Golf club head having support for limiting face plate deformation

Abstract

To provide a golf club head that reduces the risk of irreversible plastic deformation of a face plate.SOLUTION: The golf club head includes a body having the face plate having a strike surface and an opposing interior surface, a rear end, and a sole connecting the face plate with the rear end. The face plate, the rear end, and the sole partially define a cavity. An insert is positioned within the cavity, the insert presenting an insert surface facing the interior surface of the face plate and spaced from the interior surface.SELECTED DRAWING: None

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 313,214, filed March 25, 2016, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to golf clubs, and more particularly to a support that allows reversible elastic deformation of a golf club face plate while also providing deformation limiting to reduce the risk of irreversible plastic deformation. [Background technology]

[0003] Golf clubs come in a variety of forms, such as woods, hybrids, irons, wedges, or putters, but these clubs generally differ in head shape and design (such as the difference between woods and irons), club head material, shaft material, club length, and club loft.

[0004] Generally, during impact with a golf ball, the face plate of a golf club undergoes a certain amount of deformation. More specifically, the face plate undergoes elastic deformation in the form of a flexure, such that it flexes and springs back upon impact with the golf ball. This elastic deformation increases the coefficient of restitution (COR). A higher COR increases the kinetic energy transferred to the golf ball upon impact, generally increasing the speed of the golf ball and the distance the golf ball travels.

[0005] In some golf clubs, face plate thickness is reduced to increase face plate deflection at impact. However, excessive face plate deflection can result in irreversible plastic deformation over time. Plastic deformation of the face plate reduces the amount of elastic deformation and available "spring effect," ultimately reducing the club head's ability to produce optimal golf ball speed and distance. Summary of the Invention [Problem to be solved by the invention]

[0006] Golf clubs have a variety of known designs, but there is a need to allow elastic deformation of the golf club face plate during impact with a golf ball, while also limiting the elastic deformation to reduce the risk of irreversible plastic deformation of the golf club face plate. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view of a golf club head including one or more embodiments of the retardation support disclosed herein.

[0008] [Figure 2] 2 is a first side view of the club head of FIG. 1 showing the face plate.

[0009] [Figure 3] 2. FIG. 4 is a second side view of the club head of FIG. 1, showing the opposite underside from FIG.

[0010] [Figure 4] FIG. 2 is a top view of the club head of FIG. 1.

[0011] [Figure 5] 5 is a cross-sectional view of the club head of FIG. 1 taken along line 5-5 of FIG. 4 with the delay support removed.

[0012] [Figure 6] 2 is a perspective view of an embodiment of a delay support for use with the golf club head of FIG. 1.

[0013] [Figure 7] FIG. 7 is a second perspective view of the delay support of FIG. 6, opposite the one shown in FIG. 6.

[0014] [Figure 8] 8 is a cross-sectional view of the delay support of FIG. 6 taken along line 8-8 of FIG. 6.

[0015] [Figure 9] 9 is a cross-sectional view of the golf club of FIG. 1 taken along line 9-9 of FIG. 4 with the insert of FIG. 6 positioned within the cavity.

[0016] [Figure 9A] 9 is a cross-sectional view of the golf club of FIG. 1 taken along line 9-9 of FIG. 4 with the insert embodiment of FIG. 6 positioned within the cavity, defining a large gap between the insert and the face plate.

[0017] [Figure 10] 5 is a cross-sectional view of the golf club of FIG. 1 taken along line 5-5 of FIG. 4 with another embodiment of a delay support positioned within the cavity.

[0018] [Figure 11] FIG. 2 is a front view of the club head of FIG. 1.

[0019] [Figure 11A] 12 is a front view of an embodiment of a delay support for use with the golf club head of FIG. 11.

[0020] [Figure 11B] FIG. 11B is a side perspective view of the delay support of FIG. 11A.

[0021] [Figure 11C] 12 is a front view of an embodiment of a delay support for use with the golf club head of FIG. 11.

[0022] [Figure 11D] FIG. 11D is a side perspective view of the delay support of FIG.

[0023] [Figure 12A]12A is a side cross-sectional view of the golf club head and delay insert of FIGS. 11, 11A, and 11B taken along line 12A-12A. FIG.

[0024] [Figure 12B] FIG. 12B is a top cross-sectional view of the golf club head and delay insert of FIGS. 11, 11A, and 11B taken along line 12B-12B. DETAILED DESCRIPTION OF THE INVENTION

[0025] The golf club head disclosed herein includes a body including a face plate having a striking surface and an opposite inner surface, a rear end, and a sole connecting the face plate to the rear end. The inner surface of the face plate, the inner surface of the rear end, and the inner surface of the sole partially define a cavity. An insert is positioned within the cavity, and the insert has an insert surface facing and spaced apart from the inner surface of the face plate. In many embodiments, the insert surface allows a desired amount of deflection (or deformation) in the face plate during impact while stiffening the face plate before plastic deformation occurs. In other embodiments, the insert can be sufficiently spaced from the face plate so as not to support the face plate during impact.

[0026] In another embodiment, a golf club head includes a body including a face plate, a rear end, and a sole connecting the face plate to the rear end. The face plate, rear end, and sole partially define a cavity. The rear end has an inner surface facing the cavity. An insert is positioned within the cavity, the insert having an insert surface facing and spaced from the inner surface of the rear end.

[0027] In another embodiment, a golf club head includes a body including a face plate having a striking surface and a first inner surface opposite the striking surface, a rear end, and a sole connecting the face plate to the rear end. The face plate, rear end, and sole partially define a cavity, and the rear end has a second inner surface facing the cavity. A protrusion couples to one of the first inner surface and the second inner surface. The protrusion has a contact surface facing and spaced from the other of the first inner surface and the second inner surface.

[0028] As disclosed herein, the terms "loft" or "loft angle" of a golf club refer to the angle formed between the club face and the shaft, as measured by any suitable loft and lie instrument.

[0029] The terms "first," "second," "third," "fourth," etc., in the specification and claims, if any, are used to distinguish between similar elements and are not necessarily intended to describe a particular sequential or chronological order. Terms so used should be understood to be interchangeable in appropriate circumstances, such that the embodiments described herein are capable of operating in orders other than those illustrated or otherwise described herein. Furthermore, the terms "comprise" and "have," and any conjugations 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 to such process, method, system, article, device, or apparatus.

[0030] If any, the terms "left," "right," "front," "rear," "top," "bottom," "above," "below," etc. in this specification and claims are used for descriptive purposes and not necessarily to describe permanent relative positions. It should be understood that terms so used are interchangeable in appropriate circumstances such that embodiments of the apparatus, methods, and / or articles of manufacture described herein are operable, for example, in orientations other than those illustrated or otherwise described herein.

[0031] The terms "couple," "couples," "coupled," "coupling," and the like should be understood broadly and mean to mechanically or otherwise connect two or more elements. The connection (mechanical or otherwise) may be for any length of time, e.g., permanent, semi-permanent, or momentary.

[0032] Other features and aspects will become apparent upon review of the following detailed description and accompanying drawings. Before describing any embodiments of the present disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details or the configuration and arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of supporting other embodiments and of being practiced or carried out in various ways. It is to be understood that the description of a particular embodiment is not intended to limit the disclosure to include all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure. Moreover, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0033] For ease of discussion and understanding, and for purposes of illustration only, the following detailed description will refer to the golf club head 10 as an iron. It should be understood that an iron is provided to illustrate one or more embodiments of a delayed support that allows elastic deformation of a golf club face plate during impact with a golf ball and limits elastic deformation to reduce the risk of irreversible plastic deformation of the golf club face plate, as disclosed herein. The disclosed embodiments of the delayed support can be used with any desired iron, wood, hybrid, or other golf club whose face plate deforms during impact with a golf ball and there is a risk of elastic deformation of the face plate. For example, the club head 10 may include, but is not limited to, a driver, fairway wood, hybrid, 1-iron, 2-iron, 3-iron, 4-iron, 5-iron, 6-iron, 7-iron, 8-iron, 9-iron, pitching wedge, gap wedge, utility wedge, sand wedge, lob wedge, and / or putter.Additionally, the golf club head 10 may be configured to have a range of angles from about 3 degrees to about 65 degrees (3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18. 5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 25, 25.5, 26, 26.5, 27, 27.5, 28, 28.5, 29, 29.5, 30, 30.5, 31, 31.5, 32, 32.5, 33, 33.5, 34, 34.5, 35, 35.5, 36 , 36.5, 37, 37.5, 38, 38.5, 39, 39.5, 40, 40.5, 41, 41.5, 42, 42.5, 43, 43.5, 44, 44.5, 45, 45.5, 46, 46.5, 47, 47.5, 48, 48.5, 49, 49.5, 50, 50.5, 51, 51.5, 52, 52.5, 53, 53. The golf club may have a loft that may be in the range of (including but not limited to) 5, 54, 54.5, 55, 55.5, 56, 56.5, 57, 57.5, 58, 58.5, 59, 59.5, 60, 60.5, 61, 61.5, 62, 62.5, 63, 63.5, 64, 64.5, and / or 65 degrees.

[0034] A more detailed description may refer to one or more embodiments of a "delayed support." A delaying support refers to one or more structural components that support or stiffen the face plate during impact with a golf ball. However, the support is delayed during impact to allow a desired amount of deformation or deflection of the face plate before the support reduces, limits, minimizes, or stops the deformation or deflection so that the face plate does not undergo plastic deformation. By allowing a certain amount of deformation or deflection, the face plate creates a beneficial spring-like effect.

[0035] I) Golf club head Referring now to the figures, FIGS. 1-4 illustrate an embodiment of a golf club head 10 incorporating one or more embodiments of the delay support disclosed herein. The golf club head 10 includes a body 14 having a toe or toe end 18 opposite a heel or heel end 22. The body 14 also includes a top or topline or crown 26 opposite a sole or bottom 30. The body 14 defines a striking face 36 (shown in FIGS. 1-2 and 4) and carries a face plate or striking plate or club face 34 (shown in FIGS. 1-2 and 4) opposite a rear end or backside 38 (shown in FIGS. 3-4). A plurality of grooves 40 (shown in FIGS. 1, 2 and 4) are disposed on the face plate 34. The golf club head 10 also includes a hosel 44 having a hosel axis 48 (shown in FIG. 2) extending through the center of the hosel 44. The hosel 44 is configured to receive a golf club shaft (not shown) that carries a grip (not shown).

[0036] The face plate 34 further includes a thickness measured between the striking surface 36 and the first interior surface 72 of the face plate 34. In some embodiments, the face plate 34 can have a uniform thickness. The uniform thickness can be within a range of 0.025 to 0.150 inches. For example, in some embodiments, the thickness can be within 0.025-0.050, 0.030-0.070, 0.040-0.090, 0.040-0.110, 0.050-0.125, 0.050-0.150, 0.60-0.150, or 0.65-0.150 inches.

[0037] In other embodiments, the faceplate 34 may include a variable face thickness "VFT" (not shown). A faceplate 34 including a VFT may have a greater thickness in areas of the faceplate 34 that experience the highest stresses and a lesser thickness in areas that experience lower stresses. For example, in many embodiments, the periphery of the faceplate 34 may experience lower stresses and may have a lesser thickness than the center of the faceplate 34, which may experience higher stresses and therefore may have a greater thickness. In some embodiments, the VFT may have a minimum thickness of less than 0.10 inches and a maximum thickness of less than 0.25 inches. For example, in some embodiments, the minimum thickness can be less than 0.10, 0.09, 0.08, 0.07, 0.06, 0.05, 0.04, or 0.03 inches, and the maximum thickness can be less than 0.25, 0.24, 0.23, 0.22, 0.21, 0.20, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.10, 0.09, 0.08, 0.07, 0.06, or 0.05 inches. The thickness of the VFT region of the faceplate 34 can vary between the minimum and maximum thicknesses.

[0038] The faceplate 34 can comprise any material, such as titanium, steel, aluminum, tungsten, beryllium nickel, beryllium copper, titanium alloys, steel alloys, composite materials, ceramics, or any combination thereof. In some embodiments, the faceplate 34 can comprise materials such as 17-4 steel, 455 steel, 475 steel, 8620 steel, 1025 steel, Ti6-4, SP700, C300 steel, C350 steel, Ni-Co-Cr alloy steel, 565 steel, or any other suitable material. Furthermore, in some embodiments, any of the foregoing materials can be subjected to a heat treatment process to alter or achieve desired material properties.

[0039] 9, the sole 30 of the club head 10 can include a uniform sole thickness 35 extending from near the face plate 34 toward the back end 38. In the illustrated embodiment, the medial surface 26 of the sole 30 follows the three-dimensional contour of the lateral surface of the sole 30, and its thickness remains substantially constant from near the face plate 34 toward the back end 38 and from near the toe end 18 to the heel end 22. In some embodiments, the sole thickness 35 can be within the range of 0.015 to 0.085 inches. In other embodiments, the sole 30 can have a uniform thickness falling within the ranges of 0.020 to 0.075, 0.025 to 0.070, 0.030 to 0.065, or 0.040 to 0.060. In other embodiments, sole 30 can have a uniform thickness of less than 0.085 inches, less than 0.080 inches, less than 0.075 inches, less than 0.070 inches, less than 0.065 inches, less than 0.060 inches, less than 0.055 inches, less than 0.050 inches, less than 0.045 inches, or less than 0.040 inches. In other embodiments, sole 30 can have a uniform thickness of 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, or 0.085 inches.

[0040] In other embodiments, the sole 30 of the club head 10 can include multiple layers (not shown) having different thicknesses. For example, in some embodiments, the sole 30 can include a transition region including a first layer adjacent the face plate 34 having a first substantially constant thickness and a second layer adjacent the first layer, the second layer having a second substantially constant thickness that is less than the first substantially constant thickness. In some embodiments, the transition region can further include a third layer adjacent the second layer, where the third layer has a third substantially constant thickness that is less than the first and second substantially constant thicknesses. In other embodiments, the transition region can include any number of layers similar to the stepped sole disclosed in U.S. Patent Application No. 14 / 920,480.

[0041] 2 and 4, golf club head 10 includes a center of gravity or CG 52 that defines the origin of a coordinate system that includes an x-axis 56, a y-axis 60, and a z-axis 64. The x-axis 56 (shown in FIG. 4) extends from the toe end 18 to the heel end 22 through the center of gravity 52 of the club head 10. The y-axis 60 (shown in FIG. 2) extends from the top 26 to the sole 30 through the center of gravity 52 of the club head 10. The z-axis 64 (shown in FIG. 4) extends from the face plate 34 to the back surface 38 through the center of gravity 52 of the club head 10. To further guide the description of the inventions herein, the x-axis 56 and z-axis 64 are configured to correspond to the numbers on an analog clock in FIG. 4. The z-axis 64 extends between 12 o'clock ("12" through the faceplate 34) and 6 o'clock ("6" through the back surface 38), and the x-axis 56 extends between 3 o'clock ("3" through the toe end 18) and 9 o'clock ("9" through the heel end 22).

[0042] 5, the face plate 34, back surface 38, and sole 30 of the golf club head 10 partially define a cavity 68. More specifically, the back or first interior surface 72 of the face plate 34, the interior or upper surface of the sole 30, and the front or front side or interior surface of the back surface 38 of the club head 10 partially define the cavity 68. It should be understood that to better illustrate the cavity 68, FIG. 5 shows the cavity 68 without any delay supports or inserts.

[0043] During impact, the face plate 34 deforms or flexes in an approximate direction of movement 84 (shown in FIG. 5 ) from the face plate 34 toward the back surface 38. While some flexing in direction 84 is desirable to achieve a spring-like effect that increases golf ball speed and golf ball distance, excessive flexing can result in plastic deformation of the face plate 34. When plastic deformation occurs, the face plate 34 flexes less (or does not flex), thereby not achieving the intended spring-like effect and resulting in less than optimal golf ball speed and golf ball distance. To provide some flexing (or elastic deformation) of the face plate 34 while also limiting flexing to reduce (or avoid) the risk of plastic deformation, the golf club head 10 includes a delay support or insert 100.

[0044] II) Insert 6-8, an embodiment of an insert 100 is shown. In this embodiment, the insert 100 is in the form of a custom tuning port ("CTP") weight 100 configured to be received by or otherwise disposed in the cavity 68. The weight 100 can be any suitable or desirable insert and can be made from one or more materials, including, but not limited to, steel, tungsten, aluminum, titanium, composites, other metals, metal alloys, polymers, plastics, and / or any combination thereof. In various embodiments, the weight 100 can be made from the same material as the golf club head 10 or from a different material. In some embodiments, the weight 100 can be inserted into the cavity 68 after fabrication of the golf club head 10. In other embodiments, the weight 100 can be formed in the cavity 68 during fabrication of the golf club head 10 (e.g., during casting, forging, etc.), and in particular, can be integrally formed as a single piece with the remainder of the golf club head 10.

[0045] The insert 100 includes a bottom surface or first end 128 configured to contact the inner surface or base surface 76 of the cavity 68, a top surface or second end 132 opposite the bottom surface 128, and a front portion configured to face the inner surface 72 of the faceplate 34 when the insert 100 is disposed within the cavity 68. The front portion further includes a first surface or first insert face 104 and a second surface or second insert face 108 (shown in FIGS. 6 and 8 ). The first surface 104 is configured to abut the inner surface 72 of the faceplate 34 during impact and is positioned adjacent to and offset from the second insert face 108, which is configured to be spaced or offset from the inner surface 72 of the faceplate 34 during impact. In the illustrated embodiment, an arcuate boundary 112 defines the transition between the first surface 104 and the second surface 108. In the illustrated embodiment, the first surface 104 includes a first arm 116 adjacent the heel end 118 of the insert 100 and a second arm 120 adjacent the toe end 116 of the insert 100, both of which may extend at least partially from near the bottom end 128 to near the top end 132. The first surface 104 further includes a cross member 124 adjacent the bottom end 128 of the insert 100 that extends from the heel end 118 to the toe end 116. The first arm 116 and the second arm 120 may transition into the cross member 124 near the bottom end 128 to define a general "U" or "horseshoe" shape. Furthermore, the arms 116, 120, and the cross member 124 (i.e., the first surface 104) may lie in a common plane 126 (shown in FIG. 6 ). In other embodiments, the first and second insert faces can comprise any shape at the front portion of the insert 100. For example, in some embodiments, the first face 104 can lack one or more of the arms 116, 120, and / or the cross member 124. By way of further example, in some embodiments, the first face 104 and / or the second face 108 can form a triangle, a circle, a rectangle, a polygon, or any other suitable shape.

[0046] Referring again to FIG. 6 , in the illustrated embodiment, the first surface 104 comprises 30% of the front portion of the insert 100. In other embodiments, the first surface 104 comprises within a range of 5% to 50% of the front portion of the insert 100. For example, in some embodiments, the first surface 104 can contact between 5% and 15%, 10% and 20%, 15% and 25%, 20% and 30%, 25% and 35%, 30% and 40%, 35% and 45%, or 40% and 50% of the front portion of the insert 100. Further, in the illustrated embodiment, the arms 116, 120 have a width (from the heel end 118 to the toe end 116) that comprises 20% of the total or maximum width of the insert 100. In other embodiments, the arms 116, 120 can have a width within a range of 5% to 40% of the total or maximum width of the insert 100. For example, in some embodiments, the arms 116, 120 can have a width within a range of 5% to 15%, 10% to 20%, 15% to 25%, 20% to 30%, 25% to 35%, or 30% to 40% of the total or maximum width of the insert 100. Further still, in the illustrated embodiment, the cross member 124 has a height (from the bottom end 128 to the first end 132) that comprises 20% of the total or maximum height of the insert 100. In other embodiments, the cross member 124 can have a height within a range of 5% to 50% of the total or maximum height of the insert 100. For example, in some embodiments, the cross member 124 can have a height within a range of 5% to 15%, 10% to 20%, 15% to 25%, 20% to 30%, 25% to 35%, 30% to 40%, 35% to 45%, or 40% to 50%.

[0047] In many embodiments, an insert 100 having one or more arms 116, 120 has the advantage that the arms 116, 120 help maintain the position of the insert 100 within the cavity upon impact with a golf ball (e.g., the arms 116, 120 can prevent the insert from shifting forward within the cavity due to the force of impact with a golf ball), thereby preventing the insert 100 from loosening from the back of the cavity after repeated use.

[0048] 8 , the second surface 108 can be an inclined or tapered surface offset from the first surface 104. In particular, the second surface 108 extends from near the bottom surface 128 toward the top surface 132. In the illustrated embodiment, the distance between the first surface 104 (or alternatively, the plane 126) and the second surface 108 in a direction perpendicular to the second surface 108 or perpendicular to the plane 126 increases from the bottom surface 128 to the top surface 132. For example, at the first position 136, the second surface 108 is offset from the first surface 104 by a distance D1. In comparison, at the second position 140, which is closer to the top surface 132 than the first position 136 (or farther from the bottom surface 128 than the first position 136), the second surface 108 is offset from the first surface 104 by a distance D2, where D2 is greater than D1.

[0049] In the illustrated embodiment, the sloping or tapered second surface 108 can include a taper angle defined by the angle between the second surface 108 and the plane 126. In various embodiments, the taper angle can be greater than 0°. For example, the taper angle can range from about 0.01° to about 20°, from about 0.10° to about 15°, from about 0.10° to about 10°, from about 0.10° to about 5°, from about 0.10° to about 2°, or from about 0.10° to about 1.5°. In some embodiments, the taper angle can be about 10° or less, about 7.5° or less, about 5° or less, about 3° or less, about 2° or less, or about 1° or less.

[0050] Furthermore, the distance between second surface 108 and plane 126 (shown in FIG. 6 ) in a direction perpendicular (or orthogonal) to plane 126 is not constant or varies (e.g., increases or decreases) along y-axis 60 (shown in FIG. 2 ), or in a direction from top 26 to sole 30. Stated differently, second surface 108 is spaced from plane 126 by gap 144, and the width of gap 144 varies (e.g., increases or decreases) along a portion of second surface 108 and / or along a portion of plane 126. Thus, the distance between plane 126 and second surface 108, perpendicular to plane 126, is smaller at first end 148 (see FIG. 9) of second surface 108 than at second end 152 (see FIG. 9) of second surface 108 (where first end 148 of second surface 108 is closer to bottom surface 128 (shown in FIG. 6) than second end 152).

[0051] The distance between the second surface 108 and the plane 126 (ie, the offset between the first surface 104 and the second surface 108) can range from 0.001 inches to 0.125 inches. For example, in some embodiments, the distance between second surface 108 and plane 126 can be in the range of 0.005 inches to 0.125 inches, 0.01 inches to 0.125 inches, 0.02 inches to 0.125 inches, 0.03 inches to 0.125 inches, 0.04 inches to 0.125 inches, 0.05 inches to 0.125 inches, 0.06 inches to 0.125 inches, 0.001 inches to 0.030 inches, 0.001 inches to 0.040 inches, 0.001 inches to 0.050 inches, 0.001 inches to 0.060 inches, 0.001 inches to 0.070 inches, 0.001 inches to 0.080 inches, 0.001 inches to 0.090 inches, or 0.001 inches to 0.10 inches. Additionally, the maximum distance between second surface 108 and flat surface 126 can be greater than 0.005 inches, greater than 0.020 inches, greater than 0.030 inches, greater than 0.040 inches, greater than 0.050 inches, greater than 0.060 inches, greater than 0.075 inches, greater than 0.100 inches, or greater than 0.125 inches. Additionally, the minimum distance between second surface 108 and flat surface 126 can be less than 0.100 inches, less than 0.075 inches, less than 0.060 inches, less than 0.050 inches, less than 0.040 inches, less than 0.030 inches, less than 0.020 inches, less than 0.010 inches, less than 0.005 inches, or less than 0.001 inches.

[0052] In other embodiments of the insert 100, the second surface 108 can be offset a uniform distance from the plane 126. Thus, the distance between the second surface 108 and the plane 126 in a direction perpendicular (i.e., normal) to the plane 126 is constant (e.g., does not increase or decrease) along a portion of the second surface 108. Thus, the distance between the plane 126 and the second surface 108 perpendicular to the plane 126 is the same near the bottom end 128 of the insert 100 and near the top end 132 of the insert 100.

[0053] Additionally, second surface 108 can be offset a variable, non-uniform distance from plane 126 that varies according to any contour. Thus, the distance between second surface 108 and plane 126 in a direction perpendicular (i.e., orthogonal) to plane 126 can vary at various locations along second surface 108. For example, the distance between second surface 108 and plane 126 in a direction perpendicular (i.e., orthogonal) to plane 126 can increase, decrease, and then increase again along y-axis 60 or x-axis 3.

[0054] Referring now to FIG. 10 , another embodiment of the club head 10 includes another embodiment of an insert 200. In this embodiment, the insert 200 is shown as a protrusion or projection 200 configured to extend from the first interior surface 72 of the face plate 34 toward the second interior surface 80 of the back end 38 and into the cavity 68. The projection 200 may be of any suitable length, diameter, or related dimensions. For example, the projection 200 may be sized to fill up to a majority of the cavity 68. Furthermore, the projection 200 may be fabricated from one or more materials, including, but not limited to, steel, tungsten, aluminum, titanium, composites, other metals, metal alloys, polymers, plastics, and / or any combination thereof. In various embodiments, the projection 200 may be fabricated from the same material as the golf club head 10 or from a different material. Further, in various embodiments, the protrusion 200 may be bonded or otherwise attached to the face plate 34, or the protrusion 200 may be integrally formed as one piece with the face plate 34 during manufacturing of the golf club head 10 (e.g., during casting, forging, etc.). In other embodiments, the protrusion 200 may also be positioned at any desired location on the first interior surface 72 of the face plate 34 (e.g., along the x-axis 56, y-axis 60, and / or z-axis 64). In one or more embodiments, multiple protrusions 200 may be positioned at various locations on the first interior surface 72 of the face plate 34.

[0055] 10, protrusion 200 includes a contact surface 204 spaced apart from and opposite inner surface 80 by a gap 208. Gap 208 can range from about 0.005 inches to about 0.125 inches, from about 0.005 inches to about 0.075 inches, or from about 0.020 inches to about 0.040 inches.

[0056] In other embodiments of the club head 10, the protrusion or projection 200 is configured to extend from the second interior surface 80 of the back end 38 into the cavity 68 toward the first interior surface 72 of the face plate 34. The projection 200 may be of any suitable length, diameter, or related dimensions. For example, the projection 200 may be sized to fill up to a majority of the cavity 68. Furthermore, in various embodiments, the projection 200 may be bonded or otherwise attached to the back end 38, or the projection 200 may be integrally formed as a single piece with the back end 38 during fabrication of the golf club head 10 (e.g., during casting, forging, etc.). In other embodiments, the projection 200 may also be positioned at any desired location on the second interior surface 80 of the back end 38 (e.g., along the x-axis 56, y-axis 60, and / or z-axis 64). In one or more embodiments, multiple protrusions 200 may be positioned at various locations on the second interior surface 80 of the back end 38 .

[0057] 11A and 11B show another embodiment of an insert 300 configured to be received or otherwise disposed by cavity 68 of club head 100 (FIG. 11). Insert 300 is similar to insert 100, with like numbers referring to like features. Insert 300 differs from insert 100 in that a front surface 310 of insert 300 includes first insert face 304 and second insert face 308 having different configurations.

[0058] In the embodiment shown, the first insert face 304 comprises a first arm 316 extending along the toe end 314 of the insert from near the bottom surface 328 to near the top surface 332, and a second arm 320 extending along the heel end 318 of the insert from near the bottom surface 328 to near the top surface 332. The first face 304 of the insert 300 lacks a cross member extending along or adjacent to the bottom surface 328 of the insert 300.

[0059] In the illustrated embodiment, the first surface 304 of the insert 300 further includes one or more ribs 340 configured to contact the inner surface 72 of the faceplate 34. In the illustrated embodiment, the first arm 316 and the second arm 320 of the first surface 304 of the insert 300 each include a rib 340 extending in a direction from near the top surface 332 to near the bottom surface 328 of the insert 300. In other embodiments, the first surface 304 of the insert 300, the first arm 316 of the first surface 304, and / or the second arm 320 of the first surface 304 can include any number of ribs extending in any direction. In many embodiments, the one or more ribs 340 are configured to contact the inner surface 72 of the faceplate 34.

[0060] In other embodiments, the first insert face 304 can include one or more protrusions 346 instead of or in addition to the one or more ribs 340. In these embodiments, the one or more protrusions 346 can be configured to contact the inner surface 72 of the faceplate 34. For example, with reference to FIGS. 11C and 11D , the first insert face 304 can include one or more spherical protrusions 346 near the heel end 318 and one or more spherical protrusions 346 near the toe end 314. In these embodiments, the protrusions 346 can have any cross-sectional shape, such as a circle, a triangle, an oval, a square, a rectangle, a trapezoid, or any other polygon, or a shape having at least one curved surface. Further, in some embodiments, the contact area of ​​the protrusions 346 with the inner surface 72 of the faceplate 34 can be less than the contact area of ​​the ribs with the inner surface 72 of the faceplate 34.

[0061] In the illustrated embodiment, the second surface 308 of the insert 300 comprises a curved profile rather than the tapered, angled, straight profile of the insert 100. The second surface 308 of the insert 300 is curved in a direction extending from near the bottom surface 328 of the insert 300 to near the top surface 332 of the insert, and in a direction extending from near the heel end 318 of the insert to near the toe end 314 of the insert 320. The curvature of the second surface 308 of the insert is concave relative to the first surface 304 of the insert 300. In other embodiments, the second surface of the insert can vary according to any profile relative to the first surface of the insert.

[0062] III) Inserts for Golf Club Heads 9, an insert 100 is shown relative to the faceplate 34. A first surface 104 and a second surface 108 are located on a front portion of the insert 100 facing the inner surface 72 of the faceplate 34. The first surface 104 contacts the inner surface 72, while the second surface 108 is offset from the inner surface 72. In other embodiments, a portion of the first surface 104 can contact the inner surface 72, while the second surface 108 is offset or spaced from the inner surface 72.

[0063] In the illustrated embodiment of FIGS. 9 and 9A, the first surface 104 of the insert 100 contacts 25% of the inner surface 72 of the faceplate 34 within the cavity. In other embodiments, the first surface 104 of the insert 100 can contact between 0.5% and 30% of the inner surface 72 of the faceplate 34 within the cavity. For example, in some embodiments, the first surface 104 of the insert 100 can contact between 1% and 5%, between 0.5% and 10%, between 1% and 15%, between 1% and 20%, or between 1% and 25% of the inner surface 72 of the faceplate 34 within the cavity. In the illustrated embodiment of FIGS. 12A and 12B, one or more ribs 240 on the first surface 204 of the insert 100 contact 2% of the inner surface 72 of the faceplate 34 within the cavity. In other embodiments, one or more ribs 240 or protrusions 346 on the first surface 204 of the insert 100 can contact between 1% and 30% of the inner surface 72 of the faceplate 34 within the cavity. For example, in some embodiments, one or more ribs 240 or protrusions 346 on the first surface 204 of the insert 100 can contact between 1% and 5%, between 1% and 10%, between 1% and 15%, between 1% and 20%, or between 1% and 25% of the inner surface 72 of the faceplate 34 within the cavity. In the illustrated embodiment, the sloped or tapered second surface 108 can include a taper angle defined by the angle between the second surface 108 and the inner surface 72 of the faceplate 34. In various embodiments, the taper angle can be greater than 0°. For example, the taper angle can range from about 0.01° to about 20°, about 0.10° to about 15°, about 0.10° to about 10°, about 0.10° to about 5°, about 0.10° to about 2°, or about 0.10° to about 1.5°. In some embodiments, the taper angle can be about 10° or less, about 7.5° or less, about 5° or less, about 3° or less, about 2° or less, or about 1° or less. In the illustrated embodiment, the sloped or tapered second surface 108 can include a slope rate or taper rate or degree.9-9A, the slope of the second surface 108 is negative (decreasing when viewed from left to right). Thus, in various embodiments, the slope can range from about −0.005 to about −0.500, about −0.010 to about −0.400, about −0.015 to about −0.300, about −0.015 to about −0.200, or about −0.020 to about −0.200. In some embodiments, the slope of the second surface 108 can be about −0.400 or greater (e.g., −0.390, −0.385, etc.), about −0.300 or greater (e.g., −0.290, −0.285, etc.), or about −0.200 or greater (e.g., −0.190, −0.185, etc.). In other embodiments, the slope rate of second surface 108 can be positive (increasing when viewed from left to right, such as in the view provided in FIG. 5). Thus, in various embodiments, the slope rate can range from about 0.005 to about 0.500, about 0.010 to about 0.400, about 0.015 to about 0.300, about 0.015 to about 0.200, or about 0.020 to about 0.200. In some embodiments, the slope rate of second surface 108 can be about 0.400 or less (e.g., 0.390, 0.385, etc.), about 0.300 or less (e.g., 0.290, 0.285, etc.), or about 0.200 or less (e.g., 0.190, 0.185, etc.).

[0064] In the illustrated embodiment, the distance between the second surface 108 and the medial surface 72 in a direction perpendicular (or orthogonal) to the medial surface 72 is not constant or varies (e.g., increases or decreases) along the y-axis 60, or in a direction from the upper part 26 to the sole 30. Stated differently, the second surface 108 is spaced from the medial surface 72 by a gap 144, and the width of the gap 144 varies (e.g., increases or decreases) along a portion of the second surface 108 and / or along a portion of the medial surface 72 to define an inclined second surface 108. Thus, the distance between the medial surface 72 and the second surface 108, perpendicular to the medial surface 72, is smaller at a first end 148 of the second surface 108 than at a second end 152 of the second surface 108 (the first end 148 of the second surface 108 is closer to the sole 30 than the second end 152).

[0065] The distance between the second surface 108 and the inner surface 72 of the faceplate 34 (ie, the width of the gap 144) can range from about 0.001 inches to about 0.125 inches. For example, in some embodiments, the distance between the second surface 108 and the inner surface 72 of the faceplate 34 can be in the range of 0.005 inches to 0.125 inches, 0.01 inches to 0.125 inches, 0.02 inches to 0.125 inches, 0.03 inches to 0.125 inches, 0.04 inches to 0.125 inches, 0.05 inches to 0.125 inches, 0.06 inches to 0.125 inches, 0.001 inches to 0.030 inches, 0.001 inches to 0.040 inches, 0.001 inches to 0.050 inches, 0.001 inches to 0.060 inches, 0.001 inches to 0.070 inches, 0.001 inches to 0.080 inches, 0.001 inches to 0.090 inches, or 0.001 inches to 0.10 inches. Additionally, the maximum distance between the second surface 108 and the inner surface 72 of the faceplate 34 can be greater than 0.005 inches, greater than 0.020 inches, greater than 0.030 inches, greater than 0.040 inches, greater than 0.050 inches, greater than 0.060 inches, greater than 0.075 inches, greater than 0.100 inches, or greater than 0.125 inches. Additionally, the minimum distance between the second surface 108 and the inner surface 72 of the faceplate 34 can be less than 0.100 inches, less than 0.075 inches, less than 0.060 inches, less than 0.050 inches, less than 0.040 inches, less than 0.030 inches, less than 0.020 inches, less than 0.010 inches, less than 0.005 inches, or less than 0.001 inches. FIGS. 9 and 9A show embodiments of the insert 100 having different maximum distances between the second surface 108 and the inner surface 72 of the faceplate 34. The exemplary insert 100 shown in FIG. 9A includes a larger maximum distance between the second surface 108 and the inner surface 72 of the faceplate 34 than the exemplary insert shown in FIG. 9A.

[0066] In the embodiments shown in FIGS. 9, 9A, 12A, and 12B, the distance between the second surface 108 and the inner surface 72 of the face plate 34, perpendicular to the inner surface 72, increases further along the second surface 108 toward the center of the face plate 34 as it moves away from the sole 30 (or closer to the crown 26). In these embodiments, the maximum distance between the second surface 108 and the inner surface 72 of the face plate 34 is located near the center of the face, which experiences the most bending upon impact with a golf ball. Locating the maximum distance near the center of the face can increase face flex near the center of the face and / or eliminate bending restrictions near the center of the face. Therefore, face bending that is maintained or increased at the center of the face is transferred to the golf ball upon impact, thereby increasing ball speed and travel distance compared to a club head having an insert located adjacent to the backside of the face and near the center of the face.

[0067] In other embodiments, insert 100 can be repositioned along y-axis 60 within or partially outside cavity 68, and first end 148 can be located farther from sole 30 than second end 152. Thus, the distance between second surface 108 and inner surface 72 of faceplate 34, perpendicular to inner surface 72, decreases along second surface 108 as the distance from sole 30 increases (or as it approaches crown 26).

[0068] In other embodiments of the club head 10, the second surface 108 can be offset from the inner surface 72 of the face plate 34 by a uniform distance. Thus, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 is constant (e.g., does not increase or decrease) along a portion of the second surface 108. Thus, the distance between the inner surface 72 and the second surface 108, perpendicular to the inner surface 72, is the same at the first end 148 of the second surface 108 and the second end 152 of the second surface 108.

[0069] In other embodiments of the club head 10, the second surface 108 can be offset a variable, non-uniform distance from the inner surface 72 of the face plate 34. Thus, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can vary at various locations along the x-axis 56, the y-axis 60, and / or the z-axis 64. For example, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can increase, decrease, or remain the same along the x-axis 56, the y-axis 60, and / or the z-axis 64. In some embodiments, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can increase, decrease, and then increase again along the y-axis 60. In other embodiments, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can be smallest near the bottom end 128 of the insert 100 and largest near the top 132 of the insert 100. In other embodiments, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can be smallest near the heel end 118 and the toe end 114 of the insert 100 and largest near the center of the insert 100. In other embodiments, the distance between the second surface 108 and the inner surface 72 in a direction perpendicular (or orthogonal) to the inner surface 72 can be smallest near the bottom end 128, the heel end 118, and the toe end 114 of the insert and largest near the center and the top end 132 of the insert 100.

[0070] Although the embodiment of the insert 100 shown in Figures 6-9 shows a first surface 104 and a second surface 108 on the insert, in other embodiments, the first surface 104 and / or the second surface 108 may be located on other components of the club head 10.

[0071] In one embodiment, the first surface 104 and / or the second surface 108 can be located on the inner surface 72 of the faceplate 34. In this embodiment, the first surface 104 and / or the second surface 108 can face the insert 100. The insert 100 can have a surface facing the inner surface 72 that is in the plane 126 but spaced apart therefrom (e.g., the opposing surface of the insert 100 can have substantially the same contour as the inner surface 72 shown in FIG. 9 ). A portion of the first surface 104, including up to its entirety, can contact the opposing surface of the insert 100, while the second surface 108 can be offset from the opposing surface of the insert 100. The first surface 104 and / or the second surface 108 can be located on the inner surface 72 rather than on the insert 100, but can have substantially similar geometries, slopes, spacings, angles, and / or distances, as discussed above.

[0072] In another embodiment, the first surface 104 and / or the second surface 108 can be located on a side of the insert 100 facing the inner surface 80 of the back end 38. The insert 100 is thus in contact with the inner surface 72 of the faceplate 34, but as previously described, the gap 144 is, in this case, between the inner surface 80 and the second surface 108. A portion, up to the entirety, of the first surface 104 can be in contact with the inner surface 80, while the second surface 108 can be offset from the inner surface 80. The first surface 104 and / or the second surface 108 can have substantially similar geometries, slopes, spacings, angles, and / or distances, as described above.

[0073] In another embodiment, the first surface 104 and / or the second surface 108 can be located on the inner surface 80 of the back end 38. In this embodiment, the first surface 104 and / or the second surface 108 can face the insert 100. The insert 100 is in contact with the inner surface 72 of the faceplate 34, but as described above, a gap 144 is between the insert 100 and the second surface 108 on the inner surface 80. A portion, including up to the entire first surface 104, can contact the opposing surface of the insert 100, while the second surface 108 can be offset from the opposing surface of the insert 100. Although the first surface 104 and / or the second surface 108 are located on the inner surface 80 rather than the insert 100, they can have substantially similar geometries, slopes, spacings, angles, and / or distances, as described above.

[0074] IV) Delay Support Insert During impact with a golf ball, the face plate 34 of the club head 10 having the insert 100, 300 undergoes deformation or deflection. The face plate 34 generally deforms or deflects in the direction of movement toward the rear end 38, i.e., direction 84. The insert, acting as a delayed support, is configured to allow the face plate 34 to continue to deform or deflect until a portion of the gap 144, or the entire gap 144, collapses. For example, the face plate 34 can deform or deflect until the inner surface 72 of the face plate 34 impacts (or contacts) the insert 100, 300, more specifically, until it impacts the second surface 108, 208 of the insert 100, 300. In other embodiments, a portion of the gap 144 partially or completely collapses, thereby causing a portion of the second surface 108, 208 to contact or support the inner surface of the face plate 34. In yet other embodiments, a first portion of gap 144 may be partially collapsed, while a second portion of gap 144 may be completely collapsed. For example, gap 144, or a portion thereof, may be partially collapsed (e.g., at a first location of gap 144 defined by x-axis 56, y-axis 60, and / or z-axis 64). Additionally or alternatively, gap 144, or a portion thereof, may be completely collapsed (e.g., at a second location of gap 144 defined by x-axis 56, y-axis 60, and / or z-axis 64). The amount and / or location of gap collapse may depend on various factors, including, but not limited to, the impact location of the golf ball on face plate 34 (e.g., toward toe 18, toward heel 22, toward crown 26, toward sole 30, at the “sweet spot,” etc.), the golfer's swing speed, etc.

[0075] After the gap 144 collapses, the insert 100, 300 partially deforms, further increasing the deformation or deflection of the face plate 34. After the insert 100 can no longer deform, the face plate 34 stops moving. Thus, the insert 100, 300 supports the face plate 34 from further deformation or deflection, reducing the risk of reaching irreversible plastic deformation. The face plate 34 and insert 100 then return to their pre-impact positions (i.e., the gap 144 reforms), creating a desirable spring-like effect that results in increased golf ball velocity and increased golf ball travel.

[0076] In these embodiments, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 is less than the maximum deflection of the face plate 34. In many embodiments, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 can be between 0.010 and 0.060 inches, between 0.010 and 0.050 inches, between 0.010 and 0.040 inches, between 0.010 and 0.030 inches, or between 0.010 and 0.020 inches for club heads 10 having delay supports 100, 300. For example, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 can be less than 0.070 inches, less than 0.060 inches, less than 0.050 inches, less than 0.040 inches, less than 0.030 inches, or less than 0.20 inches for a club head 10 having a delayed support insert 100, 300. The deflection of the face plate 34 of a club head 10 having a delayed support insert 100, 300 is determined by the material of the face plate 34, the thickness or thickness characteristics of the face plate 34, the material of the insert 100, 300, and the distance between the second surface 108, 208 and the inner surface 72 of the face plate 34.

[0077] To further illustrate the behavior of the club head 10 having the insert 100, 300 during impact with a golf ball, in embodiments, the maximum thickness of the gap 144 may be 0.0125 inches. During impact, the face plate 34 deforms or deflects 0.0125 inches until the inner surface 72 of the face plate 34 impacts (or contacts) the insert 100, 300, more specifically, until it impacts the second surface 108 of the insert 100, closing the gap 144. The insert 100, 300 may then partially deform an additional 0.0125 inches to further increase the deformation or deflection of the face plate 34. For example, in some embodiments, the second surface 108 of the insert 100 may deform an additional 0.0125 inches before supporting the face plate 34 from further deformation. Thus, the total deformation or deflection of the face plate 34 is approximately 0.0250 inches.

[0078] In other embodiments of the club head 10, the insert 200 with the protrusions may have sufficient rigidity to minimize deformation when it contacts the face plate 34 upon impact with a golf ball. Thus, the insert 200 provides support to the face plate 34 after the gap 208 collapses, minimizing further deformation or deflection of the face plate 34.

[0079] During impact with a golf ball, the face plate 34 of the club head 10, having the protrusions 200, undergoes deformation or deflection. The face plate 34 deforms or deflects in a direction of movement 84 generally toward the back end 38. The face plate 34 continues to deform or deflect until the gap 208 collapses and the contact surface 204 of the protrusions 200 impacts (or otherwise contacts) the inner surface 80 of the cavity or the inner surface 72 of the face plate 34. After the contact surface 204 impacts the inner surface 80 or the inner surface 72, the protrusions 200 limit the movement of the face plate 34 by limiting further deformation or deflection of the face plate 34. The protrusions 200 then support the face plate 34 against further deformation or deflection, reducing the risk of reaching irreversible plastic deformation. The face plate 34 then returns to its pre-impact position (ie, the gap 208 reforms), creating a desirable spring-like effect that results in increased golf ball velocity and increased golf ball travel distance.

[0080] V) Non-restrictive insert During impact with a golf ball, the face plate 34 of the club head 10 having the insert 100 undergoes deformation or deflection. The face plate 34 deforms or deflects in a direction of movement generally toward the rear end 38, i.e., direction 84. The insert 100, 300 is configured to allow unrestricted face deflection upon impact. The face plate 34 will continue to deflect until it reaches a maximum deflection without completely collapsing the gap 144 or contacting the second surface 108, 208 of the insert 100, 300. In these embodiments, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 is greater than the maximum deflection of the face plate 34.

[0081] In many embodiments, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 can be between 0.010 and 0.060 inches, between 0.010 and 0.050 inches, between 0.010 and 0.040 inches, between 0.010 and 0.030 inches, or between 0.010 and 0.020 inches for club heads 10 having inserts 100, 300 with non-constrained supports. For example, the maximum distance between the second surface 108, 208 and the inner surface 72 of the face plate 34 can be less than 0.070 inches, less than 0.060 inches, less than 0.050 inches, less than 0.040 inches, less than 0.030 inches, or less than 0.20 inches for club heads 10 having inserts 100, 300 with non-constrained supports.

[0082] After the face plate 34 reaches maximum deflection, it returns to its pre-impact position without contacting the second surface 108, 208 of the insert 100, 300. The returning face plate 34 creates a desirable spring-like effect that results in increased golf ball velocity and increased golf ball travel. Furthermore, because the face plate 34 is not constrained by the insert 100, none of the impact energy is absorbed by the insert, and therefore the face plate 34 is able to return to its pre-impact position, imparting a large percentage of the energy from the impact back to the ball, increasing ball velocity and travel distance.

[0083] VI) Advantages of Club Heads with Inserts A club head 10 having an insert 100, 200, 300 described herein can increase face deflection at impact compared to a club head 10 having an insert positioned adjacent to the face (i.e., without the gap 144, 208, 344). Increased face deflection can increase energy transfer to the golf ball at impact, thus resulting in increased ball speed and travel distance.

[0084] Furthermore, upon impact, a club head 10 having an insert 100, 200, 300 described herein, in which a portion of the insert contacts the face plate 34, dampens vibrations compared to a club head having an insert that is spaced apart from or does not contact the face plate. The dampened vibrations due to the portion of the insert contacting the face plate enable the club head to maintain similar acoustic characteristics (e.g., a lower pitch, deeper sound, etc.) upon impact as a club head having an insert positioned adjacent to the face. In contrast, a club head having an insert that is spaced apart from or does not contact the face plate may produce an undesirable higher-pitched sound upon impact with a golf ball.

[0085] Thus, club head 10 with insert 100, 200, 300 can balance increased ball speed with the acoustic performance of the club head upon impact with a golf ball. For example, club head 10 with insert 100, 200, 300 can simultaneously increase face deflection and ball speed, while maintaining or improving acoustic performance upon impact with a golf ball, compared to current club heads with inserts having other configurations.

[0086] In many embodiments, a club head 10 with inserts 100, 200, 300 can generate up to 2 miles per hour more ball speed compared to a similar club head with an insert located adjacent the face, while maintaining the low frequency, deep pitched sound at impact of a club head with an insert located adjacent the face.

[0087] The vibration and acoustics of the club head can be measured using a hammer test, whereby a region of the face plate having a natural frequency mode is impacted with a hammer and a sensor is used to measure the vibration frequency of the club head in response to the hammer impact. The hammer test can be used to determine differences in frequency, vibration, and / or acoustics of a club head 10 having an insert 100, 200, 300 compared to a similar club head lacking an insert in at least partial contact with the inner surface of the face plate, or compared to a similar club head having an insert in full contact with the inner surface of the face plate.

[0088] VII) How to make A method of fabricating a club head 10 having a delayed support 100 is provided. The method includes providing a body 14 having a crown 26, a sole 30, a face plate 34, a hosel 44, and a cavity 68. An insert 100 may then be positioned within the cavity 68 and, optionally, further attached to one or more of the surfaces 72, 76, 80 that define a portion of the cavity 68 (see FIG. 5 ).

[0089] A method of making a club head 10 having a delay support 200 may include providing a body 14 having a crown 26, a sole 30, a face plate 34, a hosel 44, and a cavity 68. The protrusion 200 may be coupled to one of the opposing interior surfaces 72, 80 that define a portion of the cavity 68 (see FIG. 10 ), or may be integrally formed with one of the opposing interior surfaces 72, 80 that define a portion of the cavity 68.

[0090] The methods for fabricating club head 10 described herein are merely exemplary and are not limited to the embodiments presented herein. The methods may employ many different embodiments or examples not specifically shown or described herein. In some embodiments, the processes of the described methods may be performed in any suitable order. In other embodiments, one or more of the processes may be combined, separated, or skipped.

[0091] VIII) Example 1 An exemplary club head 10 is described herein. The exemplary club head 10 has a face plate 34 comprised of 17-4 steel, a maximum face plate thickness of 0.105 inches near the center of the face plate, a minimum face plate thickness of 0.095 inches near the periphery of the face plate, a uniform sole thickness of 0.055 inches, and an insert 300 having a maximum distance of 0.060 inches between the second surface 308 of the insert 300 and the inner surface 72 of the face plate 34, and a percent contact area within the cavity between the second surface 308 of the insert 300 and a portion of the inner surface of the face plate 34 of 2.1%. The exemplary club head 10, when tested at a swing speed of 92 miles per hour, experienced a face deflection of approximately 0.035 inches and an increased ball speed of approximately 2 miles per hour compared to a control club head.

[0092] In this example, the control club head is a similar club head having a face plate comprising 17-4 steel, a minimum face plate thickness of 0.068 inches near the center of the face plate, a maximum face plate thickness of 0.080 inches near the periphery of the face plate, a uniform sole thickness of 0.055 inches, and an insert 300 having a maximum distance of 0.0 inches between the second surface of the insert and the inner surface of the face plate (e.g., the insert is located directly adjacent to the face plate and lacks a gap), and a percent contact area within the cavity between the second surface 308 of the insert 300 and a portion of the inner surface of the face plate 34 of 100%. The control club head, when tested at a swing speed of 92 miles per hour, experienced a face deflection of approximately 0.025 inches, or a ball speed 2 miles per hour slower than the exemplary golf head described herein. Thus, the exemplary club head 10 experienced 40% more face deflection upon impact with a golf ball and achieved an additional 2 miles per hour ball speed compared to the control club head. In these embodiments, the exemplary club head and the control club head were heat treated at 1050 degrees Celsius for 1.5 hours, followed by 550 degrees Celsius for 4 hours, which resulted in similar material properties for the exemplary and control face plates.

[0093] The substitution of one or more claimed elements constitutes a rearrangement, not a repair. Furthermore, benefits, other advantages, and solutions to problems have been described above with respect to particular embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may give rise to or make more apparent any benefit, advantage, or solution should not be construed as a key, necessary, or essential feature or element of any claim unless such benefit, advantage, solution, or element is expressly recited in any or all of the claims.

[0094] Because the Rules of Golf may change from time to time (e.g., new Rules may be adopted, or old Rules may be eliminated or modified, by golf's standards organizations and / or governing bodies, such as the United States Golf Association (USGA), the Royal and American Golf Association (R&A), etc.), golf equipment related to the devices, methods, and articles of manufacture described herein may or may not conform to the Rules of Golf at any particular time. Accordingly, golf equipment related to the devices, methods, and articles of manufacture described herein may be advertised, marketed, and / or sold as conforming or non-conforming golf equipment. The devices, methods, and articles of manufacture described herein are not limited in this respect.

[0095] Although the above examples may be described in the context of iron-type golf clubs, the devices, methods, and articles of manufacture described herein may also be applied to other types of golf clubs, such as driver wood-type golf clubs, fairway wood-type golf clubs, hybrid-type golf clubs, iron-type golf clubs, wedge-type golf clubs, or putter-type golf clubs. Alternatively, the devices, methods, and articles of manufacture described herein may also be applied to other types of sports equipment, such as hockey sticks, tennis rackets, fishing rods, ski poles, etc.

[0096] Furthermore, embodiments and limitations disclosed herein are not available to the public under the doctrine of public domain if the embodiment and / or limitation (1) is not explicitly claimed in the claims and (2) is a potential equivalent of an explicit element and / or limitation of the claims under the doctrine of equivalents. Various features and advantages of the present disclosure are set forth in the following claims. Item 1 A golf club head, The main body is a face plate having a striking surface and an inner surface opposite the striking surface; the rear end, and a body including a sole connecting the face plate to the rear end, the face plate, the rear end, and the sole partially defining a cavity; an insert positioned within the cavity, the insert having an insert surface facing and spaced apart from the inner surface of the faceplate; A golf club head comprising: Item 2 Item 1. The golf club head of item 1, wherein the face plate is configured to deform toward the rear end during impact with a golf ball, and the insert surface is configured to limit movement of the face plate during the impact. Item 3 Item 1. The golf club head according to item 1, wherein the insert surface has a first end and a second end that is farther from the sole than the first end, and the distance between the inner surface and the insert surface in a direction perpendicular to the inner surface is not constant from the first end to the second end. Item 4 4. The golf club head of item 3, wherein the distance is greater at the second end than at the first end. Item 5 4. The golf club head of item 3, wherein the distance is greatest at the second end. Item 6 5. The golf club head of item 4, wherein a portion of the insert surface contacts the inner surface. Item 7 4. The golf club head of item 3, wherein the maximum distance between the inner surface and the insert surface is in the range of 0.005 to 0.125 inches. Item 8 4. The golf club head of item 3, wherein the maximum distance between the inner surface and the insert surface is greater than 0.075 inches. Item 9 A golf club head, The main body is Faceplate, the rear end, and a body including a sole connecting the face plate to the rear end, the face plate, the rear end, and the sole partially defining a cavity, the rear end having an inner surface facing the cavity; an insert positioned within the cavity, the insert having an insert surface facing and spaced from the inner surface of the aft end; A golf club head comprising: Item 10 10. The golf club head of claim 9, wherein the face plate is configured to deform toward the rear end during impact with a golf ball, and the insert surface is configured to limit movement of the face plate during the impact. Item 11 10. The golf club head according to item 9, wherein the insert surface has a first end and a second end that is farther from the sole than the first end, and the distance between the inner side surface and the insert surface in a direction perpendicular to the inner side surface is not constant from the first end to the second end. Item 12 Item 12. The golf club head of item 11, wherein the distance is greater at the second end than at the first end. Item 13 Item 12. The golf club head of item 11, wherein the distance is greatest at the second end. Item 14 Item 12. The golf club head of item 11, wherein a portion of the insert surface contacts the inner surface. Item 15 Item 12. The golf club head of item 11, wherein the maximum distance between the inner surface and the insert surface is in the range of 0.005 to 0.125 inches. Item 16 Item 12. The golf club head of item 11, wherein the maximum distance between the inner surface and the insert surface is greater than 0.075 inches. Item 17 A golf club head, The main body is a face plate having a striking surface and a first inner surface opposite the striking surface; the rear end, and a body including a sole connecting the face plate to the rear end, the face plate, the rear end, and the sole partially defining a cavity, the rear end having a second insert surface facing the cavity; a protrusion coupled to one of the first inner surface and the second inner surface and having a contact surface facing and spaced apart from the other of the first inner surface and the second inner surface; A golf club head comprising: Item 18 Item 18. The golf club head of item 17, wherein the face plate is configured to deform toward the rear end during impact with a golf ball, and the contact surface is configured to limit movement of the face plate during the impact. Item 19 Item 18. The golf club head according to item 17, wherein the distance between the contact surface and the other of the first inner surface and the second inner surface is 0.04 inches or less. Item 20 Item 18. The golf club head according to item 17, wherein the protrusion is integrally formed as part of one of the first inner surface and the second inner surface.

Claims

1. A golf club head, The main body is a face plate having a striking surface and an opposite inner surface, the distance between the striking surface and the opposite inner surface defining a thickness; a posterior end portion having a posterior medial surface; a body including a sole connecting the face plate to the rear end, the face plate, the rear end, and the sole partially defining a cavity; an insert located within the cavity, a front portion having a linearly contoured front surface that partially abuts the opposite inner surface of the faceplate; an insert including a posterior portion facing the posterior medial surface and having a posterior surface facing the posterior medial surface; a golf club head, wherein at least a portion of the front surface of the insert is spaced from the opposite inner surface of the face plate by a gap that defines a distance between the front surface of the insert and the opposite inner surface of the face plate, and wherein the width of the gap increases consistently from near the bottom surface of the insert to the top surface of the insert.

2. 2. The golf club head of claim 1, wherein the distance between the front surface and the opposite inner surface of the insert is in the range of 0.005 to 0.125 inches.

3. The golf club head of claim 1 , wherein the insert comprises a plurality of protrusions.

4. 4. The golf club head according to claim 1, wherein the insert is integrally formed with the opposite inner surface of the face plate.

5. The golf club head according to any one of claims 1 to 4, wherein the insert fills most of the cavity.

6. 6. The golf club head according to claim 1, wherein the face plate is formed of a first material or combination of materials, and the insert is formed of a second material or combination of materials different from the first material.

7. The golf club head of any one of claims 1 to 6, wherein the sole of the club head has a uniform thickness of less than 0.060 inches.

8. The golf club head of any one of claims 1 to 7, wherein the thickness of the face plate varies, the maximum thickness of the face plate being less than 0.15 inches.

9. A golf club head, The main body is a face plate having a striking surface and an opposite inner surface, the distance between the striking surface and the opposite inner surface defining a thickness; a posterior end portion having a posterior medial surface; a body including a sole connecting the face plate to the rear end, the face plate, the rear end, and the sole partially defining a cavity; an insert located within the cavity, a front portion having a substantially linearly contoured front surface configured to face the opposite interior surface of the faceplate; a rear portion having a rear surface abutting the rear medial surface; the front surface of the insert is spaced from the opposite inner surface of the faceplate, defining a distance between the front surface of the insert and the opposite inner surface of the faceplate; the insert includes a taper angle such that a gap width, measured as the distance between the front surface and the opposite inner surface of the insert in a direction perpendicular to the rear surface of the insert, increases from near a bottom surface of the insert to a top surface of the insert; The golf club head, wherein the taper angle is between 0.01° and 20°.

10. 10. The golf club head of claim 9, wherein the distance between the front surface of the insert and the opposite inner surface of the face plate ranges from 0.005 to 0.125 inches.

11. The golf club head of claim 9 or 10, wherein the insert comprises a plurality of protrusions.

12. The golf club head according to any one of claims 9 to 11, wherein the insert is integrally formed with the rear inner surface.

13. The golf club head according to any one of claims 9 to 12, wherein the insert fills a majority of the cavity.

14. 14. The golf club head according to claim 9, wherein the rear end is formed of a first material or combination of materials, and the insert is formed of a second material or combination of materials different from the first material.

15. The golf club head of any one of claims 9 to 14, wherein the sole of the golf club head has a uniform thickness of less than 0.060 inches.

16. The golf club head of any one of claims 9 to 15, wherein the thickness of the face plate varies, the maximum thickness of the face plate being less than 0.15 inches.

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