14. The internal weight 184 may have a specific gravity greater than the specific gravity of both the body 70 and the insert 140. Due to its higher specific gravity, the internal weight 184 may be used to alter the center of gravity of the club head 10 by positioning the internal weight 184 at a particular location within the insert 140. In an alternative embodiment, the golf club head 10 may include more than one internal weight (not shown).

[0102] In some embodiments, the toe weights (not illustrated) can be threaded and configured to thread into a toe cavity (also referred to as a toe port) of the body or insert. For example, the body can include threaded ports configured to receive threaded toe weights of various densities. The toe weights can alternatively be configured to receive or retain fasteners configured to engage the toe cavity and retain the toe weight on the club head. The toe weights can be replaceable (or removable). The toe weights can be exposed at the toe end 12. In some embodiments, the toe weights can be integrally formed with the insert 140.

[0103] A hosel tip weight (not shown) can be positioned within the hosel prior to attaching the shaft to the club head. The toe weight and hosel tip weight can increase the moment of inertia of the golf club head by increasing the mass at the perimeter of the club head. The combination of the hosel tip weight and internal weight 184 increases the weight distribution at the perimeter, thereby increasing the moment of inertia of the club head 10. The increased moment of inertia increases forgiveness and golfer confidence during golf ball impact.

[0104] The mass distribution of the club head can also be controlled and fine-tuned by injecting a vibration-damping material (not illustrated) into the portion of the cavity not filled by the insert. The vibration-damping material can be a hot melt epoxy. The vibration-damping material can be injected into the cavity through a small window in the face, toe end, toe cavity, or rear. The vibration-damping material can partially or completely fill the area of ​​the cavity not filled by the insert.

[0105] II. Panel Insert Embodiments 14-22 illustrate a second embodiment of a multi-material golf club head 210 including a body 270 and an insert 340. The club head 210 may be a cavity back iron. In other words, the club head 210 may be a cavity back iron including an upper rail insert 340. The club head 210 includes a toe end 212, a heel end 214 opposite the toe end 212, a hosel 216 connected to the heel end 214, an upper rail 218, a sole 220 opposite the upper rail 218, a strike face 226, and a rear 228. The upper rail insert 340 partially forms the upper rail 218, the toe end 212, and / or the strike face 226. Referring to FIG. 16, the strike face 226 defines a geometric center 250. The ground plane (not shown) is tangent to the sole 220 when the club head 210 is in the address position. The club head 210 defines a loft plane (not shown) that is tangent to the geometric center 250 of the strike face 226. The insert 340 may form part of the top rail 218 and extend as a panel downward into the sole portion behind the strike face 226. The club head 210 may be an open-back style iron with a body 270 having a rear sole portion and an open space across the rear between the top rail 18 and the sole portion.

[0106] 16, the club head 210 has a length 240 measured parallel to the ground in a direction from the heel end 214 to the toe end 212. The length 240 can range from 3.0 to 4.0 inches. The length 240 can be 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 inches. In one example, the length 240 of the club head 210 can be approximately 3.5 inches.

[0107] Body 270 may be formed of a metal. Specifically, body 270 may be formed of a steel alloy selected from the group consisting of 450 steel, C250 steel, NiMark 250 steel, 475 steel, and 17-4 steel. In other embodiments, body 270 may include a metal alloy other than a steel alloy. Body 270 has a first density that is greater than a second density of insert 340. In other words, the second density of insert 340 is less than the first density of body 270.

[0108] The insert 340 can be formed of a non-metallic material. Specifically, the insert 340 can be formed of a polymer resin and reinforcing fibers. The insert 340 can be a polymer composite. The polymer resin can be a thermoplastic, such as a thermoplastic elastomer (TPE) or a thermoplastic polyurethane (TPU). The reinforcing fibers can be carbon fiber (sometimes called graphite fiber), fiberglass, aramid fibers such as Kevlar®, or boron fiber. In other embodiments, the reinforcing fibers can be natural fibers, including, but not limited to, fibers from jute, flax, ramie, hemp, sugarcane, coir, sisal, grasses, and abaca. The reinforcing fibers can be short or long fibers. The reinforcing fibers can be randomly oriented within the composite. The insert 340 can be injection molded. In other embodiments, the insert 340 can include a lightweight metal alloy, such as an aluminum alloy or a magnesium alloy.

[0109] (i. body) 17-19 , the body 270 is configured to receive the insert 340. The body 270 forms a majority of the club head 210. The body 270 may include a cylindrical hosel 216, a hosel transition portion 306, a partial top wall 302, a sole portion 312, a face panel 272, and a toe portion 322. The hosel transition portion 306 may connect the hosel 216 to the sole portion 312, the face panel 272, and the partial top wall 302. The partial top wall 302 may form a portion of the top rail 218 of the club head 210. The remainder of the top rail 218 may be formed by the insert 340, as described below. The sole portion 312 of the body 270 may connect to a bottom edge of the face panel 272. The face panel 272 may form the strike face 226 of the golf club head 210.

[0110] 17-19, the body 270 includes a face panel 272 having a front surface 274 and a rear surface 276. The front surface 274 of the face panel 272 may form the entire strike face 226 of the club head 210. The rear surface 276 of the face panel 272 is opposite the front surface 274. FIG. 19 illustrates that the face panel 272 has a thickness 278. The thickness 278 of the face panel 272 is measured between the front surface 274 and the rear surface 276. The face panel 272 may have a uniform thickness. The face panel 272 may have a consistent thickness across the strike face 226 as measured in the heel-toe and upper rail-sole directions. The face panel 272 may have a thickness value similar to or equal to the thickness 78 of the face panel 72 described above. In one example, the face panel thickness 278 can be approximately 0.065 inches.

[0111] 16 illustrates grooves disposed on the face panel front surface 274 to improve grip of a golf ball striking the face panel 272 during impact. The grooves may extend in a heel-to-toe direction. The face panel front surface 274 may include a similar or equal number of grooves as described above for the face panel 72.

[0112] 17 illustrates that the body 270 forms a portion of the toe end 212. The toe portion 322 of the body 270 can form at least a portion of the toe end 212 of the golf club head 210. In some embodiments, the toe portion 322 of the body 270 extends upward from the sole 220 and forms at least 40%, at least 50%, at least 60%, at least 70%, or at least 80% of the height of the toe end 212 measured perpendicularly from ground level to the highest point of the toe end 212.

[0113] 17-19 , body 270 can be substantially devoid of material immediately rearward of face panel 272. In other words, body 270 can have no rear components except for a peripheral rear surface formed by hosel transition portion 306, sole portion 312, and toe portion 322. Body 270 can be configured to allow insert 340 to be slid downwardly onto body 270, such that insert 340 is ultimately positioned behind a portion of body face panel 272.

[0114] 18 , the sole portion 312 of the body 270 can include a passageway 314. The passageway 314 can be configured to assist in securing the insert 340. The passageway 314 can extend in a heel-to-toe direction. In some embodiments, the passageway 314 is angled into the sole portion 312. As the passageway 314 deepens, it can extend closer to the rear 228 of the club head 210. This angling of the passageway 314 can assist in locking the insert 340 onto the body 270.

[0115] (ii. Insert) 20-22, the golf club head 210 can include a low-density insert 340 that can temporarily limit the deflection or movement of the face panel 272 during dynamic impact with a golf ball. The insert 340 can replace or form a portion of the club head periphery, such as the toe end 212 and the top rail 218. The insert 340 is configured to mount, couple to, and / or slide onto the body 270.

[0116] The majority of the insert 340 can be positioned behind the face panel 272. A portion of the insert 340 forms part of the upper rail 218. FIG. 20 illustrates the insert 340 including a rail portion 374, an insert panel 376, a backstop 352, and a shelf 380. The rail portion 374 can be configured to form a section of the upper rail 218. The rail portion 374 can also form the upper region of the toe end 212 of the club head 210. As illustrated in FIGS. 15 and 16 , the rail portion 374 can be positioned above the body toe portion 322 at the toe end 212. The lightweight insert 340 largely replaces the metal body 270 throughout the upper rail 218 and the upper region of the toe end 212, thereby shifting mass downward within the club head 210. This lowers the center of gravity of the club head 210 and improves the launch characteristics of the iron.

[0117] 22 , the insert 340 includes an offset surface 344 and a rear surface 346 opposite the offset surface 344. A gap exists between the offset surface 344 of the insert 340 and the rear surface 276 of the face panel 272. The gap between the insert 340 and the face panel 272 can provide space for the face panel 272 to flex during golf ball impact. FIG. 22 illustrates that the gap distance 264 between the insert offset surface 344 and the face panel rear surface 276 (hereinafter referred to as the “insert gap distance 264”) can range from 0.050 inches to 0.100 inches. In other embodiments, the insert gap distance 264 can range from 0.055 inches to 0.095 inches, 0.055 inches to 0.075 inches, 0.060 inches to 0.090 inches, 0.060 inches to 0.080 inches, or 0.065 inches to 0.075 inches. For example, the insert gap distance 264 can be 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, 0.085, 0.090, 0.095, or 0.100 inches. In one example, the insert gap distance 264 can be approximately 0.075 inches. The insert 340 does not contact the face panel 272 in a static state (i.e., before impact with a golf ball). In other words, insert 340 is not in intimate contact with face panel 272 during a rest state. During golf ball impact, face panel 272 is in a deformed state under the load of the golf ball, and insert 340 contacts rear surface 276 of face panel 272 to prevent face panel 272 from deflecting to the point of failure.

[0118] 20 , the insert may include a backstop 352 protruding from (or disposed on) the insert offset surface 344. The backstop 352 may be configured to temporarily contact the face panel 272 as the face panel 272 flexes during dynamic impact. The backstop 352 does not contact the face panel 272 when the golf club 210 is at rest. The backstop 352 contacts the face panel rear surface 276 to prevent excessive deflection of the face panel 272 during dynamic impact of the club head 210 with a golf ball. In other words, the backstop 352 does not contact the rear surface 276 of the face panel 272 in the first configuration (i.e., in the rest state). The backstop 352 contacts the rear surface 276 of the face panel 272 in the second configuration (i.e., in the deformed state). The backstop 352 prevents excessive deflection of the face panel 272 during golf ball impact.

[0119] 22 , the backstop 352 of the insert 340 can be positioned behind and centered on the strike face 226. The backstop 352 can be closer to the face panel 272 than the remainder of the insert offset surface 344. In other words, the backstop 352 can be offset inward from the rear surface 276 of the face panel 272 a lesser distance than the remainder of the insert offset surface 344. FIG. 22 illustrates that the backstop 352 is offset from the rear surface 276 of the face panel 272 by a backstop gap distance 266 that is less than the insert gap distance 264. In other words, the insert gap distance 264 can be greater than the backstop gap distance 266.

[0120] 22 , the backstop gap distance 266 can range between 0.015 inches and 0.065 inches. In some embodiments, the backstop gap distance 266 can range between 0.015 inches and 0.040 inches, or between 0.040 inches and 0.065 inches. In other embodiments, the backstop gap distance 266 can range between 0.015 inches and 0.035 inches, 0.025 inches and 0.045 inches, 0.035 inches and 0.055 inches, or 0.045 inches and 0.065 inches. For example, the backstop gap distance 266 can be 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, or 0.065 inches. In one example, the backstop gap distance 266 can be approximately 0.025 inches. In another example, the backstop gap distance 266 can be 0.05 inches. The backstop gap distance 266 controls how much the backstop 152 caps or limits face deflection.

[0121] The backstop 352 can prevent excessive flexing of the face panel 272 by limiting the distance the face panel 272 can bend before encountering resistance from the insert 340. The gap between the insert 340 and the face panel 272 promotes flexing of the face without allowing excessive flexing that could result in structural failure. The insert gap distance 264 and the backstop gap distance 266 are important for balancing face flexibility (which translates to ball speed) and durability.

[0122] The backstop 352 can be positioned behind the geometric center 250 of the strike face 226. The backstop 352 protrudes from the remainder of the insert offset surface 344. The backstop 352 can include a flat surface 354 that is generally parallel to the face panel 272. The backstop flat surface 354 can have a surface area (also referred to as a backstop surface area) that ranges between 0.05 and 0.20 square inches. In some embodiments, the backstop surface area ranges between 0.05 and 0.10 square inches, 0.10 and 0.15 square inches, or 0.15 and 0.20 square inches. In one example, the backstop surface area can be approximately 0.10 square inches.

[0123] 20 , the backstop 352 can include an upper side 356, a toe side 358, and a heel side 360. The backstop 352 can be similar to the backstop 152 described above. The upper side 356 can be convex, and the toe side 358 and heel side 360 ​​can be concave relative to the geometric center 250. The toe side 358 and heel side 360 ​​can meet at a rounded point at the bottom of the backstop 352. The toe side 358 and heel side 360 ​​intersect with the upper side 356 to form a wing-like shape that points toward the toe end 212 and heel end 214, respectively. The shape of the backstop 352 can facilitate temporarily limiting bending at points or regions where the strike face 226, and specifically the face panel 272, is more flexible than desired. The flat surface 354 of the backstop can have fillet welded connections to the backstop sides (top side, toe side, and heel side), which can also have fillet welded connections to the rest of the insert 340.

[0124] 20-22, the insert 340 includes an insert panel 376 and a rail portion 374. The insert panel 376 can be connected to the bottom of the rail portion 374 and can extend behind a majority of the face panel 272 of the club head 210. All offset surfaces 344, rear surfaces 346, and top edges 348 of the insert 340 can correspond to (or be referred to as) the front surface, rear surface, and top edge of the insert panel 376, respectively. In some embodiments, the offset surfaces 344 can be parallel to the insert rear surface 346. In some embodiments, all bottom edges 350 of the insert 340 can correspond to the bottom edges of the insert panels 376. FIGS. 20 and 21 illustrate that the insert 340 further includes an alignment feature 380 attached to the bottom edge of the insert panel 376, such that all of the insert bottom edges 350 are positioned on the alignment feature. For example, the alignment feature can be a ledge 380 that extends downwardly from the insert panel 376 .

[0125] 22 , the insert panel 376 can have a thickness 378 measured between the offset surface 344 and the back surface 346 of the insert 340. The insert panel thickness 378 can be similar to the body face panel thickness 278. In some embodiments, the insert panel 376 can be thicker or thinner than the face panel 272. The insert 340 can further include the backstop 352 described above. A majority of the insert panel 376 can be positioned behind the face panel 272 by the insert gap distance 264 described above. The backstop 352 can be positioned behind the face panel 272 by the backstop gap distance 266 described above.

[0126] 20 and 21, the golf club head 210 may include alignment and / or locking features along the top edge 348 and bottom edge 350 of the insert 340. In this second embodiment, because the panel-like insert 340 is not enclosed within the body 270 (the body 270 does not have an internal cavity), the insert 340 must be secured by other means. The top edge 348 and bottom edge 350 may be epoxied to the body 270 and / or geometrically locked onto the body 270.

[0127] One means for aligning, securing, or locking the insert bottom edge 350 to the body 270 is a ledge 380 extending downward from the insert panel 376. The ledge 380 can be connected to the bottom edge of the insert panel 376. The ledge 380 can be integrally formed with the insert panel 376. The ledge 380 can be angled to match the angulation of the channel 314 in the sole portion 312 of the body 270. The ledge 380 can also be referred to as a curved ledge, angled ledge, wall, securing feature, locking feature, or angled extension. The ledge 380 can be angled downward and rearward from the insert panel 376. The ledge 380 and the insert back surface 346 can form an angle 382 ranging between 0 degrees and 90 degrees, inclusive (hereinafter referred to as the “ledge angle 382”). In some embodiments, shelf angle 382 can be between 0 and 25 degrees, 0 and 45 degrees, 0 and 65 degrees, 10 and 30 degrees, 20 and 40 degrees, or 30 and 60 degrees. Shelf 380 can be configured to slide, lock, or be glued into channel 314 of sole portion 312.

[0128] In some embodiments, the insert 340 further comprises a soft layer (not shown) positioned on the offset surface 344 of the insert 340. The soft layer can dampen impacts between the face panel 272 and the insert 340. The soft layer can be an elastomeric material having a Shore A hardness ranging between 50 and 90 inclusive. In some embodiments, the soft layer has a Shore A hardness of 70. In some embodiments, the soft layer can be molded onto the insert panel 272 through a two-stage injection molding process. In other embodiments, the soft layer can be glued or otherwise secured to the rest of the insert 340.

[0129] 20 , the insert 340 can have a length 342, measured parallel to the ground surface 258 in a direction from the heel end 214 to the toe end 212, that is between 10% and 80% of the golf club head length 240. In some embodiments, the insert 340 can have a length 342 between 10% and 30%, 10% and 50%, 30% and 70%, 30% and 60%, 30% and 50%, 40% and 50%, 20% and 50%, or 50% and 80% of the golf club head length 240. In some embodiments, the insert 340 has a length 342 that is approximately 50% of the golf club head length 240. The length of the insert 340 provides sufficient length to control the location of the backstop 352 behind the face panel 272.

[0130] In some embodiments, the insert 340 can have a volume ranging between 1 cubic inch and 6 cubic inches, inclusive. In some embodiments, the insert volume is approximately 5 cubic inches. In some embodiments, the insert 340 can have a mass ranging between 10 g and 20 g, inclusive. In some embodiments, the insert mass is approximately 15.8 g. The insert 340 can have a specific gravity that is less than the specific gravity of the body 270.

[0131] (III. Advantages) The golf club heads 10 and 210 described herein standardize spin and ball speed across the strike face. Typical irons, which do not have thin faces and inserts with backstops, impart high spin to golf balls struck low on the face and low spin to golf balls struck high on the face. The golf club head embodiments described herein standardize spin from the sole to the top rail.

[0132] The golf club heads 10 and 210 described herein reduce the spin imparted to a golf ball struck low on the strike face. The thin face geometry allows for greater flexure in the lower portion of the strike face, reducing spin. The average player strikes most balls above the geometric center of the strike face. The backstops 152 and 352 of the inserts 140 and 340 can accommodate highly used portions of the strike face. The upper portions of the backstops 152 and 352 can limit flexure in the higher portions of the face panels 72 and 272. Because the backstops 152 and 352 can limit face bending within the upper portion of the strike face, the upper portion of the strike face can impart greater spin to the golf ball. Thus, a thin face coupled with an insert backstop configuration can produce a more uniform spin response across the face (more uniform from sole to top rail).

[0133] In addition to the spin performance benefits, the golf club heads 10 and 210 can potentially increase ball speed over existing irons without the thin face panel and supporting backstop. The thin face panel allows the strike face to dynamically store and release impact energy on the golf ball. The face panel is free to flex until it contacts the backstop, at which point the backstop 152 and 352 dampens the area of ​​the face panel that is touching or near the backstop. The backstops 152 and 352 increase durability by preventing excessive flexure of the face panels 72 and 272. The backstops 152 and 352 also unify the flexure response across the face, providing more consistency to shots. Off-center shots can cause the areas of the face panels 72 and 272 that do not correspond to the backstops 152 and 352 to flex deeply. In this scenario, the face panels 72 and 272 would not be damped by the backstops 152 and 352. Typically, the strike face of a golf club head tends to store and release most of its energy in the center (hence the center is often referred to as the "hot spot" or "sweet spot"). Therefore, damping the center of the face panel results in a more uniform response regardless of the point of impact.

[0134] Furthermore, the Rules of Golf, as regulated by the United States Golf Association (USGA), limit the Characteristic Time (CT) of a strike face. Characteristic Time (CT) is a measurement of face flexibility. Thinner face panels, due to their flexibility and responsiveness, may sometimes run the risk of exceeding the CT limit set by the Rules of Golf. The backstop, and optionally, the deflection control surface, by acting as a damper, can allow for thinner (and therefore hotter, more responsive) face panels without exceeding the flexibility limit set by the Rules of Golf. Such thinner face panels increase the potential ball speed on off-center shots compared to golf club heads with thicker face panels.

[0135] In some embodiments, the inserts 140 and 340 can improve the acoustic characteristics of the club heads 10 and 210. For example, in some embodiments, forming the top rail at least in part from a polymer insert can reduce the amplitude generated upon impact.

[0136] Club heads 10 and 210 with inserts 140 and 340 improve ball speed, ball spin, and launch conditions over conventional club heads with variable face thickness (e.g., a maximum center thickness that generally tapers to a minimum thickness at the periphery of the strike face). In conventional club heads with variable face thickness, the differences in ball speed, ball spin, and launch conditions vary widely between on-center hits and off-center hits. This variability in ball performance for on-center and off-center hits results in inconsistent performance. Club heads 10 and 210 provide consistent performance (i.e., ball speed, ball spin, and launch conditions) for on-center and off-center hits. Club heads 10 and 210 bring the performance differences for on-center and off-center hits closer together (i.e., reduce the large differences between on-center and off-center hits). The club heads 10 and 210 achieve desirable performance by incorporating thinned and constant thickness face panels 72 and 272 and inserts 140 and 340 with backstops. The thinned and constant thickness face panels 72 and 272 maximize strike face deflection, resulting in maximum ball speed. The space between the strike face and inserts 140 and 340 at rest allows room for the strike face to flex. The backstops of the inserts 140 and 340 momentarily contact the strike face during golf ball impact, preventing excessive strike face flexure. The backstops prevent the strike face from flexing to failure or reaching bending failure.

[0137] IV. METHODS OF MANUFACTURING The first embodiment of the golf club head 10 described herein can be manufactured by a method including: (1) providing a body; (2) molding an insert; (3) sliding and adhering the insert 140 into the cavity 124 of the body 70; and (4) finishing the club head 10. The body 70 can be cast or forged from a metallic material. For example, the body 70 can be formed using investment casting, gravity casting, die casting, sand casting, ceramic mold casting, plaster mold casting, expendable pattern casting, permanent mold casting, shell mold casting, or centrifugal casting. In some embodiments, the face panel 72 can be cast or forged separately and welded onto the front portion 24 of the club head 10 to form the body 70. Molding the insert 140 can include providing composite pellets, providing a mold, melting the pellets, injecting the composite material into the mold to form the insert 140, cooling the insert to harden or cure it, and removing the insert from the mold. In simpler terms, the insert 140 can be injection molded. In alternative embodiments of this method, the insert 140 can be compression molded, extruded, rotationally molded, additively manufactured (such as through 3D printing), or otherwise formed into the desired shape.

[0138] Sliding and adhering the insert 140 into the cavity 124 of the body 70 may include applying an adhesive to one or more surfaces of the body 70 and / or the insert 140. The adhesive may be an epoxy, polyurethane, polyimide, or any other paste or liquid with adhesive properties. After applying the adhesive, the insert 140 may be slid into the body cavity from the toe end 12 of the club head 10. Insertion of the insert 140 is complete when the insert encapsulated portion 174 is fully within the cavity 124 and the insert exposed portion 178 is blocked by the body 70. Finishing the club head 10 may include cleaning, polishing, painting, and / or adding weights to complete the club head 10.

[0139] The second embodiment of the golf club head 210 described herein can be manufactured by a method including: (1) providing a body 270; (2) molding an insert 340; (3) clipping or hooking the insert 340 into the passageway 314 of the body sole portion 312; (4) bonding an insert rail portion 374 to the body 270; and (5) applying a finishing process to the club head 210. The body 270 can be cast or forged from a metallic material, similar to the method described above for forming the body of the first embodiment. Molding the insert 340 can include providing composite pellets, providing a mold, melting the pellets, injecting the composite material into the mold to form the insert 340, cooling the insert to solidify or harden it, and removing the insert from the mold. In simpler terms, the insert 340 can be injection molded. In embodiments of the insert with a flexible layer, the insert can be formed through a two-step injection molding process that allows the flexible layer to be overmolded onto the insert 340. In alternative embodiments of this method, the insert 340 can be compression molded, extruded, rotationally molded, additively manufactured (such as through 3D printing), or otherwise formed into the desired shape.

[0140] Clipping or hooking the insert 340 onto the body may include positioning the insert's shelf 380 within the passage 314 of the body sole portion 312. This may require holding the insert 340 at an angle that positions the rail portion 374 rearward of its final position. Once the shelf 380 is secured within the passage 314, the insert 340 may be rotated forward to align the rail portion 374 along the upper rail 218 of the club head 210. Adhesive may be applied to one or both of the body 270 and the insert before attaching the insert 340 to the body. Finishing the club head 210 may include cleaning, polishing, painting, and / or adding weights to complete the club head 210.

[0141] While Figures 1-22 depict certain embodiments of a golf club head, the disclosure of the embodiments is intended to illustrate, but not limit, the scope of the disclosure. It is intended that the scope of the disclosure be limited only to the extent required by the appended claims. While this invention has been described in connection with various aspects, it will be understood that the invention is capable of further modifications. This application is intended to cover any variations, uses, or adaptations of this invention that generally follow the principles of the invention, and includes such departures from the disclosure as come within known and customary practice within the art to which this invention pertains.

[0142] Because the Rules of golf change from time to time (e.g., new Rules may be adopted, or old Rules may be repealed or modified, by golf standards organizations and / or governing bodies such as the United States Golf Association (USGA) or the Royal and American Golf Association (R&A)), golf equipment relating to the devices, methods, and products described herein may or may not conform to the Rules of golf at any particular time. Accordingly, golf equipment relating to the devices, methods, and products described herein may be advertised, offered for sale, and / or sold as conforming or non-conforming golf equipment. The devices, methods, and products described herein are not limited in this respect.

[0143] Although a particular order of acts is described above, these acts may be performed in other temporal orders. For example, two or more of the acts described above may be performed sequentially, in parallel, or simultaneously. Alternatively, two or more acts may be performed in the reverse order. Moreover, one or more of the acts described above may not be performed at all. The apparatus, methods, and articles of manufacture described herein are not limited in this respect.

[0144] Substitution of one or more claim elements constitutes a rearrangement, not a prosthesis. Moreover, advantages, other advantages, and solutions to problems have been described in connection with particular embodiments. However, the advantages, other advantages, and solutions to problems, and any one or more elements that give rise to or make apparent any advantage, advantage, or solution, do not constitute a critical, essential, or essential feature or element of any or all elements of a claim, unless such advantage, advantage, solution, or element is expressly recited in such claim.

[0145] Furthermore, the embodiments and limitations described herein are not offered to the public under the doctrine of disclosure if the embodiments and / or limitations (1) are not explicitly claimed in the claims and (2) are equivalent or potentially equivalent to the express elements and / or limitations in the claims under the doctrine of equivalents.

[0146] (Example) I. Example 1: Comparison of Golf Ball Performance An exemplary club head 10 with a toe insert 140 that provides a gap between the strike face and the backstop is compared to a similar control club head that lacks the gap between the strike face and the backstop. Tests compare golf ball performance, such as ball spin and ball speed, between the exemplary club head 10 and the control club head.

[0147] The exemplary club head 10 includes a body 70 having a face panel 72 and an insert 140 having a backstop 152. The face panel 72 has a constant thickness of 0.065 inches. The backstop 152 is spaced from the rear surface 76 of the face panel 72 by a backstop gap distance 66. The backstop 152 is located behind a central portion of the face panel 72. The backstop gap distance 66 is 0.025 inches at the center of the face panel 72. The insert gap distance 64 is 0.075 inches off-center. This gap allows room for the face panel to flex upon impact with a golf ball. The increased flex in the face panel returns more energy to the golf ball, improving ball speed and spin.

[0148] The control club head, like the exemplary club head described above, includes a body, a face panel, and an insert with a backstop. The backstop of the control club head is not spaced apart from the rear surface of the face panel, but rather abuts the rear surface of the face panel. The backstop of the control club head limits the amount of deflection the face experiences upon impact with a golf ball, thereby reducing ball speed and spin.

[0149] Testing is conducted using robotic arm testing and / or player testing. Robotic arm testing is conducted by a single robot programmed to take the same swing and hit a set number of shots, with each swing delivering the club head to the ball in the same manner for each shot. The robotic arm testing can be programmed to hit the center of the strike face or any other location on the strike face so that ball speed and spin can be compared between the exemplary club head 10 and a control club head, and between on-center and off-center hits. Player testing is conducted by multiple individual players. Each player hits approximately 10 shots with each club, in five-shot increments. There may be approximately 20 players for this testing. Measurement devices are used to measure various golf ball performance values, such as ball spin, speed, distance, launch angle, etc.

[0150] This testing results in the example club head 10 providing increased ball performance over the control club head for off-center hits. For off-center hits, the example club head 10 is expected to have approximately 1 mph higher ball speed than the control club head. For off-center hits, the example club head 10 is expected to have approximately 200 rpm higher ball spin than the control club head. The example club head 10 includes a thin, consistent thickness face panel 72 and an insert 140 with a backstop 152 spaced a backstop distance 66 from the strike face. The example club head 10 results in higher ball speed and ball spin because the thinned strike face flexes freely. The backstop 152 temporarily engages the strike face to prevent excessive flexing and damage to the strike face. The control club head with the backstop in contact with the strike face during golf ball impact results in less deflection, thereby resulting in lower ball spin and velocity.

[0151] (Clause 1) A golf club head comprising: a body having a face panel, a toe end, a heel end, an upper rail, a sole, and a rear portion; and an insert having an encapsulated portion and an exposed portion, wherein the body defines an inner cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion, the body being formed of metal and the insert being formed of non-metal, the body defining an opening at the toe end of the golf club head, the inner cavity being configured to receive the insert such that the encapsulated portion fits inside the inner cavity and the exposed portion forms the toe end of the golf club head, and the entire outermost surface of the toe end is formed by the insert.

[0152] (Clause 2) The golf club head of Clause 1, wherein the insert further comprises a backstop protruding from a surface of the insert, the backstop being positioned behind the face panel to prevent excessive deflection of the face panel during golf ball impact.

[0153] (Clause 3) The golf club head of Clause 2, wherein the backstop of the insert does not contact the rear surface of the face panel in a first configuration, and the backstop of the insert contacts the rear surface of the panel in a second configuration.

[0154] (Clause 4) The golf club head of Clause 3, wherein the insert has an insert offset surface, and the insert offset surface does not contact the rear surface of the face panel.

[0155] (Clause 5) The golf club head of Clause 4, wherein an insert offset distance is provided between the insert offset surface and the rear surface of the face panel, and a backstop offset distance is provided between the backstop and the rear surface of the face panel, and the backstop offset distance is less than the insert offset distance.

[0156] (Clause 6) The golf club head of Clause 1, wherein the insert further comprises a thermoplastic material and a plurality of reinforcing fibers.

[0157] (Clause 7) The golf club head of Clause 6, wherein the body is disposed within the inner cavity and further comprises a rail integrally formed with the sole and rear portion, and the insert further comprises a passage configured to engage with the rail and slide along the rail to secure the insert to the body.

[0158] (Clause 8) The golf club head of Clause 1, further comprising an internal weight formed integrally with the insert, the internal weight having a material density greater than the material density of the body and the material density of the insert.

[0159] (Clause 9) A golf club head comprising: a body having a face panel with a strike face, a toe end, a heel end, an upper rail, a sole, and a rear portion; and an insert having an encapsulated portion and an exposed portion, wherein the body defines an inner cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion, the body being formed of a metal and the insert being formed of a non-metal, the body defining an opening at the toe end of the golf club head, the encapsulated portion fitting inside the inner cavity and the exposed portion forming the toe end of the golf club head. the strike face has a geometric center, a central reference plane extending through the geometric center and extending perpendicular to the ground when the golf club head is in an address position, a vertical reference plane extending in a front-to-back direction through the golf club head and extending perpendicular to the ground when the golf club head is in the address position, the vertical reference plane being offset from the central reference plane toward the toe end by a distance of 1.0 inch to 1.8 inches, the exposed portion of the insert being positioned completely on a toe side of the vertical reference plane, and the encapsulated portion being at least partially positioned on a heel side of the vertical reference plane.

[0160] (Clause 10) The golf club head of Clause 9, wherein the insert further comprises a backstop protruding from a surface of the insert, the backstop being positioned behind the face panel to prevent excessive deflection of the face panel during golf ball impact.

[0161] (Clause 11) The golf club head of Clause 10, wherein the backstop of the insert does not contact the rear surface of the face panel in a first configuration, and the backstop of the insert contacts the rear surface of the panel in a second configuration.

[0162] (Clause 12) The golf club head of Clause 9, wherein the insert further comprises a thermoplastic material and a plurality of reinforcing fibers.

[0163] (Clause 13) The golf club head of Clause 9, wherein the body is disposed within the inner cavity and further comprises a rail integrally formed with the sole and rear portion, and the insert further comprises a passage configured to engage with the rail and slide along the rail to secure the insert to the body.

[0164] (Clause 14) The golf club head of Clause 9, further comprising an internal weight formed integrally with the insert, the internal weight having a material density greater than the material density of the body and the material density of the insert.

[0165] (Clause 15) A golf club head comprising: a body having a face panel, a toe end, a heel end, an upper rail, a sole, and a rear portion; and an insert having an encapsulated portion and an exposed portion, wherein the body defines an inner cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion; the body is formed of a first material having a first density, and the insert is formed of a second material having a second density, the second density being less than the first density; the body defines an opening at the toe end of the golf club head; the inner cavity is configured to receive the insert such that the encapsulated portion fits inside the inner cavity and the exposed portion forms the toe end of the golf club head; the insert forms a portion of the upper rail, the sole, and the rear portion, and no portion of the body forms the outermost surface of the toe end.

[0166] (Clause 16) The golf club head of Clause 15, wherein the insert further comprises a backstop protruding from a surface of the insert, the backstop being positioned behind the face panel to prevent excessive deflection of the face panel during golf ball impact.

[0167] (Clause 17) The golf club head of Clause 16, wherein the backstop of the insert does not contact the rear surface of the face panel in a first configuration, and the backstop of the insert contacts the rear surface of the panel in a second configuration.

[0168] (Clause 18) The golf club head of Clause 15, wherein the insert includes an insert offset surface, and the insert offset surface does not contact the rear surface of the face panel.

[0169] (Clause 19) The golf club head of Clause 15, wherein the body is disposed within the inner cavity and further comprises a rail integrally formed with the sole and rear portion, and the insert further comprises a passage configured to engage with the rail and slide along the rail to secure the insert to the body.

[0170] (Clause 20) The golf club head of Clause 15, further comprising an internal weight formed integrally with the insert, the internal weight including a third material having a third density greater than the first density and the second density.

[0171] (Clause 21) A golf club head, comprising: a body including a toe end, a heel end opposite the toe end, a hosel connected to the heel end, an upper rail, a sole opposite the upper rail, a leading edge at a front portion of the sole, a front portion, a rear portion, a cylindrical hosel, a hosel transition portion adjacent the heel end, a face panel, a toe portion adjacent the toe end, and a sole portion adjacent the sole; and an insert including an offset surface, a back surface opposite the offset surface, a top edge, a bottom edge opposite the top edge, a rail portion, an insert panel, a backstop, and a fixing mechanism, wherein the insert has a front the face panel having a face panel thickness of less than 0.060 inches, the insert having a density less than that of the body, the insert offset surface and the face panel defining an insert gap distance ranging from 0.055 inches to 0.075 inches, inclusive, and the backstop and the face panel defining a backstop gap distance ranging from 0.015 inches to 0.040 inches, inclusive.

[0172] (Clause 22) The golf club head of Clause 21, wherein the securing mechanism includes a shelf extending from the insert panel, the sole portion of the body defining a passage configured to receive the shelf, and the shelf having a shape complementary to the passage in the sole portion.

[0173] (Clause 23) The golf club head of Clause 21, wherein the shelf extends rearward from the insert panel, and the shelf and the insert back surface form an angle in the range of 0 degrees to 45 degrees.

[0174] (Clause 24) A golf club head according to Clause 21, wherein the insert comprises a resin and reinforcing fibers, the resin being a material selected from the group consisting of thermoplastic elastomers (TPE) and thermoplastic polyurethanes (TPU), and the reinforcing fibers being a material selected from the group consisting of carbon fibers, fiberglass, aramid fibers, boron fibers, jute fibers, flax fibers, ramie fibers, hemp fibers, sugarcane fibers, coir fibers, sisal fibers, grass fibers, and abaca fibers.

[0175] (Clause 25) The golf club head of Clause 21, wherein the insert includes a metal material selected from the group consisting of aluminum alloys and magnesium alloys.

[0176] (Clause 26) The golf club head of Clause 21, wherein the insert comprises a soft layer attached to the offset surface of the insert panel, the soft layer comprising an elastomeric material.

[0177] (Clause 27) The golf club head of Clause 21, wherein the toe portion of the body extends upwardly from the sole to form at least 50% of the toe end of the club head.

[0178] (Clause 28) The golf club head of Clause 21, wherein the body comprises a cast steel alloy selected from the group consisting of 450 steel, C250 steel, NiMark 250 steel, 475 steel, and 17-4 steel.

[0179] (Clause 29) The golf club head of Clause 21, wherein the toe end of the body forms a toe port, the golf club head further comprises a toe weight fitted within the toe port, and the golf club head further comprises a tip weight fitted within the hosel.

[0180] (Clause 30) The golf club head of Clause 21, wherein the length of the insert measured in the direction from the heel end to the toe end is between 30% and 60% of the overall length of the golf club head.

[0181] Various features and advantages of the disclosure are set forth in the following claims.

Claims

1. A golf club head, a body having a face panel, a toe end, a heel end, an upper rail, a sole, and a rear portion; an insert having an encapsulated portion and an exposed portion; the body defining an interior cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion; The body is made of a metal and the insert is made of a non-metal; the body defining an opening at the toe end of the golf club head; the inner cavity is configured to receive the insert such that the encapsulated portion fits inside the inner cavity and the exposed portion forms the toe end of the golf club head; the entire outermost surface of the toe end is formed by the insert; the insert further comprises a backstop protruding from a surface of the insert; the backstop has a shape with a top side, a toe side, and a heel side; the upper side is convex, and the toe side and the heel side are concave relative to a geometric central reference axis; the toe side and the heel side meet at a round point at the bottom of the backstop; the toe side and the heel side intersect with the upper side to form a pair of wing-like shapes pointing to the toe end and the heel end, the shape facilitates temporarily limiting bending of the strike face in areas where the face panel is more flexible than desired; The backstop is disposed behind the face panel to prevent excessive deflection of the face panel during golf ball impact. Golf club head.

2. the backstop of the insert does not contact the rear surface of the face panel in a first configuration; The golf club head of claim 1 , wherein the backstop of the insert contacts the rear surface of the face panel in the second configuration.

3. the insert having an insert offset surface; The golf club head of claim 2 , wherein the insert offset surface does not contact the rear surface of the face panel.

4. an insert offset distance is provided between the insert offset surface and the rear surface of the face panel; a backstop offset distance is provided between the backstop and the rear surface of the face panel; The golf club head of claim 3 , wherein the backstop offset distance is less than the insert offset distance.

5. The golf club head of claim 1 , wherein the insert further comprises a thermoplastic material and a plurality of reinforcing fibers.

6. the body further includes a rail disposed within the inner cavity and integrally formed with the sole and the rear portion; The golf club head of claim 1 , wherein the insert further comprises a passage configured to engage the rail and slide along the rail to secure the insert to the body.

7. further comprising an internal weight integrally formed with the insert; The golf club head of claim 1 , wherein the internal weight has a material density greater than a material density of the body and a material density of the insert.

8. A golf club head, a body having a face panel with a strike face, a toe end, a heel end, an upper rail, a sole, and a rear portion; an insert having an encapsulated portion and an exposed portion; the body defining an interior cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion; The body is made of a metal and the insert is made of a non-metal; the body defining an opening at the toe end of the golf club head; the inner cavity is configured to receive the insert such that the encapsulated portion fits inside the inner cavity and the exposed portion forms the toe end of the golf club head; the strike face has a geometric center; a central reference plane extending through the geometric center and perpendicular to the ground when the golf club head is in an address position; a vertical reference plane extending in a front-to-rear direction through the golf club head and extending perpendicular to the ground surface when the golf club head is in the address position; the vertical reference plane is offset from the central reference plane toward the toe end by a distance of 1.0 (2.54 cm) to 1.8 inches (4.572 cm); the exposed portion of the insert is positioned entirely to the toe side of the vertical reference plane; the encapsulation portion is at least partially disposed on a heel side of the vertical reference plane; the insert further comprises a backstop protruding from a surface of the insert; the backstop has a shape with a top side, a toe side, and a heel side; the upper side is convex, and the toe side and the heel side are concave relative to a geometric central reference axis; the toe side and the heel side meet at a round point at the bottom of the backstop; the toe side and the heel side intersect with the upper side to form a pair of wing-like shapes pointing to the toe end and the heel end, the shape facilitates temporarily limiting bending of the strike face in areas where the face panel is more flexible than desired; The backstop is disposed behind the face panel to prevent excessive deflection of the face panel during golf ball impact. Golf club head.

9. the backstop of the insert does not contact the rear surface of the face panel in a first configuration; The golf club head of claim 8 , wherein the backstop of the insert contacts the rear surface of the face panel in the second configuration.

10. The golf club head of claim 8 or 9, wherein the insert further comprises a thermoplastic material and a plurality of reinforcing fibers.

11. the body further includes a rail disposed within the inner cavity and integrally formed with the sole and the rear portion; 11. The golf club head of claim 8, wherein the insert further comprises a passage configured to mate with and slide along the rail to secure the insert to the body.

12. further comprising an internal weight integrally formed with the insert; The golf club head of claim 8 , wherein the internal weight has a material density greater than a material density of the body and a material density of the insert.

13. A golf club head, a body having a face panel, a toe end, a heel end, an upper rail, a sole, and a rear portion; an insert having an encapsulated portion and an exposed portion; the body defining an interior cavity bounded by the face panel, the heel end, the upper rail, the sole, and the rear portion; the body being formed of a first material having a first density and the insert being formed of a second material having a second density; the second density is less than the first density; the body defining an opening at the toe end of the golf club head; the inner cavity is configured to receive the insert such that the encapsulated portion fits inside the inner cavity and the exposed portion forms the toe end of the golf club head; the insert forming a portion of the upper rail, the sole, and the rear section; no portion of the body forms an outermost surface of the toe end; the insert further comprises a backstop protruding from a surface of the insert; the backstop has a shape with a top side, a toe side, and a heel side; the upper side is convex, and the toe side and the heel side are concave relative to a geometric central reference axis; the toe side and the heel side meet at a round point at the bottom of the backstop; the toe side and the heel side intersect with the upper side to form a pair of wing-like shapes pointing to the toe end and the heel end, the shape facilitates temporarily limiting bending of the strike face in areas where the face panel is more flexible than desired; The backstop is disposed behind the face panel to prevent excessive deflection of the face panel during golf ball impact. Golf club head.

14. the backstop of the insert does not contact the rear surface of the face panel in a first configuration; The golf club head of claim 13 , wherein the backstop of the insert contacts the rear surface of the face panel in the second configuration.

15. the insert having an insert offset surface; The golf club head of claim 14 , wherein the insert offset surface does not contact the rear surface of the face panel.

16. the body further includes a rail disposed within the inner cavity and integrally formed with the sole and the rear portion; 16. The golf club head of claim 13, wherein the insert further comprises a passage configured to mate with and slide along the rail to secure the insert to the body.

17. further comprising an internal weight integrally formed with the insert; 17. The golf club head of claim 13, wherein the internal weight includes a third material having a third density greater than the first density and the second density.

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