Golf club head with impact response modulator

Abstract

Embodiments of a golf club head comprising an Impact Response Modulator disposed in the sole. The Impact Response Modulator comprises a casing with a plurality of casing walls that form an aperture therebetween. The casing walls comprises specific geometries and dimensions that improve the performance and durability of the Impact Response Modulator when implemented into a fairway wood type club head.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation-in-part of U.S. patent application Ser. No. 19 / 090,340, filed on Mar. 25, 2025, which claims the benefit of U.S. Provisional Application No. 63 / 569,638, filed on Mar. 25, 2024. This further claims the benefit of U.S. Provisional Application No. 63 / 648,946, filed on May 17, 2024, U.S. Provisional Application No. 63 / 654,776, filed on May 31, 2024, U.S. Provisional Application No. 63 / 664,628, filed on Jun. 26, 2024, U.S. Provisional Application No. 63 / 699,398, filed on Sep. 26, 2024, and U.S. Provisional Application No. 63 / 769,579, filed on Mar. 10, 2025, and U.S. Provisional Application No. 63 / 784,868, filed on Apr. 7, 2025, all of which are incorporated in their entirety.FIELD OF INVENTION

[0002] This invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.BACKGROUND

[0003] The strike face of a golf club head deflects upon impact with a golf ball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. Increased strike face deflection increases energy transfer between the club head and the golf ball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted on the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air and increases carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and / or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. Conventional golf club heads fail to increase strike face deflection without compromising club head durability.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0005] FIG. 2 is a bottom, front, toe-side perspective view of the golf club head of FIG. 1.

[0006] FIG. 3 is a front, elevation view of the golf club head of FIG. 1.

[0007] FIG. 4 is a toe-side, elevation view of the golf club head of FIG. 1.

[0008] FIG. 5 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0009] FIG. 6 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0010] FIG. 7 is a detailed, plan view of the golf club head of FIG. 1, in cross-section.

[0011] FIG. 8 is a toe-side, detailed, elevation view of the golf club head of FIG. 1, in cross-section.

[0012] FIG. 9 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0013] FIG. 10 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0014] FIG. 11 is a toe-side, detailed, elevation view of the golf club head of FIG. 8, in cross-section.

[0015] FIG. 12 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0016] FIG. 13 is a detailed, top, rear, toe-side, perspective view of a golf club head according to the present invention, in cross-section.

[0017] FIG. 14 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0018] FIG. 15 is a detailed, top, rear, toe-side, perspective view of a golf club head of the golf club head of FIG. 13.

[0019] FIG. 16 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0020] FIG. 17 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0021] FIG. 18 is a toe-side, detailed, elevation view of the golf club head of FIG. 17, in cross-section.

[0022] FIG. 19 is a front, toe-side perspective view of a golf club head according to the present invention.

[0023] FIG. 20 is a toe-side, elevation view of a golf club head according to the present invention.

[0024] FIG. 21 is a rear, heel-side perspective view of a golf club head faceplate.

[0025] FIG. 22 is a heel-side, detailed, elevation view of a golf club head comprising the faceplate of FIG. 21, in cross-section.

[0026] FIG. 23 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0027] FIG. 24 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0028] FIG. 25 is a detailed, plan view of the golf club head of FIG. 24, in cross-section.

[0029] FIG. 26 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0030] FIG. 27 is a detailed, plan view of the golf club head of FIG. 26, in cross-section.

[0031] FIG. 28 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0032] FIG. 29 is a detailed, bottom view of the golf club head of FIG. 28.

[0033] FIG. 30 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0034] FIG. 31 is a bottom view of a golf club head according to the present invention.

[0035] FIG. 32 is a detailed, toe-side, elevation view of the golf club head of FIG. 31, in cross section.

[0036] FIG. 33 is a bottom, front, toe-side perspective view of a golf club head according to the present invention.

[0037] FIG. 34 is a bottom view of a golf club head according to the present invention.

[0038] FIG. 35 is a rear, top, toe-side view of the golf club head of FIG. 34, in cross-section.

[0039] FIG. 36 is a detailed, plan view of the golf club head of FIG. 34, in cross-section.

[0040] FIG. 37 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0041] FIG. 38 is a detailed, plan view of the golf club head of FIG. 37, in cross-section.

[0042] FIG. 39 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0043] FIG. 40 is a detailed, plan view of the golf club head of FIG. 39, in cross-section.

[0044] FIG. 41 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0045] FIG. 42 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0046] FIG. 43 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0047] FIG. 44 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0048] FIG. 45 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0049] FIG. 46 is a detailed, plan view of the golf club head of FIG. 41, in cross-section.

[0050] FIG. 47 is a detailed, sole-side, plan view of a golf club head.

[0051] FIG. 48 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0052] FIG. 49 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0053] FIG. 50 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0054] FIG. 51 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0055] FIG. 52 is a detailed, front, elevation view of a golf club head according to the present invention, in cross-section.

[0056] FIG. 53 is a detailed, front, elevation view of a golf club head according to the present invention, in cross-section, with the shaft sleeve removed.

[0057] FIG. 54 is a bottom view of a golf club head according to the present invention.

[0058] FIG. 55 is a bottom view of a golf club head according to the present invention.

[0059] FIG. 56 is a detailed, rear, elevation view of a golf club head according to the present invention, in cross-section.

[0060] FIG. 57 is a bottom view of a golf club head according to the present invention.

[0061] FIG. 58 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0062] FIG. 59 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0063] FIG. 60 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0064] FIG. 61 is a toe-side, elevation view of the golf club head according to the present invention, in cross-section.

[0065] FIG. 62 is a toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0066] FIG. 63 is a bottom view of the golf club head of FIG. 62.DETAILED DESCRIPTION

[0067] Described herein are various embodiments of wood-type golf club heads (i.e. drivers, fairway woods, or hybrids) comprising an impact response modulator (hereafter “IRM”) in the sole. The IRM strategically weakens the sole to increase strike face deflection, thereby improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material. The casing includes various stress reducing geometries and / or selected regions of high-strength material to increase strike face deflection while maintaining sufficient club head durability.

[0068] In some embodiments, a high-strength material component, such as a faceplate, a cartridge, or an appendage, can form and reinforce one or more portions of the casing, thereby increasing strike face deflection without compromising durability. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Selectively using high-strength material reduces stress in the casing walls. Accordingly, the casing walls can have a reduced thickness and / or be placed closer to the strike face without exceeding the yield strength of the high-strength material, thereby increasing strike face deflection.

[0069] In some embodiments, the club head comprises a body and a faceplate coupled together, wherein the faceplate forms at least a portion of the casing. The body comprises a body material that is easily castable to form various complex club head geometries. The faceplate comprises a high-strength faceplate material with a yield strength greater than 175 ksi (i.e., C300 steel, C350 steel, Ti-9s, Ti-9s+, etc.) The faceplate material is more durable than the body material and is suitable to withstand direct impact with a golf ball. In some embodiments, the faceplate comprises a sole return that forms one or more portions of the casing. In some embodiments, the body and the faceplate combine to form the casing, whereby the body and the faceplate each form at least a portion of the casing.

[0070] In some embodiments, the club head comprises a separately formed, high-strength material member that forms one or more portions of the casing, referred to herein as a “cartridge,” The cartridge is located on the sole of the club head and integrally forms at least portions of the casing front wall and the casing rear wall. The cartridge can be coupled to both the faceplate and the body, or can be coupled to and entirely surrounded by the body. Similar to the faceplate, the cartridge can comprise a high-strength cartridge material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0071] In other embodiments, the club head can comprise a separately formed high-strength component that forms a portion of the casing front wall, but not a portion of the casing rear wall, referred to herein as an “appendage.” The appendage is located on the sole of the club head and is coupled to both the faceplate and the body. In such embodiments, the body and the appendage combine to form the casing, whereby the body and the appendage each form at least a portion of the casing. Similar to both the faceplate and the cartridge, the appendage can comprise a high-strength appendage material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0072] The IRM selectively uses high-strength material to increase strike face deflection while maintaining durability. For example, one or both of the casing front wall and the casing rear wall can be integrally formed by high-strength material (i.e., the faceplate material, the cartridge material, or the appendage material). In some embodiments, a portion of the front wall front surface, front wall rear surface, front wall base, and / or front wall top surface can be integrally formed by a high-strength component. Similarly, in some embodiments, a portion of the rear wall front surface, rear wall rear surface, rear wall base, and / or rear wall top surface can be integrally formed by a high-strength component. Forming portions of the casing with high-strength material, whether via the faceplate, a cartridge, or an appendage, increases strike face deflection without compromising durability.

[0073] The IRM further balances strike face deflection and club head durability through various stress-reducing casing geometries, dimensions, and / or parameters. Balancing certain casing parameters or localized reinforcements can increase strike face deflection without a corresponding stress increase. For example, balancing the length of the aperture, offset distance of the aperture, relief geometries, and front wall geometries can improve the strike face deflection while maintaining durability.

[0074] Any casing geometry described herein can be combined with any suitable high-strength material reinforcement. For example, any IRM geometry or local reinforcement can be combined with any faceplate configuration including a faceplate with a sole return integrally forming the entire IRM or a faceplate a sole return integrally forming only a portion of the IRM. The IRM can comprise any suitable geometry described herein and be integrally formed by the faceplate, the body, a cartridge, an appendage, or any combination thereof. The combination of high-strength material reinforcement and stress-reducing casing geometries further increases strike face deflection without compromising durability.

[0075] As such, certain aspects of the present invention, including high-strength material reinforcement and stress-reducing casing geometries, balance strike face deflection and durability. Such aspects increase strike face deflection (and thereby ball flight performance) without a corresponding increase in stress, increase durability without sacrificing performance, or both.I. Definitions

[0076] The terms “first,”“second,”“third,”“fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” 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 comprises 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.

[0077] The terms “left,”“right,”“front,”“back,”“top,”“bottom,”“over,”“under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and / or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0078] The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golf ball. The term “strike face” can be used interchangeably with the term “face.”

[0079] The strike face 102 is bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club head 100 deviates from a bulge curvature and / or roll curvature of the strike face 102 (defined below). The strike face perimeter includes at least an upper edge 118 that defines a transition between the strike face 102 and the crown 110 and a leading edge 103 that defines a transition from the strike face 102 to the sole 112. The upper edge 118 defines a face apex (FA), located at the intersection between the upper edge 118 and the YZ plane (described below). The leading edge 103 defines a face nadir (FN) located at the intersection between the leading edge 103 and the YZ plane. The strike face 102 further defines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in FIG. 4. The face center (FC) can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA).

[0080] The strike face 102 defines a strike face height (HSF). Referring to FIG. 3, the strike face height (HSF) is measured within the YZ plane (described in further detail below) and parallel to the loft plane 15 between the face nadir (FN) and the face apex (FA).

[0081] The strike face 102 comprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike face 102 in the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and / or the roll curvature can comprise one or more radii.

[0082] The golf club head 100 defines a ground plane (GP) as a reference plane associated with the surface on which a golf ball is placed. The ground plane GP is a horizontal plane tangent to the sole 112 in the address position. The ground plane GP is illustrated in FIG. 3.

[0083] The golf club head 100 defines a loft plane 15 as a plane that is tangent to the strike face 102 at the face center (FC). The loft plane 15 is illustrated in FIG. 4.

[0084] The golf club head 100 defines a loft angle 20 as the angle measured between the loft plane 15 and the XY plane (defined below). The loft angle 20 is illustrated in FIG. 4.

[0085] The golf club head 100 defines a lie angle 25 as the angle between a hosel axis 30, extending longitudinally through the hosel 105, and the ground plane GP. The lie angle 25 is measured from a front view of the golf club head 100, as illustrated in FIG. 3.

[0086] The golf club head 100 can define an address position, wherein the golf club head 100 is oriented such that the golf club head 100 forms its intended loft angle 20 and lie angle 25. For example, in the address position, the loft plane 15 and the XY plane form the intended loft angle 20 between one another. Likewise, in the address position, the hosel axis 30 and the ground plane GP form the intended lie angle 25 between one another.

[0087] As illustrated in FIGS. 3 and 4, the golf club head 100 defines a primary coordinate system centered about the face center (FC). The primary coordinate system comprises an X-axis 40, a Y-axis 50, and a Z-axis 60. The X-axis 40 extends in a heel-to-toe direction, parallel to the ground plane GP. The X-axis 40 is positive towards the heel 104 and negative towards the toe 106. The Y-axis 50 extends in a crown-to-sole direction and is orthogonal to both the ground plane GP and the X-axis 40. The Y-axis 50 is positive towards the crown 110 and negative towards the sole 112. The Z-axis 60 extends in a front-to-rear direction, parallel to the ground plane GP, and is orthogonal to both the X-axis 40 and the Y-axis 50. The Z-axis 60 is positive towards the strike face 102 and negative towards the rear 111.

[0088] The primary coordinate system, as described herein, defines an XY plane as a vertical plane extending along the X-axis 40 and the Y-axis 50. The primary coordinate system defines an XZ plane as a horizontal plane extending along the X-axis 40 and the Z-axis 60. The primary coordinate system further defines a YZ plane as a vertical plane extending along the Y-axis 50 and the Z-axis 60. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the primary coordinate system origin located at the face center (FC). In these or other embodiments, the golf club head 100 can be viewed from a front view when the strike face 102 is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head 100 can be viewed from a side view when the heel 104 or the toe 106 is viewed from a direction perpendicular to the YZ plane.

[0089] The golf club head 100 comprises a club head center of gravity (hereafter “CG” or “club head CG”), referring to the point at which the mass is centered within the golf club head 100. The club head CG is illustrated in FIGS. HA and HB.

[0090] The “body depth,” or “depth” DB of the club head 100, as used herein, refers to a front-to-rear dimension measured across the body. Referring to FIG. 4, the body depth DB is measured parallel to the Z-axis 60 from the leading edge 103 to the rearward-most point of the body 101.

[0091] The “body height,” or “height” HB of the club head 100, as described herein, can refer to a crown-to-sole dimension measured across the body 101. Referring to FIG. 3, the body height HB can be measured as a vertical distance (parallel to the Y-axis 50) between the ground plane GP and the highest point of the crown 110. In many embodiments, the height HB can be measured according to a golf governing body such as the United States Golf Association (USGA).

[0092] The “body width,” or “width” WB of the club head 100, as described herein, can refer to a heel-to-toe dimension measured across the body. Referring to FIG. 3, the body width WB can be measured parallel to the X-axis 40 from a body heel apex (BHA) to a body toe apex (BTA). The body toe apex (BTA) is defined as the toeward-most point of the body 101. The body heel apex (BHA) is heelward-most point of the heel 104 that is located at a height 0.875 mm from the ground plane GP. In many embodiments, the body width (WB) can be measured according to a golf governing body such as the United States Golf Association (USGA). The ranges specified for the body depth (DB), body height (HB), and body width (WB) can be designed in accordance with the USGA regulations.

[0093] The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golf ball.

[0094] The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head.

[0095] The term “cartridge” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall and at least a portion of the casing rear wall.

[0096] The term “appendage” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall but does not form a portion of the casing rear wall.

[0097] “Driver” or “driver-type” golf club heads as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a club head volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the club head volume of the driver can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc 650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.

[0098] Driver embodiments can comprise a body height HB between 2.0 and 3.0 inches. In some driver embodiments, the body height HB can be between 2.0 and 2.2 inches, between 2.2 and 2.4 inches, between 2.4 and 2.6 inches, between 2.6 and 2.8 inches, or between 2.8 and 3.0 inches. In some driver embodiments, the body height HB can be greater than 2.0 inches, greater than 2.2 inches, greater than 2.4 inches, greater than 2.6 inches, greater than 2.8 inches, or greater than 3.0 inches.

[0099] Driver embodiments can comprise a body width WB between 4.4 and 5.0 inches. In some driver embodiments, the body width WB can be between 4.4 and 4.6 inches, between 4.6 and 4.8 inches, or between 4.8 and 5.0 inches. In some driver embodiments, the body width WB can be greater than 4.4 inches, greater than 4.6 inches, greater than 4.8 inches, or greater than 5.0 inches.

[0100] Driver embodiments can comprise a body depth DB between 4.3 and 4.9 inches. In some driver embodiments, the body depth DB can be between 4.3 and 4.5 inches, between 4.5 and 4.7 inches, or between 4.7 and 4.9 inches. In some driver embodiments, the body depth DB can be greater than 4.3 inches, greater than 4.5 inches, greater than 4.7 inches, or greater than 4.9 inches.

[0101] “Fairway wood” or “fairway wood-type” golf club heads as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

[0102] Further, “fairway wood” or “fairway wood-type” golf club heads as used herein comprises a club head volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the club head volume of the fairway wood can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.

[0103] Fairway wood embodiments can comprise a body height HB between 1.25 and 1.75 inches. In some fairway wood embodiments, the body height HB can be between 1.25 and 1.40 inches, between 1.40 and 1.55 inches, or between 1.55 and 1.75 inches.

[0104] Fairway wood embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some fairway wood embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches.

[0105] Fairway wood embodiments can comprise a body depth DB between 3.0 and 4.0 inches. In some fairway wood embodiments, the body depth DB can be between 3.0 and 3.3 inches, between 3.3 and 3.6 inches, between 3.6 and 3.8 inches, or between 3.8 and 4.0 inches.

[0106] “Hybrid” or “hybrid-type” golf club heads as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0107] Further, “hybrid” or “hybrid-type” golf club heads as used herein comprise a club head volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the club head volume of the hybrid can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

[0108] Hybrid embodiments can comprise a body height HB between 1.1 and 1.5 inches. In some hybrid embodiments, the body height HB can be between 1.1 and 1.25 inches, between 1.25 and 1.4 inches, or between 1.4 and 1.5 inches. In some hybrid embodiments, the body height HB can be less than 1.5 inches, less than 1.4 inches, less than 1.3 inches, or less than 1.2 inches.

[0109] Hybrid embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some hybrid embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches. In some hybrid embodiments, the body width WB can be less than 4.5 inches, less than 4.25 inches, or less than 4.0 inches.

[0110] Hybrid embodiments can comprise a body depth DB between 2.25 and 2.75 inches. In some hybrid embodiments, the body depth DB can be between 2.25 and 2.4 inches, between 2.4 and 2.6 inches, or between 2.6 and 2.75 inches. In some hybrid embodiments, the body depth DB can be less than 2.75 inches, less than 2.6 inches, less than 2.4 inches, or less than 2.25 inches.

[0111] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, 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.II. General Description of a Golf Club Head

[0112] Various embodiments of a golf club are illustrated in the figures. A golf club is generally understood to comprise a club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

[0113] Referring to FIGS. 1 and 2, the club head 100 defines a crown 110, a sole 112 opposite the crown 110, a heel 104, a toe 106, a front 108, a rear 111 and a strike face 102. The club head 100 further comprises a hosel 105, which is configured to receive the shaft. In some embodiments, as illustrated in the embodiment of FIGS. 1 and 2, the club head 100 comprises a body 101 and a faceplate 114 coupled together to form an interior cavity. The body 101 forms at least a portion of the crown 110, at least a portion of the sole 112, at least a portion of the heel 104, and at least a portion of the toe 106. The faceplate 114 forms at least a portion of the strike face 102. Specific configurations of the body 101 and the faceplate 114 are described in further detail below.

[0114] The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club head 100 comprises a crown 110 and a sole 112, whereas club head 200 comprises a crown 210 and a sole 212). Any one or more of the features below can be used in combination with one another.

[0115] The body 101 comprises a body material that provides sufficient structural strength and is easily formed into complex geometries. In many embodiments, the body material is a metallic material that is easily castable. In some embodiments, the body material can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the body material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the body material can be formed from Ni (Nickel)-Co (Cobalt)-Cr (Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6Al-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3Al-2.5V, Ti-6Al-1Zr-1Nb-1Mo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals. Generally, the body material can comprise a yield strength between 145 and 165 ksi.

[0116] In some embodiments, the body 101 comprises a multi-material construction including one or more lightweight materials, such as a lightweight composite material, in addition to the metallic body material. In some embodiments, a portion of the crown 110, a portion of the sole 112, a portion of the heel 104, a portion of the toe 106, or a combination thereof can be formed by a composite material. In such embodiments, the club head 100 can comprise one or more composite panels. In some embodiments, referring to FIG. 5, the club head 100 can comprise a crown panel 196 made of a composite material. The crown panel 196 can comprise a heel wrap 197a and a toe wrap 197b that wrap over the heel 104 and toe 106, respectively, and form portions of the sole 112. Further in some embodiments, the club head 100 can comprise a sole panel 198 forming at least a portion of the sole 112. In other embodiments, referring to FIG. 6, the club head 100 can comprise a central panel 199 that continuously wraps around the crown 110, sole 112, heel 104, toe 106, or various combinations thereof.

[0117] In some embodiments, the one or more composite panels can comprise a composite formed from a polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic resin. In some embodiments, the one or more composite panels can comprise a carbon fiber composite material having multiple layers of unidirectional carbon fibers formed as a single, continuous piece. In some embodiments, the one or more composite panels may comprise a bi-directional woven carbon fiber composite material having a single layer formed as a single, continuous piece. In some embodiments, the one or more composite panels can comprise a fiber reinforced thermo-plastic material. The one or more composite panels can be extruded, compression molded, injection molded, blow molded or bladder molded, 3-D printed, or otherwise formed by any other appropriate forming means.

[0118] The faceplate 114 comprises a faceplate material having sufficient strength to withstand repeated impacts with a golf ball. As such, the faceplate material comprises a greater yield strength than the body material and is thus more durable. In some embodiments, the faceplate material can be a high-strength steel alloy, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

[0119] In other embodiments, the faceplate material can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).

[0120] The faceplate material comprises a high yield strength. In some embodiments, the faceplate material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater than 230 ksi, greater than 240 ksi, or greater than 250 ksi. The faceplate material can comprise a higher yield strength than the body material. In some embodiments, the club head 100 comprises a faceplate strength ratio comparing the yield strength of the faceplate material to the yield strength of the body material. In some embodiments, the faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.

[0121] The club head body 101 and the faceplate 114 can be formed through one or a combination of manufacturing processes, such as casting, forging, metal injection molding, metal 3D printing, stamping, or any other well-known manufacturing processes. In some embodiments, the club head body 101 is cast, whereas the faceplate 114 is forged.III. Impact Response Modulator

[0122] The golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”) reinforced by high-strength material that increases strike face deflection at impact with a golf ball while maintaining sufficient durability. Referring to FIGS. 2 and 3, the IRM 120 is disposed in the sole 112. The IRM 120 strategically weakens the sole 112 to increase strike face deflection. The IRM 120 comprises a casing 130 surrounding an aperture 140 that is configured to receive an insert 170. As illustrated in FIG. 2, the IRM 120 extends in a substantially heel-to-toe direction across the sole 112 to increase strike face deflection.

[0123] The casing 130 is the structure that surrounds and forms the aperture 140. One or more portions of the casing 130 can be formed by a high-strength material component, such as a cartridge or an appendage. As illustrated in FIGS. 7 and 8, the casing 130 comprises a front wall 132 proximate the strike face 102, a rear wall 142 spaced rearward from the front wall 132, a heel wall 152 proximate the heel 104 and a toe wall 154 proximate the toe 106. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 of the casing collectively form and define the aperture 140 therebetween. The aperture 140 is a through-hole fluidly communicating between the club head exterior and the interior cavity. The front wall 132 comprises a front wall front surface 134 disposed towards the strike face 102, a front wall rear surface 136 disposed towards the aperture 140, a front wall base 133, and a front wall top surface 138 opposite the front wall base 133. The rear wall 142 comprises a rear wall front surface 144 disposed towards the aperture 140, a rear wall rear surface 146 disposed towards the rear 111, a rear wall base 143, and a rear wall top surface 148 opposite the rear wall base 143.

[0124] The casing 130 is spaced rearwardly from the strike face 102. As best illustrated in FIG. 8, the front wall 132 is separated from the strike face 102 by a forward sole region 166. The forward sole region 166 separates the front wall 132 from the strike face 102 by an offset distance OD, which is described in further detail below.

[0125] The forward sole region 166 balances durability and strike face deflection. If not for the forward sole region 166, the casing 130 and / or aperture 140 would directly abut the strike face 102. In such cases, the impact stress and in the casing 130 and the strike face 102 would be so high that the strike face 102 and / or the casing walls would need to be significantly thickened to preserve durability. Doing so would hinder strike face deflection such that any performance gains achieved by the inclusion of the IRM 120 would be lost or greatly diminished. Spacing the casing 130 rearward of the strike face 102 by the forward sole region 166 allows the strike face 102 and casing walls to be thinner and therefore increase strike face deflection. Specific casing geometries and specific casing wall dimensions are described in detail below.

[0126] The IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170 closes off the aperture 140 to prevent migration of debris into the interior chamber and can impact the performance of the IRM and durability of the club head. The insert 170 is configured to engage the casing walls, thereby securing the insert 170 within the casing 130. The material composition, overall construction, inclusion of hybrid materials, and geometry of the insert 170 can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert 170 and the casing 130 can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert 170 within the casing 130, even after repeated, violent impacts.

[0127] In some embodiments, the insert 170 entirely fills the aperture 140 with solid material between the casing front wall 132 and the casing rear wall 142. In some embodiments, the insert 170 can be hollowed out or provided with some other suitable geometry that creates a gap 171 or channel within the insert 170. For example, in some embodiments, as best illustrated in FIG. 16, the insert 170 can comprise a front wall 174, a rear wall 176, and a base 172, and takes a generally U-shaped appearance. The insert 170 may further comprise a rear extension 178 to increase bonding surface area. Various embodiments of the insert are discussed in further detail below.

[0128] To better understand the strategic locations at which high-strength material is used, the casing 130 can be divided up into multiple regions. The casing 130 can include a casing heel region 135 proximate the heel wall 152, a casing toe region 137 proximate the toe wall 154, and a casing center region 131 therebetween. The casing regions can help describe the location of various casing features and / or describe specific portions of the casing 130 that are reinforced by a high-strength material component in the various embodiments described below.

[0129] In some embodiments, the casing can comprise one or more reliefs that dissipate stress in the casing walls. The reliefs are portions of the casing that extend away from the strike face to dissipate stress. Generally, a significant portion of the casing 130, particularly at or near the casing center region 131, extends substantially equidistant to the strike face curvature, as best illustrated in FIG. 9. The relief(s) are angled rearward relative to the strike face 102. Referring to FIG. 9, the casing 130 comprises a toe relief 128 in the casing toe region 137 and a heel relief 129 in the casing heel region 135. The toe relief 128 and the heel relief 129 space the casing toe wall 154 and the casing heel wall 152, respectively, away from the strike face 102, such that the casing toe wall 154 and the casing heel wall 152 are further from the strike face 102 than the center of the casing 130. This spacing is advantageous because stress concentrations typically occur near the heel wall 152 and the toe wall 154, because the heel wall 152 and the toe wall 154 generally comprise tight curvatures. The toe relief 128 and the heel relief 129 reduce these concentrations by spacing the casing toe wall 154 and the casing heel wall 152, respectively, further from the strike face 102. The reliefs 128, 129 allow the casing 130 (and the aperture 140) to be lengthened without compromising durability, thereby increasing strike face deflection. The illustrated embodiment includes both a toe relief 128 and a heel relief 129. In other embodiments, the casing 130 can comprise only a toe relief 128 or only a heel relief 129. Specific relief geometries and dimensions are discussed in further detail below.

[0130] In some embodiments, the casing 130 can further comprise one or more end reinforcements 126, as best illustrated in FIG. 9. The end reinforcements 126 can be thickened portions of the sole 112 that surround one or more of the casing walls. In the illustrated embodiment, casing 130 comprises a heel end reinforcement 126a surrounding the heel wall 152 and a toe end reinforcement 126b surrounding the toe wall 154. The end reinforcements 126a, 126b are concentrations of club head mass with a substantially greater thickness TER than the surrounding casing walls. As illustrated in FIG. 5, the toe end reinforcement 126b can comprise an end reinforcement thickness TER measured between the casing toe wall 154 and an outer surface of the toe end reinforcement 126b, the measurement taken perpendicularly to the casing toe wall 154. Similarly, the heel end reinforcement 126a can comprise an end reinforcement thickness TER measured between the casing heel wall 152 and an outer surface of the heel end reinforcement 126a, the measurement taken perpendicularly to the casing heel wall 152. In some embodiments, the end reinforcement thickness TER can be between 0.25 inch and 0.75 inch. In some embodiments, the end reinforcement thickness TER can be greater than 0.25 inch, greater than 0.30 inch, greater than 0.35 inch, greater than 0.40 inch, greater than 0.45 inch, greater than 0.50 inch, greater than 0.55 inch, greater than 0.60 inch, greater than 0.65 inch, or greater than 0.70 inch. In some embodiments the end reinforcement thickness TER is between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, or between 0.65 and 0.70 inch, between 0.70 and 0.75 inch.

[0131] Similar to the reliefs 128, 129, the end reinforcements 126a, 126b reduce stress concentrations occurring in the heel wall 152 and the toe wall 154, respectively, thereby increasing overall casing durability. Although the end reinforcements 126a, 126b are concentrations of club head mass located on the casing walls, they are located towards the heel 104 and the toe 106 and thus do not hinder strike face deflection. In the illustrated embodiment, the end reinforcements 126a, 126b are generally circular in shape. In other embodiments, the end reinforcements 126a, 126b can be any suitable shape for reducing stress near the heel wall 152 and the toc wall 154. The end reinforcements 126a, 126b can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. The illustrated embodiment includes both a heel end reinforcement 126a and a toe end reinforcement 126b. In other embodiments, the casing 130 can comprise a heel end reinforcement 126a, a toe end reinforcement 126b, or both. Specific relief geometries and dimensions are discussed in further detail below.

[0132] In some embodiments, the casing 130 can further comprise one or more front wall reinforcements 139, as best illustrated in FIG. 10. The front wall reinforcements 139 can be thickened portions of casing front wall 132. In the illustrated embodiment, the casing 130 comprises a front wall reinforcement 139 located in the casing center region 131. The front wall reinforcements 139 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. Similar to the end reinforcements 126a, 126b, the front wall reinforcements 139 reduce stress concentrations occurring in the front wall 132, thereby increasing overall casing 130 durability. In the illustrated embodiment, a single front wall reinforcement 139 is generally located in the center region 131. In other embodiments, the front wall reinforcements 139 can be located in the heel region 135, in the toe region 137, or in any combination of central, heel, and toe regions 131, 135, 137. The front wall reinforcements 139 can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. Specific front wall reinforcement 139 geometries and their relation to the overall front wall thickness FWT are discussed in further detail below.

[0133] In many embodiments, the casing 130 comprises a casing recess 182 that retains the insert 170 and increases strike face deflection. In the illustrated embodiment of FIG. 11, the casing recess 182 is located at the rear wall base 143. The casing recess 182 includes a seating surface 184 that is inset from an exterior surface 109 of the sole 112 by a rising surface 183. The casing recess 182 can be in direct communication with the aperture 140. The casing recess 182 forms a lap joint configured to receive one or more portions of the insert 170, as described in further detail below. Although the casing recess 182 of the illustrated embodiment is located only at the rear wall base 143, in other embodiments, the casing recess 182 can also be formed at the front wall base 133. In some embodiments, the casing recess 182 extends around and entirely circumscribes the aperture 140.

[0134] The casing recess 182 removes mass from the rear wall base 143, thereby increasing the amount the rear wall 142 and the sole 112 bend at impact. In some embodiments, the casing recess 182 defines a recess depth DR measured between the exterior surface of the sole 112 and the seating surface 184. Increasing the recess depth DR will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, increasing the recess depth DR also potentially increases stress in the casing 130. The recess depth DR can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the recess depth DR can be between 0.1 and 0.75 inch. For example, in some embodiments, the recess depth DR can be between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, between 0.20 and 0.25 inch, between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, between 0.65 and 0.70 inch, or between 0.70 and 0.75 inch.

[0135] In alternative embodiments, rather than a lap joint configuration including a rising surface and a seating surface, the casing recess 182 can comprise a bevel. As best illustrated in FIG. 12, the casing recess 182 defines a beveled surface 185 that gradually slopes between the exterior surface 109 of the sole 112 and the rear wall front surface 144 and / or the front wall rear surface 136. Rather than a recess depth, the beveled surface 185 can comprise a bevel angle αB defined between the exterior surface 109 of the sole 112 and the beveled surface 185. A greater bevel angle αB, will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, a greater bevel angle αB also potentially increases stress in the casing 130. The bevel angle αB can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the bevel angle αB can be between 5 and 60 degrees. For example, in some embodiments, the bevel angle αB can be between 5 and 10 degrees, between 10 and 16 degrees, between 16 and 21 degrees, between 21 and 27 degrees, between 27 and 32 degrees, between 32 and 38 degrees, between 38 and 43 degrees, between 43 and 49 degrees, between 49 and 54 degrees, or between 54 and 60 degrees.

[0136] In some embodiments, the casing can form one or more retainers configured to engage the insert without restricting strike face flexure. In some embodiments, the retainers can be one or more tabs 4545, as best illustrated in FIG. 13. The tabs 4545 are part of the casing 4530 and are configured to engage the insert 4550 and facilitate installation of the insert 4550 to the proper location within the aperture 4540, without contributing significant mass. In the illustrated embodiment, the tabs 4545 are small, distinct protrusions that extend rearward from the casing front wall 4532 into the aperture 4540. The tabs 4545 overhang at least part of the aperture 4540 and terminate at cantilevered ends that are suspended in or overhang the aperture 4540. As illustrated in FIG. 14, the tabs 4545 extend over and overlap at least a portion of the insert 4550. When the insert 4550 is installed from the sole 4512, the tabs 4545 create a mechanical stop that engages the insert top surface 4588 and prevents the insert 4550 from being pushed through the aperture 4540 and into the interior cavity.

[0137] In some embodiments, referring to FIG. 14, the tabs 4545 can protrude above the front wall top surface 4538 and rearward over at least a portion of the aperture 4540. The tabs 4545 can each comprise a tab underside surface 4549 that is substantially flush with the front wall top surface 4538. In such embodiments, the tabs 4545 do not extend into the aperture 4540 itself, but rather overhang the aperture 4540. In some embodiments, one or more tabs 4545 can extend forward from the casing rear wall 4542 into the aperture 4540, rather than extending from the casing front wall 4532.

[0138] As described above, the one or more tabs 4545 are small, distinct protrusions that do not contribute a significant amount of mass to the casing walls, nor do they prohibit strike face deflection. Referring to FIG. 15, the tabs 4545 can comprise a tab width WT measured between lateral surfaces of the tab 4545 in a direction parallel to the front wall rear surface 4536. In some embodiments, the tab width WT can be between 0.05 inch and 0.25 inch. In some embodiments, the tab width WT can be between 0.05 and 0.10 inch, between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, or between 0.20 and 0.25 inch. The tabs 4545 can also comprise a tab depth DT measured perpendicularly from the front wall rear surface 4536 to the end of the tab 4545. The tab depth Dr represents the amount the tab 4545 extends across the aperture 4540. The tabs 4545 extend only partially across the aperture 4540. In some embodiments, the tab depth DT can be between 0.05 inch and 0.25 inch. In some embodiments, the tab depth Dr can be between 0.05 and 0.10 inch, between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, or between 0.20 and 0.25 inch.

[0139] Additionally, in some embodiments, the insert 4550 can also comprise one or more retainers configured to engage the tabs 4545 and more precisely locate the insert 4550 in its intended position. The insert 4550 can comprise one or more pockets 4594 recessed into the insert top surface 4588. The pockets 4594 can be shaped complementarily to the tabs 4545 such that when the insert 4550 engages the tabs 4545, the tabs 4545 fit into the corresponding pockets 4594 and align the insert 4550. The pockets 4594 improve insert retention over the tabs that simply rest on the insert top surface 4588 by preventing lateral insert movement within the aperture 4540. In such embodiments, rather than overhanging the aperture 4540, the tabs 4545 can extend into the aperture 4540 itself to engage the insert 4550 disposed therein. In some embodiments, as illustrated in FIG. 15, the tabs 4545 may not extend above the front wall top surface 4538. Instead, each of the tabs 4545 can comprise a tab upper surface 4547 that is flush with the front wall top surface 4538.

[0140] The tabs 4545 can provide unique advantages over other solutions for mechanically the insert 4550. For example, some embodiments of lap joints or bevels form mechanical stops by removing mass from the casing walls. In some of these embodiments, this mass removal can potentially create stress concentrations that require other portions of the casing walls to be thickened, thereby diminishing strike face deflection and creating an uneven response in the IRM. In contrast, the tabs 4545 are freely suspended in or over the aperture 4540 and thus are configured such that they do not significantly affect casing wall deflection.

[0141] In some embodiments, the faceplate 114 comprises one or more return portions that are used in combination with the IRM 120 to increase strike face deflection. The return portions are portions of the faceplate 114 that wrap over the strike face perimeter and form other forward portions of the club head 100, such as forward portions of the crown 110, sole 112, heel 104, or toe 106. The return portions replace these portions of the club head 100, which typically experience high impact stresses and would otherwise be formed of the body material, with the high-strength faceplate material. This allows these areas of the club head 100 to be thinned without sacrificing durability, thereby increasing strike face deflection.

[0142] The one or more return portions can be described in relation to the faceplate perimeter 155, which is the outermost edge of the faceplate 114 that couples to the body 101 and / or other club head components. Referring to FIG. 17, in some embodiments, the faceplate 114 comprises a crown return 115 that wraps over the transition from the strike face 102 to the crown 110, thereby to form a forward portion of the crown 110. In embodiments comprising a crown return 115, the faceplate top edge 160 is located on the crown 110 and not on the strike face 102. Similarly, in other embodiments such as that illustrated in FIG. 19, the faceplate 114 can comprise a toe return 161, wrapping over the transition between the strike face 102 and the toe 106, thereby to form a forward portion of the toe 106. In embodiments comprising a toe return 161, the faceplate toe edge 159 is located on the toe 106 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a sole return (discussed in further detail below) that wraps over the leading edge 103 and forms a forward portion of the sole 112, wherein the faceplate bottom edge 157 is located on the sole 112 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a heel return (discussed in further detail below) that wraps over the transition between the strike face 102 and the heel 104, thereby to form a forward portion of the heel 104, wherein the faceplate heel edge 158 is located on the heel 104 and not on the strike face 102. The faceplates described herein can comprise a crown return, a heel return, a toe return, or any combination thereof. Specific return combinations and configurations are discussed in detail below.

[0143] In some embodiments, the club head 100 can comprise a “reverse L-cup” faceplate 114, as best illustrated in FIGS. 17 and 18. The reverse L-cup faceplate 114 can comprise a crown return 115 yet be devoid of a sole return. As such, the reverse L-cup faceplate 114 comprises a faceplate top edge 160 that is located on the crown 110. The faceplate bottom edge that is located on the strike face 102, above the leading edge 103. The reverse L-cup faceplate 114 does not extend to or wrap over the leading edge 103, nor does the reverse L-cup faceplate 114 form any portion of the sole 112. Due to the absence of a sole return, the body 101 of the illustrated embodiment forms a forward portion of the sole 112 as well as the entire casing 130.

[0144] The crown return increases durability and performance by reinforcing (via the high-strength faceplate material) the transition between the strike face 102 and the crown 110 and forward portions of the crown 110, which are both areas that experience impact stresses. Further, the reverse L-cup faceplate 114 simplifies manufacture. The lack of a sole return in the reverse L-cup faceplate 114 enables the complex casing geometries to be easily cast out of body material. The IRM 120 and the crown return 115 work in conjunction to increase strike face deflection without sacrificing durability. In particular, the IRM 120 increases sole flexibility, whereas the crown return 115 increases crown flexibility.

[0145] In some embodiments, such as the illustrated embodiment of FIGS. 17 and 18, the reverse L-cup faceplate 114 comprises a crown return 115, but no heel return or toe return. However, in other embodiments, the reverse L-cup faceplate 114 can further comprise a toe return 161, as illustrated in FIG. 19. In such embodiments, the faceplate toe edge 159 is located on the toe 106. The toe return 161 further increases durability by reinforcing the transition between the strike face 102 and the toe 106. The toe return 161 thereby allows portions of the toc 106 to be thinned without exceeding the yield strength of the high-strength faceplate material. The reverse L-cup faceplate 114 with both a crown return 115 and a toe return 161 increases strike face deflection over a reverse L-cup faceplate 114 with only a crown return 115. In some embodiments, referring to FIG. 19, the faceplate toe edge 159 can run substantially parallel to the strike face 102. In other embodiments, as best illustrated in FIG. 20, the faceplate toe edge 159 can be divided into a toe edge sole segment 159a that extends in a substantially horizontal direction parallel to the sole 112 and a toe edge crown segment 159b that extends in a substantially vertical direction perpendicular to the sole 112. This configuration simplifies manufacture by smoothing the transition between the toe edge sole segment 159a and the faceplate bottom edge 157 and the transition between the toe edge crown segment 159b and the faceplate top edge 160.

[0146] The IRM 120 delofts the strike face 102 at impact. This delofting effect reduces stress in the crown 110, thereby allowing the crown 110 to be thinned without sacrificing durability. In some embodiments, as shown in FIGS. 21 and 22, the crown return 115 further comprises an indentation 141. The indentation 141 is recessed into an interior surface of the crown return 115. The indentation 141 is a region of reduced thickness relative to the remainder the crown return 115. In the illustrated embodiment, the indentation 141 is isolated within the crown return 115, such that the indentation perimeter 194 is located entirely within the bounds of the crown return 115. The indentation 141 increases strike face deflection without compromising faceplate durability. The indentation 141 can increase ball speed by upwards of 0.5 mph (without compromising durability) over a club head comprising a crown return without an indentation. Specifically, the indentation 141 strategically weakens the forward portion of the crown 110, thereby increasing the amount the crown 110 deflects upward at impact. This increased upward crown deflection in turn increases the amount of strike face deflection. Because the indentation 141 is isolated within the crown return 115, this additional deflection can occur without exceeding the yield strength of the high-strength faceplate material.

[0147] The indentation 141 comprises an indentation thickness TI that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indentation thickness TI can be between 0.005 and 0.020 inch, whereas the crown return thickness TCR can be between 0.020 and 0.050 inch. In some embodiments, the indentation thickness TI can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return 115 can comprise an indentation thickness ratio TI / TCR defined as the indentation thickness TI divided by the crown return thickness TCR. In some embodiments, the indentation thickness ratio TI / TCR can be less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1.

[0148] In the illustrated embodiment, the indentation 141 is located approximately in the center of the crown return 115 and extends in a generally heel-toe direction. In other embodiments, the indentation can be offset towards to the toe 106 or towards the heel 104. In the illustrated embodiment, the indentation 141 has an approximately rectangular shape. In other embodiments, the indentation 141 can have other shapes such as an elongated oval or an arcuate shape.

[0149] The casing embodiments described herein can comprise one or more of the casing features described above. In particular, any casings formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof can include any combination of reliefs, end reinforcements, casing recesses, or returns.IV. Impact Response Modulator with High-Strength Material Reinforcement

[0150] As described above, a high-strength component forms at least part of the casing. In some embodiments, the faceplate forms part or all of the casing, whereas in other embodiments, a separate, high-strength material component (such as a cartridge or an appendage) forms part or all of the casing. The high-strength material reinforces the casing, increasing strike face deflection without compromising durability. Specifically, design choices that increase strike face deflection, such as decreasing front wall offset, increasing the casing length, or shortening or thinning the front wall, can be implemented without exceeding the high-strength material's yield strength, thereby maintaining durability.

[0151] The club heads described below include an IRM having high-strength material while improving or simplifying manufacture. In general, high-strength components with complex geometries are difficult to manufacture, particularly by forging. In general, a monolithically forged component can have no more than two “bends” in a given cross-section, wherein a “bend” refers to adjacent surfaces or portions of the component being significantly angled relative to each other. For example, a monolithically forged faceplate can have no more than two bends in a vertical (i.e., crown-to-sole) cross section and no more than two bends in a horizontal (i.e., heel-to-toe) cross section. Components with more than two bends in given cross section may not provide sufficient clearance for a forging tool to be removed post-manufactured.

[0152] As described above, in some embodiments, the faceplate can comprise a crown return, a heel return, or a toe return to reinforce portions of the crown, heel, or toe, respectively, to improve strike face deflection. However, due to the manufacturing constraints discussed above, it can be difficult or impossible to monolithically forge a faceplate with a crown return, heel return, or toe return if the faceplate also forms a sole return and one or more casing geometries. Such an embodiment would exceed the maximum number of two bends in a single cross-section. Some embodiments of the IRM described herein comprise faceplates and / or other high-strength material components having complex geometries that are capable of being manufactured by forging or other processes by selectively placing high-strength material and strategically combining monolithic faceplate geometries (i.e., crown returns, sole returns, toe returns, heel returns, and casing geometries).A. Body and Faceplate Forming the Casing

[0153] In some embodiments, the faceplate and the body combine to form the casing. The embodiments described below with reference to FIGS. 23-30 include a faceplate that combines with the body to form the casing and reinforce the casing with high-strength faceplate material (having a yield strength above 175 ksi). The faceplate reduces stress in the casing walls, allowing the casing walls to have reduced thickness, reduced length, or being located closer to the strike face, thereby increasing strike face deflection without compromising durability. The embodiments described below increase strike face deflection while maintaining sufficient club head durability and overall manufacturability. The faceplates have relatively simple designs (including two or less bends in a given cross-section) that are suitable for monolithic forging while still reinforcing areas of the casing. Any other complex casing geometries can be cast out of the body material.

[0154] In some embodiments, the club head 700 can comprise an “L-cup” faceplate 714 that reinforces the casing 730. As best illustrated in FIG. 23, the L-cup faceplate 714 comprises a sole return 716 that extends rearward from the strike face 702 and forms a forward portion of the sole 712. The sole return 716 is coupled to the body 701 at a sole return rear edge 757. The sole return 716 terminates at the front wall base 733, such that the sole return rear edge 757 is forward of the casing front wall 732. The L-cup faceplate 714, therefore, does not form any portion of the casing front wall 732 or the casing rear wall 742, nor does it form any portion of the aperture 740. In the illustrated embodiment, both the casing front wall 732 and the casing rear wall 742 are integral with the body 701. The body 701 therefore encapsulates and defines the entire aperture 740.

[0155] In some embodiments, the sole return 716 can extend along the entirety of the casing front wall 732. In other embodiments, the sole return 716 can extend along less than the entirety length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 40%, between 30% and 45%, between 35% and 50%, between 40% and 55%, between 45% and 60%, between 50% and 65%, between 55% and 70%, between 60% and 75%, between 65% and 80%, between 70% and 85%, between 75% and 90%, between 80% and 95%, or between 85% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 is located only in the casing center region to locally reinforce areas of the casing 730 that typically experience the greatest deflection and the highest impact stresses.

[0156] The L-cup faceplate 714 is readily manufacturable and reinforces the casing 730. The sole return 716 reinforces high-stress areas of the sole 712 immediately in front of the casing front wall 732 with high-strength material. The L-cup faceplate 714 is easily forged, because it does not include any of the complicated casing wall geometries. The L-cup faceplate 714 comprises only a single bend in the vertical cross-section, located at the juncture between the strike face 702 and the sole return 716. The casing walls, which are integral with the body 701, can be easily cast out of the body material. At impact, the L-cup faceplate 714, specifically the sole return 716, deflects with the portion of the sole 712 immediately in front of the casing front wall 732, which in turn increases strike face deflection.

[0157] In some embodiments, the club head 800 can comprise a “J-cup” faceplate 814 that reinforces the casing front wall 832. As best illustrated in FIG. 24, the J-cup faceplate 814 comprises a sole return 816 that extends rearward from the strike face 802. In comparison to the sole return 716 of the L-cup faceplate 714, which only forms a forward portion of the sole 712, the sole return 816 forms both a forward portion of the sole 812 and the casing front wall 832. The J-cup faceplate 814, forms no portion of the casing rear wall 842. As such, the casing front wall 832 can be integral with the J-cup faceplate 814, whereas the casing rear wall 842 can be integral with the body 801. In this configuration, the J-cup faceplate 814 and the body 801 combine to form the aperture 840 therebetween.

[0158] In some embodiments, the sole return 816 can form the entire casing front wall 832. In other embodiments, the sole return 816 forms only a portion of the casing front wall 832. As best illustrated in FIG. 25, the casing front wall 832 comprises a support segment 868 that is integral with the J-cup faceplate 814 and a core segment 869 that is integral with the body 801. The support segment 868 is the portion of the casing front wall 832 formed by the J-cup faceplate 814, whereas the core segment 869 is the portion of the casing front wall 832 formed by the body 801.

[0159] In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall front surface 834. For example, in some embodiments, the support segment 868 can form between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 834. In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall rear surface 836. For example, in some embodiments, the support segment 868 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall rear surface 836.

[0160] In some embodiments, such as the illustrated embodiment of FIG. 25, support segment 868 is located primarily in the casing center region 831, and the core segment 869 is located primarily in the casing heel region 835 and the casing toe region 837. In the present configuration, the sole return 816 locally reinforces the casing center region 831, where the greatest deflection and highest impact stresses typically occur. In other embodiments, the support segment 868 and the core segment 869 can have alternate configurations. For example, the support segment 868 can be located primarily in the casing center region 831, the casing heel region 835, the casing toe region 837, or any combination thereof.

[0161] In embodiments where the sole return 816 forms only a portion of the casing front wall 832, the sole return 816 can span a lesser distance in a heel-to-toe direction than the aperture 840. As illustrated in FIG. 25, the sole return 816 comprises a sole return width WSR measured in a heel-to-toe direction from the sole return heel edge 858 to the sole return toe edge 859. In some embodiments, the sole return width WSR is less than the total length TL of the aperture 840 (defined below).

[0162] The J-cup faceplate 814 is readily manufacturable and reinforces the casing 830. The sole return 816 reinforces high-stress areas of the casing front wall 832 with high-strength material. In some embodiments, the J-cup faceplate 814 can be monolithically forged, because it does not include any overly complicated geometries. Referring to FIG. 24, the J-cup faceplate 814 comprises only two bends in the vertical cross-section. The J-cup faceplate 814 comprises a first bend at the juncture between the strike face 802 and the sole return 816 and a second bend at the juncture between the sole 812 and the casing front wall 832. In the illustrated embodiment, the J-cup faceplate 814 is devoid of a crown return. The introduction of a crown return to the J-cup faceplate 814 would add a third bend at the juncture between the strike face 802 and the crown 810, making the J-cup faceplate geometry too complicated for monolithic forging. At impact, the J-cup faceplate 814, specifically the sole return 816, deflects with the casing front wall 832, which in turn increases strike face deflection.

[0163] In some embodiments, the club head 900 can comprise a “partial J-cup” faceplate 914 that reinforces the casing front wall 932. As best illustrated in FIG. 26, the partial J-cup faceplate 914 comprises a sole return 916 that extends rearward from the strike face 902. The sole return 916 forms both a forward portion of the sole 912 and a portion of the casing front wall 932. Specifically, the sole return 916 forms the front wall front surface 934 of the casing 930, but not the front wall rear surface 936. In contrast to the J-cup faceplate 814, which forms the entire casing front wall 832, the partial J-cup faceplate 914 forms only a portion of the front wall thickness FWT. The front wall front surface 934 is therefore integral with the partial J-cup faceplate 914. Similar to the J-cup faceplate 814 illustrated in FIG. 24, the partial J-cup faceplate 914 forms no portion of the casing rear wall 942. As such, both the front wall rear surface 936 and the rear wall 942 of the casing 930 can be integral with the body 901. The partial J-cup faceplate 914 therefore forms no portion of the aperture 940 and the aperture 940 is entirely encapsulated within the body 901.

[0164] In some embodiments, the sole return 916 can form the entire front wall front surface 934 of the casing 930. In other embodiments, the sole return 916 forms only a portion of the front wall front surface 934. As best illustrated in FIG. 27, The casing front wall 932 comprises a support segment 968 that is integral with the partial J-cup faceplate 914 and a core segment 969 that is integral with the body 901. The support segment 968 is the portion of the casing front wall 932 formed by the partial J-cup faceplate 914, whereas the core segment 969 is the portion of the casing front wall 932 formed by the body 901.

[0165] In some embodiments, the support segment 968 forms between 25 and 100% of a surface area of the front wall front surface 934. For example, in some embodiments, the support segment 968 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 934. In some embodiments, the support segment 968 forms no portion of the front wall rear surface 936. In contrast to the core segment 869 of the J-cup faceplate 814, which only forms portions of the front wall rear surface 836, the core segment 969 of the partial J-cup faceplate 914 forms the entire front wall rear surface 936.

[0166] In some embodiments, such as the illustrated embodiment of FIG. 27, support segment 968 is located primarily in the casing center region 931. In such embodiments, the core segment 969 forms the entire casing front wall 932 in the casing heel region 935 and the casing toe region 937. In the present configuration, the sole return 916 locally reinforces the casing center region 931, where the greatest deflection and high impact stresses typically occur. In other embodiments, the support segment 968 and the core segment 969 can have alternate configurations. For example, the support segment 968 can be located primarily in the casing center region 931, the casing heel region 935, the casing toe region 937, or any combination thereof.

[0167] In embodiments where the sole return 916 forms only a portion of the casing front wall 932, the sole return 916 can span a lesser distance in a heel-to-toe direction than the aperture 940. As illustrated in FIG. 27, the sole return width WSR is less than the total length TL of the aperture 940 (defined below).

[0168] The partial J-cup faceplate 914 is readily manufacturable and reinforces the casing 930. The sole return 916 reinforces high-stress areas of the casing front wall 932 with high-strength material. In some embodiments, the partial J-cup faceplate 914 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 26, the partial J-cup faceplate 914 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814, the partial J-cup faceplate 914 comprises a first bend at the juncture between the strike face 902 and the sole return 816 and a second bend at the juncture between the sole 912 and the casing front wall 932. In the illustrated embodiment, the partial J-cup faceplate 914 is devoid of a crown return. The introduction of a crown return to the partial J-cup faceplate 914 would add a third bend at the juncture between the strike face 902 and the crown, making the partial J-cup faceplate geometry too complicated for monolithic forging. At impact, the partial J-cup faceplate 914, specifically the sole return 916, deflects with the front wall front surface 934, which in turn increases strike face deflection. This contrasts to the J-cup faceplate 814 described above, which deflects with the entire casing front wall 832.

[0169] In some embodiments, the club head 1100 can comprise an “underlapping J-cup” faceplate 1114 that reinforces the casing front wall 1132. As best illustrated in FIG. 28, the underlapping J-cup faceplate 1114 comprises a sole return 1116 that extends rearward from the strike face 1102. The sole return 1116 forms both a forward portion of the sole 1112 and a portion of the casing front wall 1132. The sole return 1116 comprises a faceplate lap 1118 that extends upwards at the rear end of the sole return 1116 to form the front wall rear surface 1136. The body 1101 comprises a body lap 1119 that overlaps the faceplate lap 1118 and forms the front wall front surface 1134. Together, the faceplate lap 1118 and the body lap 1119 combine to form the casing front wall 1132. The underlapping J-cup faceplate 1114 therefore forms only a portion of the front wall thickness. The front wall rear surface 1136 is integral with the underlapping J-cup faceplate 1114, whereas the front wall front surface 1134 is integral with the body 1101. As such, the underlapping J-cup faceplate 1114 contrasts with the partial J-cup faceplate 914, which forms the front wall front surface 934 but not the front wall rear surface 936. Similar to the J-cup faceplate 814 illustrated in FIG. 24, the casing rear wall 1142 is integral with the body 1101, and the underlapping J-cup faceplate 1114 forms no portion of the casing rear wall 1142. As such, both the front wall front surface 1134 and the rear wall 1142 of the casing 1130 can be integral with the body 1101. In this configuration, the underlapping J-cup faceplate 1114 and the body 1101 combine to form the aperture 1140 therebetween.

[0170] In some embodiments, the sole return 1116 can form the entire front wall rear surface 1136 of the casing 1130. In other embodiments, the sole return 1116 forms only a portion of the front wall rear surface 1136. For example, in some embodiments, as illustrated in FIG. 28, the body lap 1119 includes a cap 1117 that covers the top end of the faceplate lap 1118. The cap 1117 thereby forms the entire front wall top surface 1138 and an upper end of the front wall rear surface 1136. Further, in some embodiments, the faceplate lap 1118 does not extend along the entirety of the front wall rear surface 1136. As best illustrated in FIG. 29, the casing front wall 1132 comprises a support segment 1168 that is integral with the underlapping J-cup faceplate 1114 and a core segment 1169 that is integral with the body 1101. The support segment 1168 is the portion of the casing front wall 1132 formed by the underlapping J-cup faceplate 1114, whereas the core segment 1169 is the portion of the casing front wall 1132 formed by the body 1101.

[0171] In some embodiments, the support segment 1168 forms between 25 and 100% of a surface area of the front wall rear surface 1136. For example, in some embodiments, the support segment 1168 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall rear surface 1136. In some embodiments, the support segment 1168 forms no portion of the front wall front surface 1134. The core segment 1169 of the underlapping J-cup faceplate 1114 forms the entire front wall front surface 1134. This contrasts with the core segment 969 of the partial J-cup faceplate 914 described above, which forms the entire front wall rear surface 1136.

[0172] In some embodiments, such as the illustrated embodiment of FIG. 29, support segment 1168 is located primarily in the casing center region 1131. In such embodiments, the core segment 1169 forms the entire casing front wall 1132 in the casing heel region 1135 and the casing toe region 1137. In the present configuration, the sole return 1116 locally reinforces the casing center region 1131, where the greatest deflection and high impact stresses typically occur. In other embodiments, the support segment 1168 and the core segment 1169 can have alternate configurations. For example, the support segment 1168 can be located primarily in the casing center region 1131, the casing heel region 1135, the casing toe region 1137, or any combination thereof.

[0173] In embodiments where the sole return 1116 forms only a portion of the casing front wall 1132, the sole return 1116 can span a lesser distance in a heel-to-toe direction than the aperture 1140. As illustrated in FIG. 22, the sole return width WsR is less than the total length TL of the aperture 1140.

[0174] The underlapping J-cup faceplate 1114 is readily manufacturable and reinforces the casing 1130. The sole return 1116 reinforces high-stress areas of the casing front wall 1132 with high-strength material. In some embodiments, the underlapping J-cup faceplate 1114 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 21, the underlapping J-cup faceplate 1114 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814 and the partial J-cup faceplate 914, the underlapping J-cup faceplate 1114 comprises a first bend at the juncture between the strike face 1102 and the sole return 1116 and a second bend at the juncture between the sole 1112 and the faceplate lap 1118. In the illustrated embodiment, the underlapping J-cup faceplate 1114 is devoid of a crown return. The introduction of a crown return to the underlapping J-cup faceplate 1114 would add a third bend at the juncture between the strike face 1102 and the crown, making the underlapping J-cup faceplate geometry too complicated for monolithic forging. At impact, the underlapping J-cup faceplate 1114, specifically the faceplate lap 1118, deflects with the front wall rear surface 1136, which in turn increases strike face deflection. This contrasts with the partial J-cup faceplate 914, which deflects with the front wall front surface 1134.

[0175] In some embodiments, the club head 1200 comprises a faceplate 1214 with one or more bridges 1249 that further reinforce the casing 1230 without compromising strike face deflection. As best illustrated in FIG. 30, the faceplate 1214 comprises a sole return 1216 that extends rearward from the strike face 1202. The sole return 1216 forms both a forward portion of the sole 1212 as well as the casing front wall 1232. As such, the casing front wall 1232 is integral with the faceplate 1214. The faceplate 1214 further comprises one or more bridges 1249 that span the aperture 1240 in a face-to-rear direction. The bridges 1249 connect the front wall 1232 and the rear wall 1242 of the casing 1230. In the illustrated embodiment, the bridges 1249 connect the front wall top surface 1238 and the rear wall top surface 1244. In other embodiments, the bridges 1249 can connect other portions of the front wall 1232 and the rear wall 1242. In some embodiments, the bridges can connect the front wall base 1233 to the rear wall base 1243. In other embodiments, the bridges 1249 can connect portions of the front wall 1232 and the rear wall 1242 in between the top surfaces 1238, 1244 and the bases 1233, 1243. The faceplate 1214 can comprise any suitable number of bridges 1249 for reinforcing the casing walls 1232, 1242. In some embodiments, the faceplate can comprise one, two, three, four, five, six, seven, eight, nine, or any suitable number of bridges 1249. In some embodiments, the bridges 1249 are monolithically formed with the faceplate 1214. In other embodiments, the bridges 1249 can be separately formed from the faceplate 1214 and subsequently attached thereto, such as by welding.

[0176] The bridges 1249 can be located at strategic locations to locally reinforce the casing 1230. In some embodiments, the bridges 1249 are located within the casing center region 1231. For center strikes, the greatest deflection and highest impact stresses occur within the casing center region 1231. Placing one or more bridges 1249 in the casing center region 1231 reinforces the casing 1230 in these high-stress areas to improve durability without hindering strike face deflection.

[0177] In the illustrated embodiment, the casing front wall 1232 and the bridges 1249 are both integral with the faceplate 1214, and the casing rear wall 1242 is integral with the body 1201. In such embodiments, the bridges 1249 can be welded or otherwise coupled to the body 1201. In such embodiments, the faceplate 1214 and the body 1201 combine to form the aperture 1240. In other embodiments, the casing front wall 1232, the bridges 1249 and the casing rear wall 1242 are all integral with the faceplate 1214. In such embodiments, the faceplate 1214 entirely encapsulates the aperture 1240. At impact, the faceplate 1214 with one or more bridges 1249 bends with the casing 1230. Specifically, the sole return 1216 bends with the casing front wall 1232. As the casing walls bend towards each other, the bridges 1249 are compressed by the casing walls and return a stiffening force back to the casing walls. The stiffening force allows the casing walls to bend further than they otherwise would in the absence of bridges, thereby increasing strike face deflection.B. Cartridge Forming the Casing

[0178] In some embodiments, the club head 1400 comprises a component separate from the faceplate and body, such as a cartridge 1450, that integrally forms at least a portion of the casing 1430. Referring to FIGS. 31 and 32, the cartridge 1450 is a component distinct from the faceplate 1414 that is attached to the faceplate 1414, the body 1401, or both. Although the cartridge 1450 and the faceplate 1414 are both high-strength material components, they are not the same component. The cartridge 1450 integrally forms at least a portion of the casing 1430, including the front wall 1432 and the rear wall 1442. The cartridge 1450 is formed of a high-strength cartridge material that is more durable than the body material. As such, the cartridge 1450 reinforces the IRM 1420 and increases strike face deflection without compromising durability. In some embodiments, the cartridge 1450 houses and forms the entire casing 1430. In other embodiments, the cartridge 1450 forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 but may not form the entire casing 1430. In such embodiments, the cartridge 1450 locally reinforces the casing 1430 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1431 experiences greater deflection and higher impact stresses than the casing heel region 1435 or the casing toc region 1437. In such embodiments, the cartridge 1450 may form and reinforce the casing center region 1431. The casing heel region 1435 and the casing toe region 1437 may not require the same level of reinforcement and can therefore be formed by the body 1401, which comprises a lower-strength material.

[0179] The cartridge 1450 reinforces the IRM 1420 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1430, the cartridge 1450 is a separate, high-strength material component that forms and reinforces the casing 1430. Because the faceplate 1414 does not form any part of the complicated casing geometry, the cartridge 1450 can be combined with a faceplate 1414 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration not only reinforces the IRM 1420 but also reinforces other portions of the club head 1400 to further increase strike face deflection, as the returns (i.e., the crown return, sole return, heel return, or sole return) can have a reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process, (such as welding) between the cartridge 1450 and the faceplate 1414 or body 1401 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0180] In some embodiments, the separately formed cartridge 1450 is attached to both the faceplate 1414 and the body 1401 and houses at least a portion of the casing 1430. In the illustrated embodiment of FIG. 25, the cartridge 1450 is located in a forward portion of the sole 1412. The cartridge 1450 comprises a cartridge perimeter 1455 that includes a cartridge forward edge 1456 that couples to the faceplate 1414 and a cartridge rear edge 1457 that couples to the body 1401. In some embodiments, as illustrated in FIG. 32, the faceplate 1414 comprises a sole return 1416 extending rearward from the strike face 1402 and the cartridge forward edge 1456 couples to the sole return 1416. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the sole 1412. The cartridge 1450 is thereby located entirely within the sole 1412.

[0181] In alternative configurations, rather than the cartridge 1450 being located entirely within the sole 1412, the cartridge 1450 can partially extend onto the strike face 1402, as best illustrated in FIG. 33. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the strike face 1402. The faceplate 1414 can be devoid of a sole return 1416 and the cartridge 1450 can wrap over the leading edge 1403 and form a lower portion of the strike face 1402. In both embodiments, the cartridge 1450 forms at least a portion of the sole 1412.

[0182] In the embodiment illustrated in FIGS. 31 and 32, the cartridge 1450 houses the entire casing 1430, thereby reinforcing the entire casing 1430 with high-strength material. The cartridge perimeter 1455 is continuously attached to either the faceplate 1414 or the body 1401 in this embodiment, such that there are no unattached cartridge edges. In such embodiments, the cartridge 1450 forms and encases the entire aperture 1440. In other embodiments, the cartridge 1450 is coupled to both the faceplate 1414 and the body 1401 and forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 yet may not form the entire casing 1430. In some embodiments, the front wall 1432 and / or rear wall 1442 can comprise a support segment formed by the cartridge 1450 and a core segment formed by the body 1401, as described in further detail below. In such embodiments, the aperture 1440 is formed by a combination of the cartridge 1450 and the body 1401.

[0183] In some embodiments, the separately formed cartridge 1550 is attached only to the body 1501 and is not directly coupled to the faceplate 1514. The cartridge perimeter 1555 can be continuously coupled to the body 1501. As illustrated in FIGS. 34-36, both the cartridge forward edge 1556 and the cartridge rear edge 1557 are coupled to the body 1501, such that the cartridge 1550 is entirely housed by and isolated within the body 1501. This configuration can be especially useful in embodiments comprising face inserts, in which the faceplate 1514 is confined within an opening located on the strike face 1502. Further, in some cases, stresses concentrate near the casing front wall 1532, but not in the forwardmost portion of the sole 1512 or near the leading edge 1503. In such cases, the leading edge 1503 and the portion of the sole 1512 in front of the casing 1530 may not require high-strength reinforcement.

[0184] The cartridge 1550 can be located entirely within the sole 1512, as illustrated in FIGS. 34-36. In such embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the sole 1512. Further, the body 1501 forms a forward sole segment 1513 interposed between the cartridge forward edge 1556 and the leading edge 1503. In other embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the strike face 1502. In such embodiments, the cartridge 1550 can wrap over the leading edge 1503 and form a lower portion of the strike face 1502. In both embodiments, the cartridge 1550 forms at least a portion of the sole 1512.

[0185] In the embodiment illustrated in FIGS. 34-36, the cartridge 1550 only partially forms the casing 1530. The portion(s) of the casing walls formed by the cartridge 1550 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1501 can be referred to as core segments. In the illustrated embodiment, the front wall 1532 comprises a front wall support segment 1568a formed by the cartridge 1550 and a rear wall core segment 1569b formed by the body 1501. Similarly, the rear wall 1542 comprises a rear wall support segment 1568b formed by the cartridge 1550 and a rear wall core segment 1569b formed by the body 1501. In the illustrated embodiment, the respective support segments 1568a, 1568b are in the casing center region 1531 and extend into the casing toe region 1537, whereas the respective core segments 1569a, 1569b are primarily located in the casing heel region 1535. The cartridge 1550 comprises a cartridge heel edge 1558 that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b. Because the body 1501 and the cartridge 1550 combine to form the aperture 1540, the cartridge heel edge 1558 can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge heel edge 1558.

[0186] In other embodiments, the support segments 1568a, 1568b and core segments 1569a, 1569b can have alternative configurations. For example, the support segments 1568a, 1568b can be primarily in the casing center region 1531. In such embodiments, the core segments 1569a, 1569b are located in both the casing heel region 1535 and the casing toe region 1537. In such embodiments, the cartridge 1550 further comprises a cartridge toe edge that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b near the casing toe region 1537. As similarly described above, the cartridge toe edge in such embodiments can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge toe edge.

[0187] The front wall 1532 and rear wall 1542 can have combinations or configurations of support segments 1568a, 1568b and core segments 1569a, 1569b to produce a desired strike face deflection. The cartridge 1550 can form at least portions of the casing front wall 1532 and the casing rear wall 1542. In some embodiments, the front wall height of the casing can be greater in the front wall core segment 1569a than in the front wall support segment 1568a. The high-strength cartridge material allows the front wall height in the support segment 1568a to be reduced (thereby increasing strike face deflection) without compromising durability.

[0188] In other embodiments, by being coupled only to the body 1501 and not the faceplate 1514, the cartridge 1550 can house the entire casing 1530, thereby increasing IRM reinforcement. The cartridge perimeter 1555 is continuously attached to the body 1501 in such embodiments, such that there are no unattached or interrupted cartridge edges.

[0189] In the club head 1400 comprising a cartridge 1450, the faceplate 1414 forms no portion of the casing 1430. Instead, the casing 1430 is formed entirely by the cartridge 1450 or a combination of the cartridge 1450 and the body 1401, as described above. Similarly, the faceplate 1414 forms no portion of the aperture 1440. The cartridge 1450 separates the faceplate 1414 from the aperture 1440 and is either formed completely by the cartridge 1450 or by a combination of the cartridge 1450 and the body 1401.

[0190] As described above, manufacturing (and in particular forging) unitary, high-strength material components is limited by the number of bends the unitary component can have in a single direction (i.e., vertical, horizontal, etc.). In general, a single high-strength component can only be forged with a maximum of two bends in a single direction. The cartridge 1450 improves manufacture by forming the complex casing geometries separately from the faceplate 1414. Because the casing 1430 is separate from the faceplate 1414, the casing 1430 does not factor into the maximum number of faceplate bends. As such, the faceplate 1414 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1414 integrally forms the casing 1430. For example, the separately formed faceplate 1414 can comprise both a crown return 1415 and a sole return 1416 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1414 comprises a first bend at the juncture between the strike face 1402 and the crown return 1415 and a second bend at the juncture between the strike face 1402 and the sole return 1416. The cartridge 1450 can thereby be combined with a faceplate 1414 comprising a crown return 1415, a sole return 1416, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing key areas of the club head 1400 on the crown 1410, sole 1412, heel 1404, and toe 1406.

[0191] The cartridge 1450 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1401 or the faceplate 1414. In some embodiments, the cartridge 1450 is welded to the faceplate 1414 or the body 1401. In other embodiments, the cartridge 1450 can be coupled to the faceplate 1414 or the body 1401 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the cartridge 1450 is coupled to the body 1401 and the faceplate 1414 through a permanent fixing means. In some embodiments, the attachment means between the cartridge 1450 and the body 1401 is the same as the attachment means between the cartridge 1450 and the faceplate 1414. In other embodiments, the cartridge 1450 is coupled to both the body 1401 and the faceplate 1414 by identical means.

[0192] As described above, the cartridge 1450 is formed of a high-strength cartridge material. For example, in some embodiments, the cartridge material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0193] In other embodiments, the cartridge material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fc-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the cartridge material can be a high-strength composite or carbon fiber material.

[0194] Generally, the cartridge material is stronger than the body material. In some embodiments, the cartridge material is the same as the faceplate material. In other embodiments, the cartridge material and the faceplate material are different. The high-strength cartridge material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the cartridge material has a yield strength value of at least 175 ksi or more. In some embodiments, the cartridge material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises a cartridge strength ratio comparing the yield strength of the cartridge material to the yield strength of the body material. In some embodiments, the cartridge strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.C. Body and Appendage Forming the Casing

[0195] In some embodiments, the club head 1600 comprises an appendage 1650 that integrally forms at least a portion of the casing 1630. Referring to FIGS. 37-40, the appendage 1650 is a separate component attached to the faceplate 1614 and the body 1601. Although the appendage 1650 and the faceplate 1614 are both high-strength material components, they are not the same component. The appendage 1650 integrally forms at least a portion of the casing front wall 1632. The appendage 1650 is formed of a high-strength appendage material that is more durable than the body material. As such, the appendage 1650 reinforces the IRM 1620 and increases strike face deflection without compromising durability. In some embodiments, the appendage 1650 forms the entire front wall 1632. In other embodiments, the appendage 1650 forms only a portion of the front wall 1632 rather than the entire front wall 1632. In such embodiments, the appendage 1650 locally reinforces the casing 1630 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1631 experiences greater deflection and higher impact stresses than the casing heel region 1635 or the casing toe region 1637. In such embodiments, the appendage 1650 may form and reinforce the casing center region 1631. The casing heel region 1635 and the casing toe region 1637 may not require the same level of reinforcement and can therefore be formed by the body 1601, which comprises a lower-strength material.

[0196] The appendage 1650 reinforces the IRM 1620 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1630, the appendage 1650 is a separate, high-strength material component that forms and reinforces the casing 1630. Because the faceplate 1614 does not have to form any part of the complicated casing geometry, the appendage 1650 can be combined with a faceplate 1614 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration allows for high-strength material reinforcement of not only the IRM 1620 but also other portions of the club head 1600 to further increase strike face deflection, because the returns (i.e., the crown return, sole return, heel return, or sole return) can have reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process (such as welding) between the appendage 1650 and the faceplate 1614 or body 1601 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0197] In some embodiments, the separately formed appendage 1650 is attached to both the faceplate 1614 and the body 1601 and integrally forms at least a portion of the casing front wall 1632. In the illustrated embodiment of FIG. 38, the appendage 1650 is located in a forward portion of the sole 1612. The appendage 1650 comprises an appendage perimeter 1655 that includes an appendage forward edge 1656 that couples to the faceplate 1614. The appendage perimeter 1655 further includes an appendage heel edge 1658 and an appendage toe edge 1659 each coupled to the body 1601. While the appendage 1650 forms at least a portion of the front wall 1632, the body 1601 forms the rear wall 1642. The aperture 1640 is thereby formed between the body 1601 and the appendage 1650.

[0198] In some embodiments, the appendage 1650 is located entirely within the sole 1612. As illustrated in FIGS. 30-31, the faceplate 1614 comprises a sole return 1616 extending rearward from the strike face 1602, and the appendage forward edge 1656 couples to the sole return 1616. In such embodiments, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the sole 1612. In alternative configurations, rather than the appendage 1650 being located entirely within the sole 1612, the appendage 1650 can partially extend on to the strike face 1602. In such embodiments, as best illustrated in FIG. 39, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the strike face 1602. In such embodiments, the faceplate 1614 can be devoid of a sole return 1616 and the appendage 1650 can wrap over the leading edge 1603 and form a lower portion of the strike face 1602. In both embodiments, the appendage 1650 forms at least a portion of the sole 1612.

[0199] In some embodiments, the appendage 1650 forms entities of both the front wall front surface 1634 and front wall rear surface 1636 of the casing 1630. This configuration increases high-strength material reinforcement along the entire front wall 1632. In some embodiments, the appendage 1650 can extend laterally past the extent of the aperture 1640. Such embodiments increase heel wall 1652 and toe wall 1654 reinforcement, where stress often pools within the casing 1630. In such embodiments, the appendage forward edge 1656 can be coupled to both the faceplate 1614 and the body 1601, because the appendage 1650 extends past the extent of the faceplate 1614 and / or the sole return 1616.

[0200] In other embodiments, such as that illustrated at FIG. 38, the appendage 1650 forms only a portion of the front wall 1632 and only a portion of the front wall rear surface 1636. The portion(s) of the casing walls formed by the appendage 1650 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1601 can be referred to as core segments. As illustrated in FIG. 40, the front wall 1632 comprises a support segment 1668 formed by the appendage 1650 and a core segment 1669 formed by the body 1601. In the illustrated embodiment, the support segment 1668 occupies the casing center region 1631 whereas the respective core segment 1669 primarily occupies the casing heel region 1635 and the casing toe region 1637. The appendage heel edge 1658 and the appendage toe edge 1659 couple to the body 1601 at the junctures between the support segment 1668 and the core segment 1669. The support segment 1668 locally reinforces high-stress areas in the front wall 1632.

[0201] In other embodiments, the support segment 1668 and core segment 1669 can have alternative configurations. For example, in some embodiments, the support segment 1668 can extend from the casing center region 1631 into either the casing heel region 1635 or the casing toe region 1637. The front wall 1632 and rear wall 1642 can have any configuration of the support segment 1668 and the core segment 1669 to produce a desired strike face deflection. The appendage 1650 can form any amount or portion of the casing front wall 1632. In some embodiments, the front wall height of the casing 1630 can be greater in the core segment 1669 than in the support segment 1668. The high-strength appendage material allows the front wall height FWH in the support segment 1668 to be reduced (thereby increasing strike face deflection) without compromising durability.

[0202] The appendage 1650 can define an appendage length LA measured in a heel-to-toe direction between the heelmost and toemost extent of the appendage 1650. In embodiments wherein the appendage 1650 forms less than the entirety of the front wall 1632, the appendage length LAP can be less than the total length TL of the aperture 1640 (defined below). In such embodiments, strike face deflection and club head durability are improved without excess high-strength material being required to form the appendage 1650.

[0203] In the club head 1600 comprising an appendage 1650, the faceplate 1614 forms no portion of the casing 1630. Instead, the casing 1630 is formed entirely by a combination of the appendage 1650 and the body 1601, as described above. Similarly, because the casing 1630 forms the aperture 1640, the faceplate 1614 also forms no portion of the aperture 1640. The appendage 1650 separates the faceplate 1614 from the aperture 1640. Instead, the aperture 1640 is formed completely by a combination of the appendage 1650 and the body 1601 within the casing 1630.

[0204] As described above, manufacturing (particularly forging) high-strength material components is limited by the number of bends the unitary component can have in a single direction. The appendage 1650 improves manufacture by allowing the complex casing geometries to be forged separately from the faceplate 1614. Because the appendage 1650 is separate from the faceplate 1614, the front wall geometry does not factor into the maximum number of faceplate bends. As such, the faceplate 1614 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1614 integrally forms the front wall. For example, the separately formed faceplate 1614 can comprise both a crown return and a sole return 1616 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1614 comprises a first bend at the juncture between the strike face 1602 and the crown return and a second bend at the juncture between the strike face 1602 and the sole return 1616. The appendage 1650 thereby separately forms a third bend at the juncture between the sole 1612 and the front wall 1632. The appendage 1650 can thereby be combined with a faceplate 1614 comprising a crown return, a sole return 1616, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing areas of the club head 1600 on the crown 1610, sole 1612, heel 1604, and toe 1606.

[0205] The appendage 1650 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1601 and the faceplate 1614. In some embodiments, the appendage 1650 is welded to the faceplate 1614 or the body 1601. In other embodiments, the appendage 1650 can be coupled to the faceplate 1614 or the body 1601 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the appendage 1650 is coupled to the body 1601 and the faceplate 1614 through a permanent fixing means. In some embodiments, the attachment means between the appendage 1650 and the body 1601 is the same as the attachment means between the appendage 1650 and the faceplate 1614. In other embodiments, the appendage 1650 is coupled to both the body 1601 and the faceplate 1614 by identical means.

[0206] As described above, the appendage 1650 is formed of a high-strength appendage material. For example, in some embodiments, the appendage material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0207] In other embodiments, the appendage material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fc-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the appendage material can be a high-strength composite or carbon fiber material.

[0208] Generally, the appendage material is stronger than the body material. In some embodiments, the appendage material is the same as the faceplate material. In other embodiments, the appendage material and the faceplate material are different. The high-strength appendage material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the appendage material has a yield strength value of at least 175 ksi or more. In some embodiments, the appendage material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises an appendage strength ratio comparing the yield strength of the appendage material to the yield strength of the body material. In some embodiments, the appendage strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.V. Casing Parameters and Performance Ratio

[0209] In one embodiment of a golf club head, the casing comprises various shapes, geometries, and dimensions described below that improve the performance and durability of the IRM when implemented in a fairway wood type club head. In the current embodiment, the IRM is formed entirely within a body of the club head, and the club head further comprises an adjustable shaft-receiving mechanism (described in further detail below). The IRM includes a check-marked shaped casing such that the casing walls form a toe relief. The club head further comprises a faceplate that forms a crown return. The specific values and relationships between the casing shapes, geometries, and dimensions are particularly advantageous for a fairway wood type club head, as described in greater detail below.

[0210] The main parameters that alter the performance of the casing of this specific fairway wood embodiment are the total length TL of the aperture, the offset distance OD of the casing the front wall thickness FWT of the casing, and the front wall height FWH of the casing, as shown in FIGS. 41-46. These four parameters can be balanced to increase strike face deflection while maintaining sufficient durability. The relationship between these parameters can be expressed by a performance ratio defined below. The performance coefficient PC in the equation accounts for the change in strike face deflection and durability per unit change in each of the individual parameters and may alter or change between embodiments.X⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤Y⁢ in-2

[0211] As shown in the performance ratio above, the numerator comprises total length TL because as the total length TL increases, the performance increases. Conversely, the denominator comprises the product of offset distance OD, front wall thickness FWT, and front wall height FWH because as each of those three parameters increases, performance decreases. Accordingly, the numerator (total length TL) has an inverse relationship with the denominators (offset distance OD, front wall thickness FWT, front wall height FWH) such that if the total length increases, some combination of the offset distance OD, front wall thickness FWT, and / or front wall height FWH will also have to increase to maintain the performance ratio. Similarly, if any one of the denominators increases, at least one of the other remaining denominators will decrease to maintain the performance ratio.

[0212] The performance ratio is expressed as an inequality ranging between 14 in−2 and 18 in−2. If the performance ratio falls below 14 in−2, the IRM / casing will underperform and / or be over durable. Conversely, if the performance ratio goes above 18 in−2, the casing will be overly flexible and not sufficiently durable. The performance ratio and inequality having a range between 14-18 in−2 is especially applicable to the fairway wood type club head comprising an adjustable hosel and a casing having walls forming a check-mark shape with a toe return wherein the casing is formed with the body.

[0213] The performance coefficient PC, as described above, accounts for a change in strike face deflection and durability per unit change in each of the individual parameters. The performance coefficient PC is unique to individual embodiments. In this particular embodiment as described above, the performance coefficient can range from 0.028 to 0.035. For example, the performance coefficient can be 0.028, 0.029, 0.030, 0.031, 0.032, 0.033, 0.034, or can be 0.035.

[0214] In other embodiments of club heads comprising an IRM, the boundaries of the performance inequality and the performance coefficient may be different than the performance inequality and the performance coefficient of the above described embodiment. The parameters (OD, TL, FWT, FWH) used in the inequality may have different effects on the durability and performance of the club head.

[0215] The parameters, total length TL, offset distance OD, front wall thickness FWT, and front wall height FWH, are measurements based off of the casing front wall 132. To better define the parameters, the construction / structure of the front wall 132 must be defined first. The front wall 132 has a front wall front surface 134, a front wall top surface 138, and a front wall rear surface 136, as illustrated in FIG. 41. The front wall front surface 134 and the front wall top surface 138 connect to form a top front edge 121. The front wall top surface 138 and the front wall rear surface 136 connect to form a top rear edge 122. The front wall rear surface 136 and the sole 112 connect to form a bottom rear edge 123. An interior sole surface 125 and the front wall front surface 134 connect to form a bottom front edge 124. In some embodiments, the adjoining surfaces may have fillets or chamfers. In these embodiments, the edges described above can be defined at the intersection of the adjoining surface projections.

[0216] The total length TL of the aperture is measured from an absolute heel point (AHP) to an absolute toe point (ATP), parallel to the X-axis 40, as illustrated in FIG. 46. This length can be selected to balance between either increasing strike face deflection and decreasing durability, or decreasing strike face deflection and increasing durability. The absolute heel point AHP is located at the heel most point of the aperture 140. The absolute toe point ATP is located at the toe most point of the aperture 140. The total length TL can be increased to increase strike face deflection but decrease durability. Similarly, the total length TL of the aperture can be decreased to decrease strike face deflection but increase durability. Similar to a fixed beam, a longer casing will experience more deflection for the same amount of load. As such, the longer the aperture 140 (and therefore the longer the casing 130), the more flexible the casing 130 becomes. The potential max total length TL of the aperture is affected whether or not an adjustable shaft-receiving mechanism or a fixed shaft receiving mechanism is utilized in the club head, which is described in further detail below.

[0217] The total length TL to be used in the above performance inequality can range between 2.00 and 2.05 inches, 2.05 and 2.10 inches, 2.10 and 2.15 inches, 2.15 and 2.20 inches, 2.20 and 2.25 inches, 2.25 and 2.30 inches, 2.30 and 2.35 inches, 2.35 and 2.40 inches, 2.40 and 2.45 inches, 2.45 and 2.50 inches, 2.50 and 2.55 inches, 2.55 and 2.60 inches, 2.60 and 2.65 inches, 2.65 and 2.70 inches, or between 2.70 and 2.75 inches. In the specific embodiment described above, the total length TL is approximately 2.359 inches.

[0218] The offset distance OD generally quantifies the location of the aperture relative to the strike face and is defined as the distance from the leading edge 103 to the front wall bottom rear edge 123, parallel to the Z-axis 60, in the YZ plane. As mentioned above, the offset distance OD can be selected to either increase strike face deflection and decrease durability or decrease strike face deflection and increase durability. Specifically, as the offset distance OD increases (i.e., the casing 130 is further away from the strike face 102) the strike face deflection decreases and the durability increases. Similarly, as the offset distance OD decreases (i.e., the casing 130 is positioned closer to the strike face 102), the strike face deflection increases and the durability decreases. A reduced offset distance OD of the aperture increases the deflection of the casing 130 by moving the aperture 140 closer to the strike face 102 and experiences higher deflection. When the casing 130 experiences an increase in deflection, the casing 130 flexes more and increases energy returned back to the strike face 102 and the golf ball.

[0219] The offset distance OD can range between 0.225 and 0.230 inch, 0.230 and 0.235 inch, 0.235 and 0.240 inch, 0.240 and 0.245 inch, 0.245 and 0.250 inch, 0.250 and 0.255 inch, 0.255 and 0.260 inch, 0.260 and 0.265 inch, 0.265 and 0.270 inch, 0.270 and 0.275 inch, 0.275 and 0.280 inch, 0.280 and 0.285 inch, 0.285 and 0.290 inch, 0.290 and 0.295 inch, or between 0.295 and 0.300 inch. In the specific embodiment described above, the offset distance OD is approximately 0.245 in.

[0220] The front wall thickness FWT is measured as the distance between front wall front surface 134 and the front wall rear surface 136, in the YZ plane. As mentioned above, the front wall thickness FWT can be selected to either increase strike face deflection and decrease durability or to decrease strike face deflection and increase durability. Specifically, the front wall thickness FWT can be increased (i.e., made thicker) to decrease strike face deflection but increase durability. Alternatively, the front wall thickness FWT can be decreased (i.e., made thinner) to increase strike face deflection but decrease durability.

[0221] The front wall thickness FWT can range between 0.065 and 0.070 inch, 0.070 and 0.075 inch, 0.075 and 0.080 inch, 0.080 and 0.085 inch, 0.085 and 0.090 inch, 0.090 and 0.095 inch, 0.095 and 0.100 inch, 0.100 and 0.105 inch, 0.105 and 0.110 inch, or between 0.110 and 0.115 inch. In the specific embodiment described above, the front wall thickness FWT is approximately 0.0851 inch.

[0222] The front wall height FWH, as used above, is measured as the distance between the front wall bottom rear edge 123 and the front wall top rear edge 122, along the front wall rear surface 136, in the YZ plane. As mentioned above, the front wall height FWH can be selected to either increase strike face deflection and decrease durability, or to decrease strike face deflection and increase durability. Specifically, increasing the front wall height FWH (i.e., providing a taller front wall 132) decreases strike face deflection but increases durability. Similarly, as the front wall height FWH decreases (i.e., providing a shorter front wall 132), the strike face deflection increases but the durability decreases. The front wall height FH can be constant along the length of the casing 130, or the front wall height FWH can vary along the length of the casing 130.

[0223] The front wall height FWH can range between 0.200 and 0.205 inch, 0.205 and 0.210 inch, 0.210 and 0.215 inch, 0.215 and 0.220 inch, 0.220 and 0.225 inch, 0.225 and 0.230 inch, 0.230 and 0.235 inch, 0.235 and 0.240 inch, 0.240 and 0.245 inch, or between 0.245 and 0.250 inch. In the specific embodiment described above, the front wall height FWH is approximately 0.221 in.

[0224] The above-described parameters and ranges are particularly advantageous for the fairway wood type club head comprising a casing with walls that are formed in a check-mark shape that increases strike face deflection while maintaining a sufficient durability. In other embodiments of club heads, variation can occur for the performance ratio and / or ranges of parameters. For example, a casing in a hybrid type club head may have different parameters that result in a similar increase in strike face deflection while maintaining sufficient durability. Furthermore, in other embodiments, a club head can comprise one or more additional parameters measured at various positions along the length of the casing.

[0225] The additional parameters can be better understood with reference to certain reference planes, as shown in FIGS. 42-47. The reference planes are located at various positions along the length of the casing, from the heel end to the toe end. The reference planes are also used to define various cross-sectional views to visualize other specific casing geometries. For example, the casing can comprise a front wall thickness that is measured in a heel plane, a toe plane, and an XY plane. The front wall thickness can be different in each of these planes (cross-sections), or the front wall thickness can be the same in each of the planes (cross-sections). The front wall thickness, heel plane, toe plane, and XY plane are discussed below.

[0226] The casing comprises a heel plane HP that is perpendicular to the leading edge plane LEP and the ground plane GP and intersects the front wall rear surface 136 at the heel end where the front wall rear surface 136 deviates to the heel relief, or heel wall, as illustrated in FIG. 47. The front wall rear surface 136 deviates to the heel relief, or heel wall, where the radius of curvature of the front wall 132 changes. The heel plane HP creates a heel plane HP cross-section, as shown in FIG. 43.

[0227] The casing comprises a toe plane TP that is perpendicular to the leading edge plane LEP and the ground plane GP and intersects the front wall rear surface 136 at the toe end where the front wall rear surface 136 deviates to the toe relief, or toe wall, as illustrated in FIG. 47. The front wall rear surface 136 deviates to the toe relief, or toe wall, where the radius of curvature of the front wall 132 changes. The toe plane TP creates a toe plane TP cross-section, as shown in FIG. 44.

[0228] The casing comprising various shapes, geometries, and dimensions described above, such as total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT, that improve the performance and durability of the IRM when implemented in a fairway wood type club head having an adjustable hosel, a faceplate with a crown return, and a check-marked shaped IRM.A. Offset Distance

[0229] In some embodiments, the offset distance OD can vary along the length of the casing to either increase deflection or durability of a specific area of the casing. In other embodiments, the offset distance OD can be constant along the length of the casing. In some embodiments, the offset distance OD can be greatest in the casing center region and smallest in the casing heel region and the casing toe region. In other embodiments, the offset distance OD can be smallest in the casing center region and greatest in the casing heel region and the casing toe region.

[0230] The offset distance OD can be measured at three different locations along the length of the casing in a center, heel, and toe portions of the casing. The first offset distance OD1 is measured in the YZ plane, as shown in FIG. 42. The second offset distance OD2 is measured in the heel plane HP, as shown in FIG. 43. The third offset distance OD3 is measured in the toe plane TP, as shown in FIG. 44. The offset distances OD1,2,3 can be equal or in other embodiments, the offset distances OD1,2,3 can be different such that the offset distances OD1,2,3 vary across the length of the casing. Each offset distance OD1,2,3 can be adjusted individually to alter the performance and durability of the casing.

[0231] Each of the casing offset distances OD1,2,3 can range from 0.075 to 1.00 inch. For example, the casing offset distance OD1,2,3 can range from 0.075-0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, 0.40 to 0.50 inch, 0.50 to 0.60 inch, 0.60 to 0.70 inch, 0.70 to 0.80 inch, 0.80 to 0.90 inch, or from 0.90 to 1.00 inch. In some embodiments, the casing offset distance OD1,2,3 can be 0.075 inch, 0.080 inch, 0.085 inch, 0.090 inch, 0.095 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, or 1.0 inch. In one embodiment, the offset distance OD1 is 0.177 inch, the offset distance OD2 is 0.170 inch, and the offset distance OD3 is 0.140 inch. In other embodiments, the offset distances OD1,2,3 can be equal.B. Total Length

[0232] The aperture comprises a total length TL, measured from an absolute heel point (AHP) to an absolute toe point (ATP), parallel to the X-axis 40, as illustrated in FIG. 46, that can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. The total length TL can be increased to increase strike face deflection, but decrease durability. Similarly, the total length TL of the casing can be decreased to decrease strike face deflection, but increase durability. Similar to a fixed beam, a longer casing will experience more deflection for the same amount of load. As such, the longer the casing, the casing is more flexible. The potential maximum total length TL of the casing is affected whether or not an adjustable shaft-receiving mechanism or a fixed shaft-receiving mechanism is utilized in the club head. This is described in further detail below.

[0233] Furthermore, the aperture comprises an effective length EL measured from the heel plane HP to the toe plane TP parallel to the X-axis, as illustrated in FIG. 46. The effective length EL is a measurement of the length of the aperture not including the reliefs and / or rounded ends. The effective length EL can be increased to increase strike face deflection, but decrease durability. Similarly, the effective length EL of the casing can be decreased to decrease strike face deflection, but increase durability. In the embodiments that do not have a heel relief or a toe relief, the effective length EL will be the same as the total length TL.

[0234] The total length TL can range from 0.50 to 4.0 inches. For example, the total length TL can range from 0.50 to 1.0, 1.0 to 2.0 inches, 2.0 to 3.0 inches, or 3.0 to 4.0 inches. In some embodiments, the total length can be 0.5 inches, 0.75 inches, 1.0 inches, 1.25 inches, 1.50 inches, 1.75 inches, 2.00 inches, 2.25 inches, 2.50 inches, 2.75 inches, 3.00 inches, 3.25 inches, 3.50 inches, 3.75 inches, or 4.00 inches. In one embodiment, the total length TL is 2.681 inches.

[0235] The effective length EL can range from 0.50 to 4.0 inches. For example, the total length TL can range from 0.50 to 1.0, 1.0 to 2.0 inches, 2.0 to 3.0 inches, or 3.0 to 4.0 inches. In some embodiments, the total length can be 0.5 inches, 0.75 inches, 1.0 inches, 1.25 inches, 1.50 inches, 1.75 inches, 2.00 inches, 2.25 inches, 2.50 inches, 2.75 inches, 3.00 inches, 3.25 inches, 3.50 inches, 3.75 inches, or 4.00 inches. In one embodiment, the effective length EL is 1.998 inches.

[0236] The casing comprises a toe effective length TEL, measured as the distance from the toe plane TP to the YZ plane parallel to the X-axis 40. The toe effective length TEL can range from 0.25 to 2.0 inches. For example, the toe effective length TEL can range from 0.25 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or 1.5 to 2.0 inches.

[0237] The casing comprises a heel effective length HEL, measured as the distance from the heel plane HP to the YZ plane parallel to the X-axis 40. The heel effective length HEL can range from 0.25 to 2.0 inches. For example, the toe effective length HEL can range from 0.25 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or 1.5 to 2.0 inches.

[0238] In some embodiments, the toe effective length TEL can be greater than the heel effective length HEL. In other embodiments, the heel effective length HEL can be greater than the toe effective length TEL. In some embodiments, the toe effective length TEL can be equal to the heel effective length HEL.C. Relief Angle

[0239] In the embodiments where the casing comprises reliefs, the reliefs comprise relief angles, defined below. As mentioned above, the relief angles can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, increasing the relief angle (i.e., angling the relief more rearwardly), decreases strike face deflection but increases durability. Similarly, decreasing the relief angle (i.e., angling the relief more flat or parallel to the length of the casing), increases strike face deflection but decreases durability. The use of a fixed shaft-receiving mechanism or an adjustable shaft-receiving mechanism can affect whether or not the casing includes a heel relief. An adjustable shaft-receiving structure comprises a heel recess or indentation for a mechanical fastener. The heel recess prevents the casing from extending into the heel thereby preventing the casing from including a heel relief.

[0240] In some embodiments, the casing can comprise a heel relief 129, a toe relief 128, or both. In some embodiments, the heel relief angle HRA can be the same as the toe relief angle TRA. In other embodiments, the heel relief angle HRA can be different than the toe relief angle TRA.

[0241] The casing comprises a heel relief angle HRA measured as the angle between a line that extends between the intersection of the heel plane HP and the front wall bottom rear edge 123 to the absolute heel point AHP and the leading edge plane LEP, as illustrated in FIG. 47. The heel relief angle HRA can range between 2 and 75 degrees. The heel relief angle HRA can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the heel relief angle HRA is 53 degrees.

[0242] The casing comprises a toe relief angle TRA measured as the angle between a line that extends between the intersection of the toe plane TP and the front wall bottom rear edge 123 to the absolute toe point ATP and the leading edge plane LEP, as illustrated in FIG. BQ. The toe relief angle TRA can range between 2 and 75 degrees. The toe relief angle TRA can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the toe relief angle is 53.38 degrees.D. Relief Length

[0243] In the embodiments where the casing comprises on or more reliefs, the reliefs comprise a relief length on the heel and / or toe ends. The relief lengths can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, increasing the relief length (i.e., lengthening the relief) increases strike face deflection but decreases durability. Similarly, decreasing the relief length (i.e., shortening the relief) decreases strike face deflection but increases durability. The relief angle, defined above, can change the effective factor of the relief length.

[0244] The casing can comprise a toe relief length TRL, measured as the distance from the toe plane TP to the absolute toe point ATP. The toe relief length TRL can range from 0.1 to 0.5 inch. In some embodiments, the toe relief length TRL can range from 0.1 to 0.2 inch, 0.2 to 0.3 inch, 0.3 to 0.4 inch, or from 0.4 to 0.5 inch.

[0245] The casing can comprise a heel relief length HRL, measured as the distance from the heel plane HP to the absolute heel point AHP. The heel relief length HRL can range from 0.1 to 0.5 inch. In some embodiments, the toe relief length HRL can range from 0.1 to 0.2 inch, 0.2 to 0.3 inch, 0.3 to 0.4 inch, or from 0.4 to 0.5 inch.

[0246] In some embodiments, the toe relief length TRL is the same as the heel relief length HRL. In other embodiments, the toe relief length TRL can be different than the heel relief length HRL. For example, the toe relief length TRL can be longer than the heel relief length HRL, or the toe relief length TRL can be shorter than the heel relief length HRL.E. Front Wall Height

[0247] The front wall height FWH can be measured at three different locations along the length of the casing. The first front wall height FWH1 is measured in the YZ plane, defined above. The second front wall height FWH2 is measured in the heel plane HP, defined above. The third front wall height FWH3 is measured in the toe plane TP, defined above.

[0248] The front wall heights FWH1,2,3 can range from 0.050 to 0.50 inch. In some embodiments, the front wall heights FWH1,2,3 can range from 0.050 to 0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, or from 0.40 to 0.50 inch. In some embodiments, the first front wall height FWH1 is greater than both the second front wall height FWH2 and the third front wall height FWH3. In other embodiments, the first front wall height FWH1 is equal to both the second front wall height FWH2 and third front wall height FWH3. In other embodiments, the first front wall height FH1 is less than both the second front wall height FWH2 and the third front wall height FWH3. In other embodiments, the second front wall height FWH2 is greater than both the first front wall height FWH1 and the third front wall height FWH3. In other embodiments, the second front wall height FWH2 is less than both the first front wall height FWH1 and the third front wall height FWH3. In other embodiments, the third front wall height FWH3 is greater than both the first front wall height FWH1 and the second front wall height FWH2. In other embodiments, the third front wall height FWH3 is less than both the first front wall height FWH1 and the second front wall height FWH2.F. Front Wall Thickness

[0249] As mentioned above, the front wall thickness can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, the front wall thickness can be increased (i.e., thickening the front wall) to decrease strike face deflection, but increase durability.

[0250] In some embodiments, the front wall thickness is constant along the length of the casing. In other embodiments, the front wall thickness varies along the length of the casing. For example, in some embodiments, the front wall thickness is greater in the YZ plane than in the heel plane and toe plane. As such, the front wall thickness can be measured at three different locations along the length of the casing. The first front wall thickness FWT1 is measured in the YZ plane, defined above. The second front wall thickness FWT2 is measured in the heel plane HP, defined above. The third front wall thickness FWT3 is measured in the toe plane TP, defined above.

[0251] The front wall thicknesses FWT1,2,3 can range from 0.010 to 0.175 inch. In some embodiments, the front wall thickness FWT1,2,3 can range from 0.010 to 0.025 inch, 0.025 to 0.050 inch, 0.050 to 0.075 inch, 0.075 to 0.100 inch, 0.100 to 0.125 inch, 0.125 to 0.150 inch, or from 0.150 to 0.175 inch.

[0252] The front wall thickness FWT can also be expressed as a cross-sectional area within the YZ plane. As illustrated in FIG. BP, the cross-sectional area can be the area defined by the front wall top surface, the front wall front surface, the front wall rear surface, the exterior sole surface, and the forward surface extension 127. The forward surface extension 127 is an imaginary line that is co-planar to the front wall front surface and extends downward towards the exterior sole surface. The front wall 132 can have a variable cross-sectional area along the length of the casing.

[0253] The front wall 132 can comprise one or more front wall reinforcements 139. The front wall reinforcements 139 are areas of increased thickness to strategically reduce stress in specific regions. The front wall reinforcements 139 can protrude from the front wall front surface 134 towards the strike face, or the front wall reinforcements 139 can protrude from the front wall rear surface 136 towards the rear of the club head, as illustrated in FIG. 10.G. Forward Sole Thickness

[0254] The club head comprises a forward sole thickness FST which is the thickness of the sole in front of the front wall. Or in other words, the forward sole thickness is the thickness of the forward sole region 166, described above, measured from an interior sole surface to an exterior sole surface, as illustrated in FIGS. 42-44. As mentioned above, the forward sole thickness FST can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, the forward sole thickness FST can be increased (i.e., thickened) to decrease strike face deflection but increase durability. Similarly, the forward sole thickness FST can be decreased (i.e., thinned) to increase strike face deflection but decrease durability. The forward sole thickness FST can be constant along the length of the casing or can vary along the length of the casing. Similarly, the forward sole thickness FST can be constant in a front-back direction or can vary.

[0255] The forward sole thickness FST can be measured at three different locations along the length of the casing. The first forward sole thickness FST1 is measured in the YZ plane, defined above. The second forward sole thickness FST2 is measured in the heel plane HP, defined above. The third forward sole thickness FST3 is measured in the toe plane TP, defined above.

[0256] The forward sole thicknesses FST1,2,3 can range from 0.010 to 0.175 inch. In some embodiments, the forward sole thicknesses FST1,2,3 can range from 0.010 to 0.025 inch, 0.025 to 0.050 inch, 0.050 to 0.075 inch, 0.075 to 0.100 inch, 0.100 to 0.125 inch, 0.125 to 0.150 inch, or from 0.150 to 0.175 inch. In some embodiments, the first forward sole thickness FST1 is greater than both the second forward sole thickness FST2 and the third forward sole thickness FST3. In other embodiments, the first forward sole thickness FST1 is equal to both the second forward sole thickness FST2 and third forward sole thickness FST3. In other embodiments, the first forward sole thickness FST1 is less than both the second forward sole thickness FST2 and the third forward sole thickness FST3. In other embodiments, the second forward sole thickness FST2 is greater than both the first forward sole thickness FST1 and the third forward sole thickness FST3. In other embodiments, the second forward sole thickness FST2 is less than both the first forward sole thickness FST1 and the third forward sole thickness FST3. In other embodiments, the third forward sole thickness FST3 is greater than both the first forward sole thickness FST1 and the second forward sole thickness FST2. In other embodiments, the third forward sole thickness FST3 is less than both the first forward sole thickness FST1 and the second forward sole thickness FST2.

[0257] In some embodiments, the golf club head can comprise a patch in the forward sole region 166. The patch is an area of increased thickness to improve durability in the high stress region. In one embodiment, the patch is located in front of the casing center region.H. End Conditions

[0258] The shape and size of the casing toe wall and the casing heel wall, where the front wall transitions to the rear wall, affect strike face deflection and durability. Generally speaking, abrupt changes in geometry, such as corners with small radii of curvature, experience greater stresses than smooth transitions between geometries, such as rounded fillets or chamfers. The same applies to the casing heel wall and the casing toe wall. As mentioned above, the radius of curvature, or shape, can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, as the radius of curvature of the heel wall and / or the toe wall decreases (i.e., providing a sharper transition between the front wall and rear wall), the strike face deflection increases, but the durability decreases. Similarly, as the radius of curvature of the heel wall and / or toe wall increases (i.e., providing a more rounded / smooth transition from the front wall to the rear wall), the strike face deflection decreases, but the durability increases.

[0259] In some embodiments, the heel wall and the toe wall are rounded with a constant radius of curvature. In other embodiments, the heel wall and the toe wall can have other shapes with varying or multiple radii of curvature. The relief angle RA and the relief length RL defined above, can change the effective factor of the end conditions. The radius of curvature in the toe end and the heel end can range from 0.075 inch to 2 inches. For example, the radius of curvature can range from 0.075 to 0.10 inch, 0.10 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or from 1.5 to 2.0 inches.VI. Insert

[0260] The IRM further comprises an insert for closing off the aperture to prevent migration of debris into the interior chamber. Additionally, the insert may further modify performance of the IRM and increase durability of the club head. The insert may be primarily formed of a flexible, polymeric material that is configured to engage the casing walls, thereby securing the insert within the casing. The material composition, overall construction, optional use of hybrid materials, and geometry of the insert can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert and the casing can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert within the casing, even after repeated, violent impacts. FIGS. 48-50 illustrate various exemplary embodiments of inserts and casings comprising corresponding geometrics.A. Z-Shaped and U-Shaped Inserts

[0261] An insert having an Z-shaped cross-section is illustrated in FIG. 48. The Z-shaped insert blocks access to the interior cavity, preventing water and debris from entering, while still allowing the IRM. The Z-shaped insert further uses complementary geometry to secure it to the club head and provide durability to the IRM. The insert 3170 of FIG. 48 can comprise an insert base 3172 and an insert front wall 3174. The base 3172 can extend along the sole of the club head from the casing front wall 3132 to the casing rear wall 3142 to cover the aperture 3140. The base 3172 can cover the entirety of the aperture 3140, such that the insert 3170 seals the interior cavity 3107 from the club head exterior thereby preventing water or debris from entering the interior cavity 3107. In general, the base 3172 extends approximately from the casing front wall rear surface 3136 to the rear wall front surface 3144. In some embodiments, the base 3172 can be substantially flush with the surrounding sole surface, creating a continuous sole appearance. The Z-shaped insert 3170 further comprises a rear extension 3178 extending rearward of the base 3172 (i.e. away from the strike face). The rear extension 3178 can extend rearward of the casing rear wall 3142, engaging a casing recess 3182 defined by the rear wall 3142, and terminating at a casing rising surface 3183. The rear wall 3142 and rear extension 3178 form a lap joint for bonding the insert 3170 to the club head. More specifically, the rear wall 3142 resists any external force applied to the insert 3170 that would otherwise push the insert 3170 into the interior cavity 3107. Further, the casing rear wall 3142 at the recess 3182 provides a mechanical stop preventing the Z-shaped insert 3170 from being pushed into the interior cavity 3107.

[0262] The insert front wall 3174 extends upward from a front end 3186 of the insert base 3172, towards the interior cavity 3107. The insert front wall 3174 comprises an insert front wall bottom end 3187 integral to a front end 3186 of the base, and an insert front wall top end 3188 opposite the insert front wall bottom end 3187. The insert front wall 3174 can be configured to abut the casing front wall 3132. The insert front wall 3174 can be shaped complementarily to the casing front wall 3132. In some embodiments, the insert front wall 3174 can be adhesively coupled to the casing front wall 3132. In other embodiments, the insert front wall 3174 can be spring loaded to be pressed and expanded as an interference fit with the casing front wall 3132. In some embodiments, the insert front wall 3174 comprises a similar height to the casing front wall 3132 to increase the bonding area between the insert front wall 3174 and the casing front wall 3132. In other embodiments, the insert front wall 3174 can be taller or shorter than the casing front wall 3132. In some embodiments, the insert front wall height can vary along the casing length L. The insert front wall height is measured as the distance between the base 3172 to the front wall top end 3188. The insert front wall height can range from 0.050 to 0.50 inch. In some embodiments, the insert front wall height can range from 0.050 to 0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, or from 0.40 to 0.50 inch.

[0263] The Z-shaped insert 3170 in FIG. 48 can further comprise a front flange 3181 extending from the insert front wall top end 3188. The front flange 3181 can extend forward towards the strike face and overlap the top end of the casing front wall 3138. In some embodiments, the front flange 3181 can be adhesively coupled to the top end of the casing front wall 3138. The front flange 3181 provides a mechanical stop preventing the insert 3170 from exiting the casing and being pushed out to the club head exterior. The top end of the casing front wall 3132 exerts a force against the front flange 3181 that opposes any outward forces applied to the insert 3170. The front flange 3181 and casing front wall 3132 thereby secure the insert 3170 within the casing. In some embodiments, the front flange 3181 extends along the entire length of the casing front wall 3132. In other embodiments, the front flange 3181 may comprise one of more discrete flange sections located along the casing length. For example, in some embodiments, the front flange 3181 can be located only in a central portion of the casing, only in the heel portion of the casing, only in the toe portion of the casing, or any combination thereof. In such examples, the front flange 3181 can secure the insert 3170 within the casing without adding unnecessary mass.

[0264] In the installed configuration illustrated in FIG. 48, the insert 3170 only fills a portion of the casing, and a gap 3171 is formed between the base 3172, the insert front wall 3174, and the casing rear wall 3142. As illustrated, in some embodiments, the gap 3171 can be open to the interior cavity 3107. The gap 3171 provides space for the insert 3170 to deform during installation. Once installed, the insert front wall 3174 can engage the casing front wall 3132, mechanically interlocking the insert 3170 within the casing. Further, once fully installed, the gap permits the insert 3170 to flex with the casing walls.

[0265] FIG. 49 illustrates an embodiment of a U-shaped insert 3570 and a casing 3530 comprising corresponding geometries. The insert 3570 is similar to the insert 3170 illustrated in FIG. 48. The insert 3570 of FIG. 49 comprises a base 3572 configured to seal the casing exterior opening, a rear extension 3578 configured to engage a casing recess 3582, and an insert front wall 3574 configured to abut and couple to the casing front wall 3532. Further, the U-shaped insert 3570 in FIG. 49 can comprise an insert rear wall 3576 extending upwards from a rear end 3589 of the base, towards the interior cavity 3507, and a rear flange 3580 configured to overlap a top end 3548 of the casing rear wall 3542. The insert rear wall 3576 comprises an insert rear wall bottom end 3591 coupled to a base rear end 3589, and an insert rear wall top end 3592 opposite the insert rear wall bottom end 3591. The insert rear wall 3576 can be configured to abut the casing rear wall 3542. The insert rear wall 3576 can be shaped complementarily to the casing rear wall 3542. In some embodiments, the insert rear wall can be adhesively coupled to the casing rear wall 3542. In some embodiments, the insert rear wall 3576 comprises a similar height to the casing rear wall 3542 to increase the bonding area between the insert rear wall 3576 and the casing rear wall 3542. In other embodiments, the insert rear wall 3576 can be taller or shorter than the casing rear wall 3542. In some embodiments, the insert rear wall height can vary along the casing length. In some embodiments, the insert rear wall height can differ from the insert front wall height. In other embodiments, the insert rear wall height can be equivalent to the insert front wall height.

[0266] The U-shaped insert 3570 can further comprise a rear flange 3580 extending from the insert rear wall top end 3592. The rear flange 3580 can extend rearward and away from the face and overlap the top end 3548 of the casing rear wall. In some embodiments, the rear flange 3580 can be adhesively coupled to the top end 3548 of the casing rear wall. The rear flange 3580 acts as a mechanical stop preventing the insert 3570 from exiting the casing 3530 and being pushed out to the club head exterior. The top end 3548 of the casing rear wall exerts a force against the rear flange 3580 that opposes outward forces applied to the insert 3570. The rear flange 3580 and casing rear wall 3542 thereby secure the insert 3570 within the casing 3530. In some embodiments, the rear flange 3580 extends along the entire length of the casing rear wall 3542. In other embodiments, the rear flange 3580 can be localized along a certain portion of the casing length. For example, in some embodiments, the rear flange 3580 can be located only in a central portion of the casing 3530, only in the heel portion of the casing 3530, only in the toe portion of the casing 3530, or any combination thereof. In such examples, the rear flange 3580 can secure the insert 3570 within the casing 3530 without using any unnecessary mass.

[0267] The rear wall 3542 at the casing recess 3582 provides a bonding surface to which the rear extension 3578 can be coupled, thereby to form a lap joint. Further, the casing recess 3582 acts as a mechanical stop preventing the insert 3570 from exiting the casing and being pushed into the interior cavity 3507. The rear wall 3542 resists outward forces applied to the insert 3570. The rear extension 3578 and casing recess 3582 thereby secure the insert 3570 within the casing.

[0268] As illustrated in FIG. 49, the insert 3570 only fills a portion of the casing 3530, and a gap 3571 is formed between the base 3572, the insert front wall 3574, and the insert rear wall 3576. In some embodiments, the gap 3571 can be open to the interior cavity 3507. The gap 3571 provides space for the U-shaped insert 3570 to deform during installation so that the rear flange 3580 can fit through both the casing exterior opening and the casing interior opening. Once installed, the insert walls can engage the casing walls and the rear flange 3580 can engage the top end 3548 of the casing rear wall, mechanically interlocking the insert 3570 within the casing 3530. Further, once fully installed, the gap 3571 permits the insert 3570 to flex with the casing walls.

[0269] In some embodiments, as illustrated in FIG. 50, the U-shaped insert comprises both a front flange 3781 and a rear flange 3780. The front flange 3781 and the rear flange 3780 can both be similar to those described, in that the front flange 3781 overlaps the casing front wall 3732 and the rear flange 3780 overlaps the casing rear wall 3742. Similar to the insert illustrated in FIG. 49, a gap 3771 is formed between the base 3772, the insert front wall 3774, and the insert rear wall 3776. The gap 3771 can be sufficiently large to allow both the front flange 3781 and the rear flange 3780 to fit through both the casing exterior opening and the casing interior opening. Once installed, the insert front wall 3774 can engage the casing front wall 3732, the insert rear wall 3776 can engage the casing rear wall 3742, the front flange 3781 can engage the top end 3738 of the casing front wall, and the rear flange 3780 can engage the top end 3748 of the casing rear wall, mechanically interlocking the insert 3770 within the casing 3730. Further, once fully installed, the gap 3771 permits the insert 3770 to flex with the casing walls, thereby increasing ball speed over a solid insert filling the entire casing.

[0270] FIG. 51 illustrates an embodiment of a U-shaped insert 3670 having an expansive rear flange 3680 and rear extension 3678 configured to engage the casing rear wall 3642. The insert 3670 is substantially similar to the insert 3570 illustrated in FIG. 49, in that the insert 3670 comprises a base 3672, an insert front wall 3674 configured to couple to the casing front wall 3632, an insert rear wall 3676 configured to couple to the casing rear wall 3642, a rear extension 3678 configured to engage a casing recess 3682, and a rear flange 3680 configured to overlap a top end of the casing rear wall 3642. As illustrated, the insert 3670 further comprises a lip 3693 extending soleward from the end of the rear flange. The lip 3693 can engage a backside surface 3646 of the casing rear wall. In some embodiments, the lip 3693 can be adhesively coupled to the backside surface 3646 of the casing front wall. The lip 3693 acts as a mechanical stop preventing the insert 3670 moving in a front-to-rear direction during use. The backside surface 3646 of the casing rear wall 3642 exerts a force against the lip 3693 that opposes forces acting on the insert 3670 from the rear. This prevents the insert rear wall 3676 from deforming into the casing 3630 and disengaging the insert 3670 from the casing 3630.

[0271] Similar to the insert illustrated in FIGS. 49, a gap 3671 is formed between the base 3672, the insert front wall 3674, and the insert rear wall 3676. The gap 3671 can be sufficiently large to allow the rear flange 3680 and the lip 3693 to fit through both the casing exterior opening and the casing interior opening. Once installed, the insert front wall 3674 can engage the casing front wall 3632, the insert rear wall 3676 can engage the casing rear wall 3642, the rear flange 3680 can engage the top end of the casing rear wall, and the lip 3693 can engage the backside surface 3646 of the casing rear wall, mechanically interlocking the insert 3670 within the casing 3630. Further, once fully installed, the gap 3671 permits the insert 3670 to flex with the casing walls. Although FIG. 51 illustrates a rear flange 3680 and lip 3693 extending from the insert rear wall, it should be noted that in other embodiments, a similar flange and lip can be formed by the insert front wall. In such embodiments, the insert can form a front flange similar to those described above, wherein the lip extends soleward from the end of the front flange and engages a frontside surface of the casing front wall.B. Materials

[0272] The insert can be formed of a flexible, polymeric material, such as a polymer matrix composite. The polymer matrix composite can comprise a glass-filled elastomer, a stainless steel-filled elastomer, a tungsten-filled elastomer, a thermoplastic polyurethane (TPU) composite, a thermoplastic elastomer (TPE) composite, or any other elastomer matrix composite, a Kevlar® (aramid) fiber-reinforced polymer, a carbon-fiber reinforced polymer, rubber, ethylene-vinyl acetate foam, polymer-based foam, any combination of a suitable resin and a suitable reinforcing fiber, or any combination of the above materials.

[0273] In many embodiments, the insert can comprise a material density between 0.75 and 2.0 g / cm3. In many embodiments, the insert can comprise a material density between 0.75 and 1.0 g / cm3, between 1.0 and 1.25 g / cm3, between 1.25 and 1.5 g / cm3, between 1.5 and 1.75 g / cm3, or between 1.75 and 2.0 g / cm3.

[0274] In many embodiments, the insert can comprise a material durometer between shore 30A and shore 90D. In some embodiments, the material hardness of the insert can be between shore 30A and shore 50A, between shore 50A and shore 70A, between shore 70A and shore 90A, between shore 10D and shore 30D, between shore 30D and shore 50D, between shore 50D and shore 70D, or between shore 70D and shore 90D.

[0275] In many embodiments, the effective density of the insert can be between 0.35 and 1.0 g / cm3. In many embodiments, at least a portion of the insert can have an effective density between 0.35 and 0.50 g / cm3, between 0.40 and 0.55 g / cm3, between 0.45 and 0.60 g / cm3, between 0.50 and 0.65 g / cm3, between 0.55 and 0.70 g / cm3, between 0.60 and 0.75 g / cm3, between 0.65 and 0.80 g / cm3, between 0.70 and 0.85 g / cm3, between 0.75 and 0.90 g / cm3, between 0.80 and 0.95 g / cm3, or between 0.85 and 1.0 g / cm3.VII. Shaft-Receiving Mechanism

[0276] Strike face deflection and club head durability are affected by the presence or absence of an adjustable shaft-receiving mechanism and said mechanism's relationship to the IRM. The adjustable shaft-receiving mechanism can adjust the loft angle 20 and / or the lie angle 25 to better fit a given player and improve launch characteristics. However, adjustable shaft-receiving mechanisms often include a lower opening located on the sole (discussed in further detail below), near the strike face, and therefore in close proximity to the IRM. Accordingly, the presence of an adjustable shaft-receiving mechanism can limit the area of the sole available for the IRM to occupy. In embodiments including an adjustable shaft-receiving mechanism, the IRM size can be reduced or the IRM profile can be tailored to improve strike face deflection while retaining loft angle and lie angle adjustability, all without sacrificing club head durability.

[0277] The adjustable shaft-receiving mechanism can be similar to those described in U.S. patent application Ser. No. 15 / 003,494, filed on Jan. 21, 2016, now U.S. Pat. No. 9,868,035, granted on Jan. 16, 2018; and U.S. patent application Ser. No. 17 / 304,836, filed on Jan. 25, 2021, now U.S. Pat. No. 11,607,590, granted on Mar. 21, 2023; which are both incorporated fully herein by reference.

[0278] The adjustable shaft-receiving mechanism, as best illustrated in FIG. 52, comprises a shaft sleeve 5026 configured to receive a golf club shaft and retained within the hosel 5005 by a fastener 5027. The shaft sleeve 5026 and the hosel 5005 comprise complementary geometries that allow the shaft sleeve 5026 to be removably rotated into a plurality of different configurations. Rotating the shaft sleeve 5026 between different configurations will adjust a loft angle 20 and / or a lie angle 25 of the golf club head 5000.

[0279] In some embodiments, as best shown in FIGS. 52 and 53, the golf club head 5000 can comprise a lightweight shaft-receiving mechanism 5025 that creates discretionary mass. The shaft-receiving structure 5025 has reduced structural mass. At least a portion of the shaft sleeve 5026 is exposed to the interior cavity 5007. In the present embodiment, rather than being retained by an internal structure such as an interior hosel tube or hosel wall, the shaft sleeve 5026 is retained and supported in the golf club head 5000 by structures that also form at least a portion of the exterior of the body 5001. In many embodiments, the shaft-receiving mechanism 5025 comprises an upper end 5038A and a lower end 5038B. In the present embodiment, the shaft sleeve 5026 is secured only at the upper end 5038A and the lower end 5038B. The shaft sleeve 5026 is inserted through a hosel bore opening 5039 and retained at the upper end 5038A by the hosel 5005. The shaft sleeve 5026 can be secured to the golf club head 5000 by a fastener 5027. The fastener 5027 can extend through a lower opening 5022 formed in the sole 5012 and couple to a bottom end of the shaft sleeve 5026. The fastener 5027 can releasably couple the shaft sleeve 5026 to the hosel 5005.

[0280] The IRM 5020 can be configured to accommodate the adjustable shaft-receiving mechanism and provide loft angle and lie angle adjustability while improving strike face deflection. Referring to FIG. 54, the casing 5030 can comprise a “checkmark” shape, wherein the casing toe region 5037 comprises a toe relief 5028 and the casing heel region 5035 is truncated. In such embodiments, the casing heel region 5035 does not comprise a heel relief. The casing comprises a toe length LT measured from the absolute toe point (ATP) to the YZ plane and a heel length LH measured from the absolute heel point (AHP) to the YZ plane. In the illustrated embodiment, the toe length LT is greater than the heel length LH.

[0281] The checkmark shape having a truncated casing heel region 5035 allows for room between the casing 5030 and the lower opening 5022 of the adjustable shaft-receiving mechanism 5025. The checkmark shape improves club head durability, because if the absolute heel point (AHP) is too close to the lower opening 5022, excessive stress can pool in the casing heel region 5035 or in the adjustable shaft-receiving mechanism 5025. Referring to FIG. 54, the club head defines a heel region offset OH, measured as a heel-to-toe distance between the absolute heel point (AHP) and the lower opening 5022. In some embodiments, the heel region offset OH can be between 0.1 and 0.5 inch. In some embodiments, the heel region offset OH can be greater than 0.1 inch, greater than 0.2 inch, greater than 0.3 inch, greater than 0.4 inch, or greater than 0.5 inch. In some embodiments, the heel region offset OH can be less than 0.5 inch, less than 0.4 inch, less than 0.3 inch, less than 0.2 inch, or less than 0.1 inch. The heel region offset OH influences the heel length LH and balances strike face deflection with club head durability by either increasing or decreasing the total length (TL) of the casing 5030.

[0282] The adjustable shaft-receiving mechanism 5125 can be combined with an IRM 5120 reinforced by one or more of the high-strength components described herein (i.e., cartridge, appendage, etc.). In some embodiments, the high-strength component can form one or more portions of the adjustable shaft-receiving mechanism 5125, as best illustrated in FIG. 55. In the illustrated embodiment, the club head 5100 comprises a cartridge 5150 that integrally forms the lower opening 5122. The cartridge heel edge 5158 is disposed heelward of the lower opening 5122. The cartridge 5150 integrally forms both the casing 5130 and the lower opening 5122. This configuration removes the need for a weld line between the casing 5130 and the lower opening 5122. The heel region offset OH can thereby be reduced without danger of a heat affected zone compromising the durability of the casing 5130 or the portion of the sole 5112 forming the lower opening 5122. Accordingly, the casing heel region 5135 can be lengthened further towards the heel 5104 to increase strike face deflection.

[0283] In some embodiments, strike face deflection may be prioritized over loft angle and lie angle adjustability. In such embodiments, the club head 5200 can comprise a fixed shaft-receiving mechanism 5225 that combines with the IRM 5220 to improve strike face deflection. As best illustrated in FIG. 56, the hosel 5205 comprises a hosel side wall 5241 and a hosel bottom wall 5244 at least partially bounding a hosel bore 5245. The hosel bore 5245 is configured to receive a golf shaft through a hosel opening 5239 at the upper end of the hosel 5005. The hosel side wall 5241 is tubular in shape and circumscribes the hosel axis 30. As illustrated in FIG. 56, the hosel bottom wall 5244 is located within the interior cavity 5207 and spaced from the sole 5212. The hosel bottom wall 5244 separates the hosel bore 5245 from the interior cavity 5207 such that the hosel opening 5239 is the only opening into the hosel bore 5245.

[0284] The dimensions of the fixed shaft-receiving mechanism 5225, particularly how far the hosel side wall 5241 and the hosel bottom wall 5244 extend into the interior cavity 5207, can allow the casing 5230 to be lengthened further towards the heel 5204, thereby increasing strike face deflection. The hosel 5205 can comprise a hosel bore depth DHB measured from the hosel bore opening 5039 to the hosel bottom wall 5244, parallel to the hosel axis 30, of less than about 1.25 inches. In some embodiments, the hosel bore depth DHB can be less than 1.20, less than 1.15, or less than 1.10 inches.

[0285] In some embodiments, extending the casing 5230 towards the heel 5204 places the casing walls 5232, 5242 closer to the fixed shaft-receiving mechanism 5225. The hosel bottom wall 5244 can be spaced away from the casing walls 5232, 5242 by a hosel offset distance OHS, measured perpendicularly from the hosel bottom wall 5244 to the closest point of the casing front wall 5432 or the casing rear wall 5242. In some embodiments, the hosel offset distance OHS is less than 0.5 inches. For example, in some embodiments, the hosel offset distance OHS is less than 0.5 inches, less than 0.45 inches, less than 0.40 inches, less 0.35 inch, less than 0.30 inch, less than 0.25 inch, or less than 0.20 inch.

[0286] The combination of a shallow hosel bore depth DHB (i.e., less than about 1.25 inches) and a hosel offset distance OHS less than 0.50 inches creates space for the casing walls to extend toward the heel 5204, underneath the hosel bottom wall 5244. The lesser the hosel offset distance OHS and the shallower the hosel bore depth DHB, the further towards the heel 5204 the aperture 5240 can be extended without the casing walls 5232,5242 running into the hosel walls. The casing walls 5232, 5242 can therefore be designed with the desired heights and thicknesses to increase strike face deflection without interfering with the hosel walls.

[0287] Because the fixed shaft-receiving mechanism does not facilitate adjustment of loft and lie angles, there is no need to releasably couple the shaft to the club head body. Rather, the shaft can be permanently attached to the hosel 5205 through adhesives or epoxy. Accordingly, the fixed shaft-receiving mechanism does not have a fastener and is free of a lower opening. In the fixed system, the absence of a lower opening allows the aperture 5240 to be lengthened, thereby increasing strike face deflection. In some embodiments, as illustrated in FIG. 57, the club head 5200 with a fixed shaft-receiving mechanism can be combined with a U-shaped casing 5230 that includes both a toe relief 5228 and a heel relief 5229. The U-shaped casing 5230 expands further towards the heel 5204 than the checkmark shaped casing discussed above, because there is no lower opening interfering with the casing heel region 5235.VIII. Additional FeaturesA. Variable Face Thickness

[0288] In some embodiments, the club head 5400 can further comprise a strike face 5402 with a variable face thickness (hereafter “VFT”). The VFT can comprise a profile as described in U.S. patent application Ser. No. 18 / 981,336, filed on Dec. 13, 2024, entitled “Golf Club Heads Comprising a Variable Face Thickness.” Referring to FIG. 58, the VFT profile can include at least a central region 5424, a first transition region 5429, and an intermediate region 5436 formed into the strike face rear surface 5417. The central region 5424 can be located proximate the face center (FC) and can comprise the maximum strike face thickness of the club head 5400. In some embodiments, the central region 5424 comprises a constant thickness. In some embodiments, the strike face thickness in the central region 5424 can be between 0.060 and 0.150 inch.

[0289] The strike face thickness can depend on the club type. For example, for driver-type club heads, the strike face thickness in the central region 5424 can be between 0.100 and 0.150 inch. In some embodiments, the strike face thickness in the central region 5424 for a driver-type club head can be between 0.100 and 0.125 inch, between 0.105 and 0.130 inch, between 0.110 and 0.135 inch, between 0.115 and 0.140 inch, between 0.120 and 0.145 inch, or between 0.125 and 0.150 inch.

[0290] For fairway wood and hybrid-type club heads, the strike face thickness in the central region 5424 can be between 0.060 and 0.110 inch. In some embodiments, the strike face thickness in the central region 5424 for a fairway wood or hybrid-type club head can be between 0.060 and 0.085 inch, between 0.065 and 0.090 inch, between 0.070 and 0.095 inch, between 0.075 and 0.100 inch, between 0.080 and 0.105 inch, or between 0.085 and 0.110 inch.

[0291] The intermediate region 5436 at least partially surrounds the central region 5424 and comprises a minimum thickness of the strike face 5402. In some embodiments, the intermediate region 5436 comprises a constant thickness. In some embodiments, the strike face thickness in the intermediate region 5436 can be between 0.040 and 0.090 inch. As described above, the strike face thickness can depend on the club type. For example, for driver-type club heads, the strike face thickness in the intermediate region 5436 can be between 0.055 and 0.090 inch. In some embodiments, the strike face thickness in the central region 5424 for a driver-type club head can be between 0.055 and 0.070 inch, between 0.060 and 0.075 inch, between 0.065 and 0.080 inch, between 0.070 and 0.085 inch, or between 0.075 and 0.090 inch.

[0292] For fairway wood and hybrid-type club heads, the strike face thickness in the intermediate region 5436 can be between 0.040 and 0.075 inch. In some embodiments, the strike face thickness in the central region 5424 for a fairway wood or hybrid-type club head can be between 0.040 and 0.055 inch, between 0.045 and 0.060 inch, between 0.050 and 0.065 inch, between 0.055 and 0.070 inch, or between 0.060 and 0.075 inch.

[0293] The first transition region 5429 connects the central region 5424 to the intermediate region 5436 and comprises a varying thickness that decreases as it extends from the central region 5424 the intermediate region 5436. In some embodiments, the strike face thickness in the first transition region can vary between the strike face thicknesses in the central region 5424 and the intermediate region 5436, as described above.

[0294] In some embodiments, such as the driver embodiment illustrated in FIG. 58, the VFT profile can include a central region 5424, a first transition region 5429, an intermediate region 5436, a second transition region 5442, and an outer region 5446. In such embodiments, the outer region 5446 can at least partially surround the intermediate region 5436 and can comprise a thickness greater than that of the intermediate region 5436. Further, in such embodiments, the second transition region 5442 connects the intermediate region 5436 to the outer region 5446 and comprises a varying thickness that increases as it extends from the intermediate region 5436 to the outer region 5446. In other embodiments, such as the hybrid embodiment illustrated in FIG. 59, the VFT profile comprises only a central region 5524, a first transition region 5529, and an intermediate region 5536. In such embodiments, the club head 5200 can be devoid of a second transition region or an outer region.

[0295] The VFT profile can be configured to complement the strike face deflection benefits of the IRM. In some cases, the IRM can lower CT value low on the strike face 5402. As such, the VFT can reduce the strike face thickness near the sole 5412, thereby increasing strike face deflection and ball speed, particularly on low shots. In some embodiments, because the lower portion of the strike face 5402 does not require additional thickness to keep CT within conformance limits, the central region 5424 can be biased towards the crown 5410. Referring to FIG. 58, the central region 5424 can comprise a central region center point 5425 located at a geometric center of the central region 5424, on the strike face rear surface 5417. In some embodiments, the central region center point 5425 can be above the face center (FC). The club head 5400 can comprise a central region center height HCR measured between the face nadir (FN) and the central region center point 5425, in a direction parallel to the loft plane 15 and the YZ plane.

[0296] In some driver embodiments, the central region center height HCR can be between 0.700 and 1.200 inch. In some driver embodiments, the central region center height HCR can be between 0.700 and 0.850 inch, between 0.750 and 0.900 inch, between 0.800 and 0.950 inch, between 0.850 and 1.000 inch, between 0.900 and 1.050 inch, between 0.950 and 1.100 inch, between 1.000 and 1.150 inch, or between 1.200 inch. In some driver embodiments, the central region center height HCR can be greater than 0.700 inch, greater than 0.750 inch, greater than 0.800 inch, greater than 0.850 inch, greater than 0.900 inch, greater than 0.950 inch, greater than 1.000 inch, greater than 1.050 inch, greater than 1.100 inch, greater than 1.150 inch, or greater than 1.200 inch.

[0297] In some fairway wood and hybrid embodiments, the central region center height HCR can be between 0.500 and 1.000 inch. In some fairway wood and hybrid embodiments, the central region center height HCR can be between 0.500 and 0.600 inch, between 0.550 and 0.650 inch, between 0.600 and 0.700 inch, between 0.650 and 0.750 inch, between 0.700 and 0.800 inch, between 0.750 and 0.850 inch, between 0.800 and 0.900 inch, or between 0.900 and 1.000 inch. In some fairway wood and hybrid embodiments, the central region center height HCR can be greater than 0.500 inch, greater than 0.550 inch, greater than 0.600 inch, greater than 0.650 inch, greater than 0.700 inch, greater than 0.750 inch, greater than 0.800 inch, greater than 0.850 inch, greater than 0.900 inch, greater than 0.950 inch, or greater than 1.000 inch. The central region center point 5425 can be located in the upper half of the strike face rear surface 5417. The club head 5400 can comprise a central region center ratio defined as the central region center height HCR divided by the strike face height HSF. In some embodiments, the central region center ratio can be between 0.40 and 0.75. In some embodiments, the central region center ratio can be between 0.40 and 0.55, between 0.45 and 0.60, between 0.50 and 0.65, between 0.55 and 0.70, or between 0.60 and 0.75. In some embodiments, the central region center ratio can be greater than 0.40, greater than 0.45, greater than 0.50, greater than 0.55, greater than 0.60, greater than 0.65, greater than 0.70, or greater than 0.75.

[0298] Further, to reduce the strike face thickness near the sole 5612, the bottom of the VFT profile can be truncated. Referring to FIG. 60, the transition region 5629 comprises a transition region perimeter 5633 including a transition region nadir 5634 at a sole-most point of the transition region perimeter 5633 and a transition region apex 5635 at the crown-most point of the transition region perimeter 5633. In some embodiments, the transition region 5629 is truncated such that the distance between the transition region nadir 5634 and the central region center point 5625 is less than the distance between the transition region apex 5635 and the central region center point 5625, as measured parallel to the YZ plane (YZ).

[0299] The transition region perimeter 5633 can be raised away from the leading edge 5603. This configuration increases the area of the intermediate region 5636 to reduce the strike face thickness near the sole 5612. The club head 5600 comprises a transition region nadir height HTN measured between the face nadir (FN) and the transition region nadir 5634, in a direction parallel to the loft plane 15 and the YZ plane. In some driver embodiments, the transition region nadir height HTN can be between 0.030 and 0.050 inch. In some driver embodiments, the transition region nadir height HTN can be between 0.030 and 0.035 inch, between 0.035 and 0.040 inch, between 0.040 and 0.045 inch, between 0.045 and 0.050 inch, between 0.050 and 0.055 inch, between 0.055 and 0.060 inch, between 0.060 and 0.065 inch, or between 0.065 and 0.070 inch. In some driver embodiments, the transition region nadir height HTN can be greater than 0.030 inch, greater than 0.035 inch, greater than 0.040 inch, greater than 0.045 inch, greater than 0.050 inch, greater than 0.055 inch, greater than 0.060 inch, greater than 0.065 inch, greater than 0.070 inch, greater than 0.075 inch, or greater than 0.080 inch. In some fairway wood and hybrid embodiments, the transition region nadir height HTN can be between 0.200 and 0.400 inch. In some fairway wood and hybrid embodiments, the transition region nadir height HTN can be between 0.200 and 0.250 inch, between 0.225 and 0.275 inch, between 0.250 and 0.300 inch, between 0.275 and 0.325 inch, between 0.300 and 0.350 inch, between 0.325 and 0.375 inch, between 0.350 and 0.400 inch, or between 0.375 and 0.425 inch. In some fairway wood embodiments, the transition region nadir height HTN can be greater than 0.200 inch, greater than 0.225 inch, greater than 0.250 inch, greater than 0.275 inch, greater than 0.300 inch, greater than 0.325 inch, greater than 0.350 inch, greater than 0.375 inch, greater than 0.400 inch, greater than 0.425 inch, or greater than 0.450 inch.

[0300] Further, the club head 5600 can comprise a transition region nadir ratio defined as the transition region nadir height HTN divided by the strike face height HSF. In some embodiments, the transition region nadir ratio can be between 0.20 and 0.50. In some embodiments, the transition region nadir ratio can be between 0.20 and 0.35, between 0.25 and 0.40, or between 0.35 and 0.50. In some embodiments, the central region center ratio can be greater than 0.20, greater than 0.25, greater than 0.30, greater than 0.35, greater than 0.40, greater than 0.45, or greater than 0.50.B. Weighting Features

[0301] In some embodiments, the club head further comprises one or more weights that complement the IRM to improve club head performance. The one or more weights can create a desirable CG position that, in combination with the strike face deflection created by the IRM, increases ball speed and reduces spin rate. The one or more weights can be integral with the club head body, such as one or more internal mass pads, or one or more separate weight members such as a removable weight member or a sole plate.

[0302] In many embodiments, the club head can comprise one or more internal mass pads control the club head CG location. Referring to FIG. 61, the club head 5700 comprises a mass pad 5751 formed integrally with the club head body 5701, located on the sole 5712, and within the interior cavity 5707. The mass pad 5751 is a region of increased thickness surrounding regions of the sole 5712. The mass pad 5751 can be rearward of the aperture 5740. In some embodiments, the mass pad 5751 is integral with a portion of the casing 5730. In the illustrated embodiment, the mass pad 5751 is integral with the casing rear wall 5742. In such embodiments, the mass pad top surface 5753 can abut the rear wall rear surface 5746. In some embodiments, such as the illustrated embodiment of FIG. 61, the mass pad top surface 5753 can be lower than the rear wall top surface 5748, such that at least a portion of the rear wall 5742 extends above the mass pad 5751. In other embodiments, the mass pad top surface 5753 and the rear wall top surface 5748 can be flush. In such embodiments, mass pad 5751 essentially forms the rear wall 5742 and thereby bounds at least a portion of the aperture 5740. In other embodiments, the mass pad 5751 and the casing 5730 can be separated. In such embodiments, the mass pad 5751 can be spaced rearward of the casing rear wall 5742 such that the mass pad 5751 does not contact the casing rear wall 5742.

[0303] Any IRM geometry or faceplate configuration can be combined with any mass pad embodiment described herein. One or more mass pads can be integrally formed by the faceplate, the body, a cartridge, an appendage, or any combination thereof. The combination of high-strength material reinforcement and one or more mass pads further increases strike face deflection without compromising durability.

[0304] In some embodiments, the club head comprises an IRM 5820 and a large, high-density sole pod 5866 that lowers the club head CG and improves performance characteristics, as best illustrated in illustrated in FIGS. 62 and 63. In some embodiments, the sole pod can be similar to the sole insert as described in U.S. application Ser. No. 18 / 665,424, filed on May 15, 2024, which is fully incorporated herein by reference. The sole pod 5866 comprises a sole pod material with a higher density than that of the body material. The sole pod 5866 can reside within a sole pod recess 5867 formed into the exterior surface of the sole 5812. In some embodiments, the sole pod 5866 forms a portion of the sole 5812. The sole pod 5866 concentrates mass near the sole 5812, thereby lowering CG. The low-CG complements the strike face deflection benefits of the IRM 5820 to further increase ball speed and lower spin.

[0305] The sole pod 5866 is a large and heavy weight member. The sole pod 5866 can be made of a relatively high-density material, such as tungsten or a tungsten alloy. In some embodiments, the sole pod 5866 can comprise a sole pod mass between 50 and 100 grams. In some embodiments, the sole pod mass can be greater than 50 grams, greater than 60 grams, greater than 70 grams, greater than 80 grams, greater than 90 grams, or greater than 100 grams. Any one or combination of club head embodiments described herein can comprise a high-density sole pod 5866.

[0306] In some embodiments, the sole pod 5866 can be located immediately rearward of the casing 5830. This forward positioning of the sole pod 5866 moves the CG forward to increase ball speed and reduce spin without hindering strike face deflection. Referring to FIG. 63, the club head 5800 can comprise a sole pod offset OSI, defined as the front-to-back distance between the casing front wall 5832 and a sole pod forward edge 5868. The sole pod offset OSI can be substantially small. As such, the sole pod 5866 moves the CG forward while still allowing the IRM 5820 to flex. In some embodiments, the sole pod offset OSI can be between 0.2 and 1.0 inch. In some embodiments, the sole pod offset OSI can be less than 1.0 inch, less than 0.9 inch, less than 0.8 inch, less than 0.7 inch, less than 0.6 inch, less than 0.5 inch, less than 0.4 inch, or less than 0.3 inch. The combination of IRM 5820 performance benefits and the CG position provided by the sole pod 5866 creates a high performing club head.

[0307] The sole pod 5866 can be secured within the sole pod recess 5867 by mechanical means, adhesive means, welding, or a combination thereof. In some embodiments, the sole pod 5866 is secured within the sole pod recess 5867 by one or more external threaded fasteners 5871.

[0308] Any IRM geometry or faceplate configuration can be combined with a sole pod as described above. For example, a sole pod can be combined with a club head comprising a reverse L-cup faceplate, an L-cup faceplate, a J-cup faceplate, a partial J-cup faceplate, an underlapping J-cup, an appendage, a cartridge, or any other faceplate configuration described herein.

[0309] Further, as illustrated in FIG. 63, the club head 5800 can comprise one or more removable weights 5869 located in and removably coupled to a rearward portion of the sole 5812. The removable weight 5869 can be used for swing weighting, by selecting a removable weight mass that will result in the desired club head mass. In some embodiments, the removable weight mass can be between 1 and 35 grams. In some embodiments, the removable weight mass can be between 1 and 5 grams, between 5 and 10 grams, between 10 and 15 grams, between 15 and 20 grams, between 20 and 25 grams, between 25 and 30 grams, or between 30 and 35 grams. In some embodiments, the removable weight mass can be greater than 1 gram, greater than 5 grams, greater than 10 grams, greater than 15 grams, greater than 20 grams, greater than 25 grams, greater than 30 grams, greater than 35 grams, or greater than 40 grams.

[0310] Similar to the sole pod 5866, the removable weight 5869 can lower the club head CG, thereby improving launch characteristics. Further, the removable weight 5869 can be located in a rear portion of the sole 5812 to increase club head MOI. Although the removable weight 5869 is illustrated in combination with the sole pod 5866, the removable weight 5869 can be provided in any embodiment described herein.

[0311] Any IRM geometry or faceplate configuration can be combined with a removable weight as described above. For example, a removable weight can be combined with a club head comprising a reverse L-cup faceplate, an L-cup faceplate, a J-cup faceplate, a partial J-cup faceplate, an underlapping J-cup, an appendage, a cartridge, or any other faceplate configuration described herein.EXAMPLESA. Example 1—Ball Flight Performance of Golf Club Head with IRM

[0312] The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head, but was devoid of an Impact Response Modulator entirely.

[0313] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club head and the control club head. The ball flight results of the player test are displayed in Table 1 below.TABLE 1Player Test Ball Flight CharacteristicsBall SpeedLaunch AngleSpin RateCarry DistanceClub Head(mph)(degrees)(rpm)(yards)Exemplary155.510.43547252.1Control154.510.33911248.7

[0314] As displayed in Table 1 above, the exemplary club head exhibited an increase in ball speed of 1.0 mph and a decrease in spin rate of 364 rpm in comparison to the control club head, with a similar launch angle. The decreased spin rate created a more piercing ball flight that cuts through the air and travels further. These improved ball flight characteristics increased carry distance by 3.4 yards on average.

[0315] In addition to the performance results obtained through player testing, robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 3 displays the results of the robotic testing at each location, as well as the averages over all locations.TABLE 2Robotic Testing Ball Flight CharacteristicsBall SpeedSpin RateCarry DistanceClub HeadLocation(mph)(rpm)(yards)ExemplaryFace Center151.93203249.00.1 inch low151.63383244.00.2 inch low150.63265235.40.3 inch low150.73070221.3Average151.23230237.4ControlFace Center150.53714240.00.1 inch low149.83916237.70.2 inch low149.43835231.30.3 inch low149.83543220.2Average149.93752232.3

[0316] At the face center (FC), the exemplary club head exhibited an increase in ball speed of 1.4 mph and a decrease in spin of 511 rpm, which creates a more piercing ball flight that cuts through the air and travels further. These improvements resulted in an increase in carry distance of 9.0 yards. On average across all locations, the exemplary club head exhibited an increase in ball speed of 1.3 mph and a decrease in spin of 522 rpm in comparison to the control club head, resulting in an increase in carry distance of 5.1 yards. Overall, results of both the player test and the robotic test illustrate the benefits of the IRM. The IRM increased strike face deflection in the exemplary club head, which improved ball speed, spin rate, and distance.B. Example 2—Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0317] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a cartridge located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The casing also wrapped over the leading edge and formed a lower portion of the strike face, similar to the casing illustrated in FIG. 26. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had a front wall height FWH of 0.274 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.192 inch due to the high-strength material reinforcement. The offset distance OD from the casing front wall to the strike face in the control club head was 0.24 inch, whereas the exemplary club head had a reduced offset distance OD of 0.177 inch. The reduced front wall height FWH and offset distance OD each increase the amount the casing bends at impact, thereby increasing strike face deflection.

[0318] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 3 below.TABLE 3Ball Flight CharacteristicsBall SpeedLaunch AngleSpin RateClub Head(mph)(degrees)(rpm)Exemplary144.711.552532Control141.511.42919

[0319] As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph compared, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength cartridge allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. The example demonstrates that reinforcing the casing with a high-strength component, such as the exemplary cartridge, results in measurable performance benefits. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the exemplary and control club heads of the present example. Similar ball speed and spin rate improvements are expected for the exemplary club head.C. Example 3—Ball Flight Performance of Club Head Comprising IRM and Fixed Shaft-Receiving Mechanism

[0320] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator and a fixed shaft-receiving mechanism were compared to those of a first control club head comprising an Impact Response Modulator and an adjustable shaft-receiving mechanism and a second control club head devoid of an Impact Response Modulator. The exemplary club head comprised a U-shaped casing extending across the majority of the sole and comprising both a heel relief and a toe relief. The exemplary club head had no lower opening on the sole to accommodate an adjustable shaft-receiving mechanism, because the exemplary shaft-receiving mechanism was fixed. The first control club head comprised a lower opening on a heel side of the sole that received a fastener to secure the shaft sleeve to the hosel. The lower opening blocked the IRM of the control club head from extending all the way towards the heel. As such, the control casing had a truncated checkmark shape with a toe relief but no heel relief. The second control club was devoid of an IRM altogether but included an adjustable shaft-receiving mechanism similar to that of the first control club head.

[0321] Robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club heads. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 4 displays the results of the robotic testing averaged over all the impact locations. Table 5 displays the results of the robotic testing averaged only over the three “low” locations (i.e., 0.1 inch, 0.2 inch, and 0.3 inch below face center (FC)).TABLE 4Ball Flight Characteristics, All LocationsClub HeadBall Speed (mph)Spin Rate (rpm)Exemplary151.62278First Control150.82959Second Control150.43197TABLE 5Ball Flight Characteristics, Low LocationsClub HeadBall Speed (mph)Spin Rate (rpm)Exemplary152.42286First Control150.83135Second Control149.63673As illustrated by Tables 4 and 5, the club heads comprising an IRM (i.e., the exemplary club head and the first control club head) exhibited significant gains over second control club head, which was devoid of an IRM. In particular, the exemplary club head and the first control club head each exhibited increased ball speed and decreased spin rate in comparison to the second control club head, both on low strikes and across all locations. Further, the exemplary club head exhibited significant gains over the first control club head. On average across all locations, the exemplary club head increased ball speed by 0.8 mph and reduced spin rate by 681 rpm. Specifically, regarding low strikes, the exemplary club head increased ball speed by 1.6 mph and reduced spin by 849 rpm.

[0323] The results of the robotic test illustrate the possible ball flight characteristic advantages of combining the IRM with a fixed shaft-receiving mechanism. As discussed above, removing the need for a lower opening associated with the adjustable shaft-receiving mechanism allows the casing to be lengthened and improves strike face flexibility, thereby leading to the improvements displayed in the above tables. However, in some cases, providing an adjustable shaft-receiving mechanism can outweigh the raw ball speed and spin rate benefits of the fixed shaft-receiving mechanism. For certain players, the ability to adjust the loft angle and / or lie angle can optimize said player's launch conditions and improve ball speed and spin rate over a fixed system.D. Example 4—Performance Ratio Comparison

[0324] The performance of an exemplary club head comprising an IRM with the above disclosed geometries and parameters, that satisfies the inequality below, is compared to two control club heads comprising IRMs with altered geometries / dimensions that do not satisfy the following inequality:14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2

[0325] The exemplary club head is a fairway wood type club head comprising a strike face with a crown return, an adjustable hosel, and an IRM formed in the body. The two control club heads are identical to the exemplary club head except that the two control club heads had different total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT than the exemplary club head.TABLE 6ExemplaryControl 1Control 2Total Length (TL)2.359in2.538in2.550inOffset Distance (OD)0.245in0.277in0.247inFront Wall Height0.221in0.238in0.235in(FWH)Front Wall Thickness0.0851in0.096in0.0753in(FWT)Performance Value16.38in−212.83in−218.66in−2Ball Speed+0.7mph+0.2mph+1.0mphSpin−250rpmnegligible−350rpmDurability2000hits2996hits1792hits

[0326] As illustrated in Table 6 above, control club head 1 and control club head 2 had altered geometries that do not satisfy a performance inequality. The performance inequality of the present disclosure ranges between 14 and 18 in−2 while control club head 1 had a performance value of 12.83 in−2 and control club head 2 had a performance value of 18.66 in−2. The Exemplary embodiment has a performance value of 16.38 in−2. These performance values were based on the performance inequality having a performance coefficient PC of 0.032.

[0327] Control club head 1 and control club head 2 were physically tested for performance and durability by a robotic test and an air cannon test, respectively. Each test compared the results of the control club head to a baseline club head without an IRM or an aperture. Control club head 1 had a 0.2 mph gain in ball speed and negligible spin difference compared to the club head without an IRM and had. Control club head 2 had a 1.0 mph gain in ball speed and reduction of 350 rpms compared to the club head without an IRM. These results show that control club head 1, which had a performance value below 14 in−2, was over durable and had minimal improvements on performance. Conversely, the results show that control club head 2, which had a performance ratio above 18 in−2, was overly flexible and resulted in a large increase in performance but insufficient durability with less than 2000 hits to failure.

[0328] The Exemplary club head is expected to exhibit, based on a Finite Element Analysis study, a 0.7 mph gain in ball speed and a 250 rpm spin reduction compared to the club head without an IRM while achieving a sufficient durability of at least 2000 hits to failure. This will be due to the balance of the four parameters (total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT) that result in a performance value of 16.38 in−2. Specifically, the total length TL was decreased relative to control 1 and control 2, the offset distance OD was decreased relative to control 1 and control 2, the front wall height FWH was decreased relative to control 1 and control 2, and the front wall thickness FWT was increased relative to control 2 but less than control 1. Accordingly, this resulted in the exemplary club head having a performance value of 16.38 in−2.Clauses

[0329] Clause 1. A golf club head, comprising a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, and a coordinate system centered about a face center comprising: an x-axis extending in a heel-to-toe direction parallel to a ground plane; a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; and a z-axis extending in a front-to-rear direction and orthogonal to both the x-axis and y-axis; the golf club head further comprising an Impact Response Modulator (IRM) including a casing having: a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface; a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a toe relief portion angled rearwardly away from the strike face; and an insert disposed within the aperture; wherein the IRM satisfies the following inequality: 14 in−2≤PC (TL) / (OD) (FWT) (FWH)≤18 in−2, wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing, wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge, wherein FWT is a front wall thickness measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface, wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, and wherein PC is a performance coefficient equal to 0.032.

[0330] Clause 2. The golf club head of clause 1, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

[0331] Clause 3. The golf club head of clause 2, wherein the central region comprises a central region center point located above a face center of the strike face.

[0332] Clause 4. The golf club head of clause 1, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

[0333] Clause 5. The golf club head of clause 1, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

[0334] Clause 6. The golf club head of clause 1, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

[0335] Clause 7. The golf club head of clause 1, wherein the casing further comprises: a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; and a toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

[0336] Clause 8. The golf club head of clause 1, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

[0337] Clause 9. A golf club head, comprising a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, a crown panel formed of a composite material having a toe wrap and a heel wrap, and a coordinate system centered about a face center comprising: an x-axis extending in a heel-to-toe direction parallel to a ground plane; a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; and a z-axis extending in a front-to-rear direction and orthogonal to both the x-axis and y-axis; the golf club head further comprising an Impact Response Modulator (IRM) including a casing having: a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface; a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a toe relief portion angled rearwardly away from the strike face; and an insert disposed within the aperture; wherein the IRM satisfies the following inequality: 14 in−2≤PC (TL) / (OD) (FWT) (FWH)≤18 in−2, wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing, wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge, wherein FWT is a front wall thickness measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface, wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, and wherein PC is a performance coefficient between 0.030 and 0.034.

[0338] Clause 10. The golf club head of clause 9, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

[0339] Clause 11. The golf club head of clause 10, wherein the central region comprises a central region center point located above a face center of the strike face.

[0340] Clause 12. The golf club head of clause 9, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

[0341] Clause 13. The golf club head of clause 9, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

[0342] Clause 14. The golf club head of clause 9, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

[0343] Clause 15. The golf club head of clause 9, wherein the casing further comprises: a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; and a toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

[0344] Clause 16. The golf club head of clause 9, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

[0345] Clause 17. The golf club head of clause 9, wherein the casing further comprises one or more tabs that extend rearward from the front wall and overhang at least a portion of the aperture, and wherein the one or more tabs are configured to engage the insert.

Examples

examples

A. Example 1—Ball Flight Performance of Golf Club Head with IRM

[0312]The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head, but was devoid of an Impact Response Modulator entirely.

[0313]Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club h...

example 2

B. Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0317]The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a cartridge located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The casing also wrapped over the leading edge and formed a lower portion of the strike face, similar to the casing illustrated in FIG. 26. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had...

example 4

D. Performance Ratio Comparison

[0324]The performance of an exemplary club head comprising an IRM with the above disclosed geometries and parameters, that satisfies the inequality below, is compared to two control club heads comprising IRMs with altered geometries / dimensions that do not satisfy the following inequality:

14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2

[0325]The exemplary club head is a fairway wood type club head comprising a strike face with a crown return, an adjustable hosel, and an IRM formed in the body. The two control club heads are identical to the exemplary club head except that the two control club heads had different total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT than the exemplary club head.

TABLE 6ExemplaryControl 1Control 2Total Length (TL)2.359in2.538in2.550inOffset Distance (OD)0.245in0.277in0.247inFront Wall Height0.221in0.238in0.235in(FWH)Front Wall Thickness0.0851in0.096in0.0753in(FWT)Performance Value16.38in−212...

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation-in-part of U.S. patent application Ser. No. 19 / 090,340, filed on Mar. 25, 2025, which claims the benefit of U.S. Provisional Application No. 63 / 569,638, filed on Mar. 25, 2024. This further claims the benefit of U.S. Provisional Application No. 63 / 648,946, filed on May 17, 2024, U.S. Provisional Application No. 63 / 654,776, filed on May 31, 2024, U.S. Provisional Application No. 63 / 664,628, filed on Jun. 26, 2024, U.S. Provisional Application No. 63 / 699,398, filed on Sep. 26, 2024, and U.S. Provisional Application No. 63 / 769,579, filed on Mar. 10, 2025, and U.S. Provisional Application No. 63 / 784,868, filed on Apr. 7, 2025, all of which are incorporated in their entirety.FIELD OF INVENTION

[0002] This invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.BACKGROUND

[0003] The strike face of a golf club head deflects upon impact with a golf ball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. Increased strike face deflection increases energy transfer between the club head and the golf ball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted on the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air and increases carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and / or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. Conventional golf club heads fail to increase strike face deflection without compromising club head durability.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. 1 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0005] FIG. 2 is a bottom, front, toe-side perspective view of the golf club head of FIG. 1.

[0006] FIG. 3 is a front, elevation view of the golf club head of FIG. 1.

[0007] FIG. 4 is a toe-side, elevation view of the golf club head of FIG. 1.

[0008] FIG. 5 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0009] FIG. 6 is a bottom, rear, toe-side perspective view of a golf club head according to the present invention.

[0010] FIG. 7 is a detailed, plan view of the golf club head of FIG. 1, in cross-section.

[0011] FIG. 8 is a toe-side, detailed, elevation view of the golf club head of FIG. 1, in cross-section.

[0012] FIG. 9 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0013] FIG. 10 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0014] FIG. 11 is a toe-side, detailed, elevation view of the golf club head of FIG. 8, in cross-section.

[0015] FIG. 12 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0016] FIG. 13 is a detailed, top, rear, toe-side, perspective view of a golf club head according to the present invention, in cross-section.

[0017] FIG. 14 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0018] FIG. 15 is a detailed, top, rear, toe-side, perspective view of a golf club head of the golf club head of FIG. 13.

[0019] FIG. 16 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0020] FIG. 17 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0021] FIG. 18 is a toe-side, detailed, elevation view of the golf club head of FIG. 17, in cross-section.

[0022] FIG. 19 is a front, toe-side perspective view of a golf club head according to the present invention.

[0023] FIG. 20 is a toe-side, elevation view of a golf club head according to the present invention.

[0024] FIG. 21 is a rear, heel-side perspective view of a golf club head faceplate.

[0025] FIG. 22 is a heel-side, detailed, elevation view of a golf club head comprising the faceplate of FIG. 21, in cross-section.

[0026] FIG. 23 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0027] FIG. 24 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0028] FIG. 25 is a detailed, plan view of the golf club head of FIG. 24, in cross-section.

[0029] FIG. 26 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0030] FIG. 27 is a detailed, plan view of the golf club head of FIG. 26, in cross-section.

[0031] FIG. 28 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0032] FIG. 29 is a detailed, bottom view of the golf club head of FIG. 28.

[0033] FIG. 30 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0034] FIG. 31 is a bottom view of a golf club head according to the present invention.

[0035] FIG. 32 is a detailed, toe-side, elevation view of the golf club head of FIG. 31, in cross section.

[0036] FIG. 33 is a bottom, front, toe-side perspective view of a golf club head according to the present invention.

[0037] FIG. 34 is a bottom view of a golf club head according to the present invention.

[0038] FIG. 35 is a rear, top, toe-side view of the golf club head of FIG. 34, in cross-section.

[0039] FIG. 36 is a detailed, plan view of the golf club head of FIG. 34, in cross-section.

[0040] FIG. 37 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0041] FIG. 38 is a detailed, plan view of the golf club head of FIG. 37, in cross-section.

[0042] FIG. 39 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0043] FIG. 40 is a detailed, plan view of the golf club head of FIG. 39, in cross-section.

[0044] FIG. 41 is a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

[0045] FIG. 42 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0046] FIG. 43 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0047] FIG. 44 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0048] FIG. 45 is a detailed, heel-side, elevation view of the golf club head of FIG. 41, in cross-section.

[0049] FIG. 46 is a detailed, plan view of the golf club head of FIG. 41, in cross-section.

[0050] FIG. 47 is a detailed, sole-side, plan view of a golf club head.

[0051] FIG. 48 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0052] FIG. 49 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0053] FIG. 50 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0054] FIG. 51 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0055] FIG. 52 is a detailed, front, elevation view of a golf club head according to the present invention, in cross-section.

[0056] FIG. 53 is a detailed, front, elevation view of a golf club head according to the present invention, in cross-section, with the shaft sleeve removed.

[0057] FIG. 54 is a bottom view of a golf club head according to the present invention.

[0058] FIG. 55 is a bottom view of a golf club head according to the present invention.

[0059] FIG. 56 is a detailed, rear, elevation view of a golf club head according to the present invention, in cross-section.

[0060] FIG. 57 is a bottom view of a golf club head according to the present invention.

[0061] FIG. 58 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0062] FIG. 59 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0063] FIG. 60 is a rear elevation view of a golf club head according to the present invention, in cross-section.

[0064] FIG. 61 is a toe-side, elevation view of the golf club head according to the present invention, in cross-section.

[0065] FIG. 62 is a toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0066] FIG. 63 is a bottom view of the golf club head of FIG. 62.DETAILED DESCRIPTION

[0067] Described herein are various embodiments of wood-type golf club heads (i.e. drivers, fairway woods, or hybrids) comprising an impact response modulator (hereafter “IRM”) in the sole. The IRM strategically weakens the sole to increase strike face deflection, thereby improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material. The casing includes various stress reducing geometries and / or selected regions of high-strength material to increase strike face deflection while maintaining sufficient club head durability.

[0068] In some embodiments, a high-strength material component, such as a faceplate, a cartridge, or an appendage, can form and reinforce one or more portions of the casing, thereby increasing strike face deflection without compromising durability. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Selectively using high-strength material reduces stress in the casing walls. Accordingly, the casing walls can have a reduced thickness and / or be placed closer to the strike face without exceeding the yield strength of the high-strength material, thereby increasing strike face deflection.

[0069] In some embodiments, the club head comprises a body and a faceplate coupled together, wherein the faceplate forms at least a portion of the casing. The body comprises a body material that is easily castable to form various complex club head geometries. The faceplate comprises a high-strength faceplate material with a yield strength greater than 175 ksi (i.e., C300 steel, C350 steel, Ti-9s, Ti-9s+, etc.) The faceplate material is more durable than the body material and is suitable to withstand direct impact with a golf ball. In some embodiments, the faceplate comprises a sole return that forms one or more portions of the casing. In some embodiments, the body and the faceplate combine to form the casing, whereby the body and the faceplate each form at least a portion of the casing.

[0070] In some embodiments, the club head comprises a separately formed, high-strength material member that forms one or more portions of the casing, referred to herein as a “cartridge,” The cartridge is located on the sole of the club head and integrally forms at least portions of the casing front wall and the casing rear wall. The cartridge can be coupled to both the faceplate and the body, or can be coupled to and entirely surrounded by the body. Similar to the faceplate, the cartridge can comprise a high-strength cartridge material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0071] In other embodiments, the club head can comprise a separately formed high-strength component that forms a portion of the casing front wall, but not a portion of the casing rear wall, referred to herein as an “appendage.” The appendage is located on the sole of the club head and is coupled to both the faceplate and the body. In such embodiments, the body and the appendage combine to form the casing, whereby the body and the appendage each form at least a portion of the casing. Similar to both the faceplate and the cartridge, the appendage can comprise a high-strength appendage material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0072] The IRM selectively uses high-strength material to increase strike face deflection while maintaining durability. For example, one or both of the casing front wall and the casing rear wall can be integrally formed by high-strength material (i.e., the faceplate material, the cartridge material, or the appendage material). In some embodiments, a portion of the front wall front surface, front wall rear surface, front wall base, and / or front wall top surface can be integrally formed by a high-strength component. Similarly, in some embodiments, a portion of the rear wall front surface, rear wall rear surface, rear wall base, and / or rear wall top surface can be integrally formed by a high-strength component. Forming portions of the casing with high-strength material, whether via the faceplate, a cartridge, or an appendage, increases strike face deflection without compromising durability.

[0073] The IRM further balances strike face deflection and club head durability through various stress-reducing casing geometries, dimensions, and / or parameters. Balancing certain casing parameters or localized reinforcements can increase strike face deflection without a corresponding stress increase. For example, balancing the length of the aperture, offset distance of the aperture, relief geometries, and front wall geometries can improve the strike face deflection while maintaining durability.

[0074] Any casing geometry described herein can be combined with any suitable high-strength material reinforcement. For example, any IRM geometry or local reinforcement can be combined with any faceplate configuration including a faceplate with a sole return integrally forming the entire IRM or a faceplate a sole return integrally forming only a portion of the IRM. The IRM can comprise any suitable geometry described herein and be integrally formed by the faceplate, the body, a cartridge, an appendage, or any combination thereof. The combination of high-strength material reinforcement and stress-reducing casing geometries further increases strike face deflection without compromising durability.

[0075] As such, certain aspects of the present invention, including high-strength material reinforcement and stress-reducing casing geometries, balance strike face deflection and durability. Such aspects increase strike face deflection (and thereby ball flight performance) without a corresponding increase in stress, increase durability without sacrificing performance, or both.I. Definitions

[0076] The terms “first,”“second,”“third,”“fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” 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 comprises 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.

[0077] The terms “left,”“right,”“front,”“back,”“top,”“bottom,”“over,”“under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and / or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0078] The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golf ball. The term “strike face” can be used interchangeably with the term “face.”

[0079] The strike face 102 is bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club head 100 deviates from a bulge curvature and / or roll curvature of the strike face 102 (defined below). The strike face perimeter includes at least an upper edge 118 that defines a transition between the strike face 102 and the crown 110 and a leading edge 103 that defines a transition from the strike face 102 to the sole 112. The upper edge 118 defines a face apex (FA), located at the intersection between the upper edge 118 and the YZ plane (described below). The leading edge 103 defines a face nadir (FN) located at the intersection between the leading edge 103 and the YZ plane. The strike face 102 further defines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in FIG. 4. The face center (FC) can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA).

[0080] The strike face 102 defines a strike face height (HSF). Referring to FIG. 3, the strike face height (HSF) is measured within the YZ plane (described in further detail below) and parallel to the loft plane 15 between the face nadir (FN) and the face apex (FA).

[0081] The strike face 102 comprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike face 102 in the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and / or the roll curvature can comprise one or more radii.

[0082] The golf club head 100 defines a ground plane (GP) as a reference plane associated with the surface on which a golf ball is placed. The ground plane GP is a horizontal plane tangent to the sole 112 in the address position. The ground plane GP is illustrated in FIG. 3.

[0083] The golf club head 100 defines a loft plane 15 as a plane that is tangent to the strike face 102 at the face center (FC). The loft plane 15 is illustrated in FIG. 4.

[0084] The golf club head 100 defines a loft angle 20 as the angle measured between the loft plane 15 and the XY plane (defined below). The loft angle 20 is illustrated in FIG. 4.

[0085] The golf club head 100 defines a lie angle 25 as the angle between a hosel axis 30, extending longitudinally through the hosel 105, and the ground plane GP. The lie angle 25 is measured from a front view of the golf club head 100, as illustrated in FIG. 3.

[0086] The golf club head 100 can define an address position, wherein the golf club head 100 is oriented such that the golf club head 100 forms its intended loft angle 20 and lie angle 25. For example, in the address position, the loft plane 15 and the XY plane form the intended loft angle 20 between one another. Likewise, in the address position, the hosel axis 30 and the ground plane GP form the intended lie angle 25 between one another.

[0087] As illustrated in FIGS. 3 and 4, the golf club head 100 defines a primary coordinate system centered about the face center (FC). The primary coordinate system comprises an X-axis 40, a Y-axis 50, and a Z-axis 60. The X-axis 40 extends in a heel-to-toe direction, parallel to the ground plane GP. The X-axis 40 is positive towards the heel 104 and negative towards the toe 106. The Y-axis 50 extends in a crown-to-sole direction and is orthogonal to both the ground plane GP and the X-axis 40. The Y-axis 50 is positive towards the crown 110 and negative towards the sole 112. The Z-axis 60 extends in a front-to-rear direction, parallel to the ground plane GP, and is orthogonal to both the X-axis 40 and the Y-axis 50. The Z-axis 60 is positive towards the strike face 102 and negative towards the rear 111.

[0088] The primary coordinate system, as described herein, defines an XY plane as a vertical plane extending along the X-axis 40 and the Y-axis 50. The primary coordinate system defines an XZ plane as a horizontal plane extending along the X-axis 40 and the Z-axis 60. The primary coordinate system further defines a YZ plane as a vertical plane extending along the Y-axis 50 and the Z-axis 60. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the primary coordinate system origin located at the face center (FC). In these or other embodiments, the golf club head 100 can be viewed from a front view when the strike face 102 is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club head 100 can be viewed from a side view when the heel 104 or the toe 106 is viewed from a direction perpendicular to the YZ plane.

[0089] The golf club head 100 comprises a club head center of gravity (hereafter “CG” or “club head CG”), referring to the point at which the mass is centered within the golf club head 100. The club head CG is illustrated in FIGS. HA and HB.

[0090] The “body depth,” or “depth” DB of the club head 100, as used herein, refers to a front-to-rear dimension measured across the body. Referring to FIG. 4, the body depth DB is measured parallel to the Z-axis 60 from the leading edge 103 to the rearward-most point of the body 101.

[0091] The “body height,” or “height” HB of the club head 100, as described herein, can refer to a crown-to-sole dimension measured across the body 101. Referring to FIG. 3, the body height HB can be measured as a vertical distance (parallel to the Y-axis 50) between the ground plane GP and the highest point of the crown 110. In many embodiments, the height HB can be measured according to a golf governing body such as the United States Golf Association (USGA).

[0092] The “body width,” or “width” WB of the club head 100, as described herein, can refer to a heel-to-toe dimension measured across the body. Referring to FIG. 3, the body width WB can be measured parallel to the X-axis 40 from a body heel apex (BHA) to a body toe apex (BTA). The body toe apex (BTA) is defined as the toeward-most point of the body 101. The body heel apex (BHA) is heelward-most point of the heel 104 that is located at a height 0.875 mm from the ground plane GP. In many embodiments, the body width (WB) can be measured according to a golf governing body such as the United States Golf Association (USGA). The ranges specified for the body depth (DB), body height (HB), and body width (WB) can be designed in accordance with the USGA regulations.

[0093] The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golf ball.

[0094] The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head.

[0095] The term “cartridge” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall and at least a portion of the casing rear wall.

[0096] The term “appendage” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall but does not form a portion of the casing rear wall.

[0097] “Driver” or “driver-type” golf club heads as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a club head volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the club head volume of the driver can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc 650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.

[0098] Driver embodiments can comprise a body height HB between 2.0 and 3.0 inches. In some driver embodiments, the body height HB can be between 2.0 and 2.2 inches, between 2.2 and 2.4 inches, between 2.4 and 2.6 inches, between 2.6 and 2.8 inches, or between 2.8 and 3.0 inches. In some driver embodiments, the body height HB can be greater than 2.0 inches, greater than 2.2 inches, greater than 2.4 inches, greater than 2.6 inches, greater than 2.8 inches, or greater than 3.0 inches.

[0099] Driver embodiments can comprise a body width WB between 4.4 and 5.0 inches. In some driver embodiments, the body width WB can be between 4.4 and 4.6 inches, between 4.6 and 4.8 inches, or between 4.8 and 5.0 inches. In some driver embodiments, the body width WB can be greater than 4.4 inches, greater than 4.6 inches, greater than 4.8 inches, or greater than 5.0 inches.

[0100] Driver embodiments can comprise a body depth DB between 4.3 and 4.9 inches. In some driver embodiments, the body depth DB can be between 4.3 and 4.5 inches, between 4.5 and 4.7 inches, or between 4.7 and 4.9 inches. In some driver embodiments, the body depth DB can be greater than 4.3 inches, greater than 4.5 inches, greater than 4.7 inches, or greater than 4.9 inches.

[0101] “Fairway wood” or “fairway wood-type” golf club heads as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

[0102] Further, “fairway wood” or “fairway wood-type” golf club heads as used herein comprises a club head volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the club head volume of the fairway wood can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.

[0103] Fairway wood embodiments can comprise a body height HB between 1.25 and 1.75 inches. In some fairway wood embodiments, the body height HB can be between 1.25 and 1.40 inches, between 1.40 and 1.55 inches, or between 1.55 and 1.75 inches.

[0104] Fairway wood embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some fairway wood embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches.

[0105] Fairway wood embodiments can comprise a body depth DB between 3.0 and 4.0 inches. In some fairway wood embodiments, the body depth DB can be between 3.0 and 3.3 inches, between 3.3 and 3.6 inches, between 3.6 and 3.8 inches, or between 3.8 and 4.0 inches.

[0106] “Hybrid” or “hybrid-type” golf club heads as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0107] Further, “hybrid” or “hybrid-type” golf club heads as used herein comprise a club head volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the club head volume of the hybrid can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

[0108] Hybrid embodiments can comprise a body height HB between 1.1 and 1.5 inches. In some hybrid embodiments, the body height HB can be between 1.1 and 1.25 inches, between 1.25 and 1.4 inches, or between 1.4 and 1.5 inches. In some hybrid embodiments, the body height HB can be less than 1.5 inches, less than 1.4 inches, less than 1.3 inches, or less than 1.2 inches.

[0109] Hybrid embodiments can comprise a body width WB between 3.75 and 4.5 inches. In some hybrid embodiments, the body width WB can be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches. In some hybrid embodiments, the body width WB can be less than 4.5 inches, less than 4.25 inches, or less than 4.0 inches.

[0110] Hybrid embodiments can comprise a body depth DB between 2.25 and 2.75 inches. In some hybrid embodiments, the body depth DB can be between 2.25 and 2.4 inches, between 2.4 and 2.6 inches, or between 2.6 and 2.75 inches. In some hybrid embodiments, the body depth DB can be less than 2.75 inches, less than 2.6 inches, less than 2.4 inches, or less than 2.25 inches.

[0111] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, 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.II. General Description of a Golf Club Head

[0112] Various embodiments of a golf club are illustrated in the figures. A golf club is generally understood to comprise a club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

[0113] Referring to FIGS. 1 and 2, the club head 100 defines a crown 110, a sole 112 opposite the crown 110, a heel 104, a toe 106, a front 108, a rear 111 and a strike face 102. The club head 100 further comprises a hosel 105, which is configured to receive the shaft. In some embodiments, as illustrated in the embodiment of FIGS. 1 and 2, the club head 100 comprises a body 101 and a faceplate 114 coupled together to form an interior cavity. The body 101 forms at least a portion of the crown 110, at least a portion of the sole 112, at least a portion of the heel 104, and at least a portion of the toe 106. The faceplate 114 forms at least a portion of the strike face 102. Specific configurations of the body 101 and the faceplate 114 are described in further detail below.

[0114] The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club head 100 comprises a crown 110 and a sole 112, whereas club head 200 comprises a crown 210 and a sole 212). Any one or more of the features below can be used in combination with one another.

[0115] The body 101 comprises a body material that provides sufficient structural strength and is easily formed into complex geometries. In many embodiments, the body material is a metallic material that is easily castable. In some embodiments, the body material can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the body material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the body material can be formed from Ni (Nickel)-Co (Cobalt)-Cr (Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6Al-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3Al-2.5V, Ti-6Al-1Zr-1Nb-1Mo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals. Generally, the body material can comprise a yield strength between 145 and 165 ksi.

[0116] In some embodiments, the body 101 comprises a multi-material construction including one or more lightweight materials, such as a lightweight composite material, in addition to the metallic body material. In some embodiments, a portion of the crown 110, a portion of the sole 112, a portion of the heel 104, a portion of the toe 106, or a combination thereof can be formed by a composite material. In such embodiments, the club head 100 can comprise one or more composite panels. In some embodiments, referring to FIG. 5, the club head 100 can comprise a crown panel 196 made of a composite material. The crown panel 196 can comprise a heel wrap 197a and a toe wrap 197b that wrap over the heel 104 and toe 106, respectively, and form portions of the sole 112. Further in some embodiments, the club head 100 can comprise a sole panel 198 forming at least a portion of the sole 112. In other embodiments, referring to FIG. 6, the club head 100 can comprise a central panel 199 that continuously wraps around the crown 110, sole 112, heel 104, toe 106, or various combinations thereof.

[0117] In some embodiments, the one or more composite panels can comprise a composite formed from a polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic resin. In some embodiments, the one or more composite panels can comprise a carbon fiber composite material having multiple layers of unidirectional carbon fibers formed as a single, continuous piece. In some embodiments, the one or more composite panels may comprise a bi-directional woven carbon fiber composite material having a single layer formed as a single, continuous piece. In some embodiments, the one or more composite panels can comprise a fiber reinforced thermo-plastic material. The one or more composite panels can be extruded, compression molded, injection molded, blow molded or bladder molded, 3-D printed, or otherwise formed by any other appropriate forming means.

[0118] The faceplate 114 comprises a faceplate material having sufficient strength to withstand repeated impacts with a golf ball. As such, the faceplate material comprises a greater yield strength than the body material and is thus more durable. In some embodiments, the faceplate material can be a high-strength steel alloy, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

[0119] In other embodiments, the faceplate material can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).

[0120] The faceplate material comprises a high yield strength. In some embodiments, the faceplate material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater than 230 ksi, greater than 240 ksi, or greater than 250 ksi. The faceplate material can comprise a higher yield strength than the body material. In some embodiments, the club head 100 comprises a faceplate strength ratio comparing the yield strength of the faceplate material to the yield strength of the body material. In some embodiments, the faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.

[0121] The club head body 101 and the faceplate 114 can be formed through one or a combination of manufacturing processes, such as casting, forging, metal injection molding, metal 3D printing, stamping, or any other well-known manufacturing processes. In some embodiments, the club head body 101 is cast, whereas the faceplate 114 is forged.III. Impact Response Modulator

[0122] The golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”) reinforced by high-strength material that increases strike face deflection at impact with a golf ball while maintaining sufficient durability. Referring to FIGS. 2 and 3, the IRM 120 is disposed in the sole 112. The IRM 120 strategically weakens the sole 112 to increase strike face deflection. The IRM 120 comprises a casing 130 surrounding an aperture 140 that is configured to receive an insert 170. As illustrated in FIG. 2, the IRM 120 extends in a substantially heel-to-toe direction across the sole 112 to increase strike face deflection.

[0123] The casing 130 is the structure that surrounds and forms the aperture 140. One or more portions of the casing 130 can be formed by a high-strength material component, such as a cartridge or an appendage. As illustrated in FIGS. 7 and 8, the casing 130 comprises a front wall 132 proximate the strike face 102, a rear wall 142 spaced rearward from the front wall 132, a heel wall 152 proximate the heel 104 and a toe wall 154 proximate the toe 106. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 of the casing collectively form and define the aperture 140 therebetween. The aperture 140 is a through-hole fluidly communicating between the club head exterior and the interior cavity. The front wall 132 comprises a front wall front surface 134 disposed towards the strike face 102, a front wall rear surface 136 disposed towards the aperture 140, a front wall base 133, and a front wall top surface 138 opposite the front wall base 133. The rear wall 142 comprises a rear wall front surface 144 disposed towards the aperture 140, a rear wall rear surface 146 disposed towards the rear 111, a rear wall base 143, and a rear wall top surface 148 opposite the rear wall base 143.

[0124] The casing 130 is spaced rearwardly from the strike face 102. As best illustrated in FIG. 8, the front wall 132 is separated from the strike face 102 by a forward sole region 166. The forward sole region 166 separates the front wall 132 from the strike face 102 by an offset distance OD, which is described in further detail below.

[0125] The forward sole region 166 balances durability and strike face deflection. If not for the forward sole region 166, the casing 130 and / or aperture 140 would directly abut the strike face 102. In such cases, the impact stress and in the casing 130 and the strike face 102 would be so high that the strike face 102 and / or the casing walls would need to be significantly thickened to preserve durability. Doing so would hinder strike face deflection such that any performance gains achieved by the inclusion of the IRM 120 would be lost or greatly diminished. Spacing the casing 130 rearward of the strike face 102 by the forward sole region 166 allows the strike face 102 and casing walls to be thinner and therefore increase strike face deflection. Specific casing geometries and specific casing wall dimensions are described in detail below.

[0126] The IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170 closes off the aperture 140 to prevent migration of debris into the interior chamber and can impact the performance of the IRM and durability of the club head. The insert 170 is configured to engage the casing walls, thereby securing the insert 170 within the casing 130. The material composition, overall construction, inclusion of hybrid materials, and geometry of the insert 170 can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert 170 and the casing 130 can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert 170 within the casing 130, even after repeated, violent impacts.

[0127] In some embodiments, the insert 170 entirely fills the aperture 140 with solid material between the casing front wall 132 and the casing rear wall 142. In some embodiments, the insert 170 can be hollowed out or provided with some other suitable geometry that creates a gap 171 or channel within the insert 170. For example, in some embodiments, as best illustrated in FIG. 16, the insert 170 can comprise a front wall 174, a rear wall 176, and a base 172, and takes a generally U-shaped appearance. The insert 170 may further comprise a rear extension 178 to increase bonding surface area. Various embodiments of the insert are discussed in further detail below.

[0128] To better understand the strategic locations at which high-strength material is used, the casing 130 can be divided up into multiple regions. The casing 130 can include a casing heel region 135 proximate the heel wall 152, a casing toe region 137 proximate the toe wall 154, and a casing center region 131 therebetween. The casing regions can help describe the location of various casing features and / or describe specific portions of the casing 130 that are reinforced by a high-strength material component in the various embodiments described below.

[0129] In some embodiments, the casing can comprise one or more reliefs that dissipate stress in the casing walls. The reliefs are portions of the casing that extend away from the strike face to dissipate stress. Generally, a significant portion of the casing 130, particularly at or near the casing center region 131, extends substantially equidistant to the strike face curvature, as best illustrated in FIG. 9. The relief(s) are angled rearward relative to the strike face 102. Referring to FIG. 9, the casing 130 comprises a toe relief 128 in the casing toe region 137 and a heel relief 129 in the casing heel region 135. The toe relief 128 and the heel relief 129 space the casing toe wall 154 and the casing heel wall 152, respectively, away from the strike face 102, such that the casing toe wall 154 and the casing heel wall 152 are further from the strike face 102 than the center of the casing 130. This spacing is advantageous because stress concentrations typically occur near the heel wall 152 and the toe wall 154, because the heel wall 152 and the toe wall 154 generally comprise tight curvatures. The toe relief 128 and the heel relief 129 reduce these concentrations by spacing the casing toe wall 154 and the casing heel wall 152, respectively, further from the strike face 102. The reliefs 128, 129 allow the casing 130 (and the aperture 140) to be lengthened without compromising durability, thereby increasing strike face deflection. The illustrated embodiment includes both a toe relief 128 and a heel relief 129. In other embodiments, the casing 130 can comprise only a toe relief 128 or only a heel relief 129. Specific relief geometries and dimensions are discussed in further detail below.

[0130] In some embodiments, the casing 130 can further comprise one or more end reinforcements 126, as best illustrated in FIG. 9. The end reinforcements 126 can be thickened portions of the sole 112 that surround one or more of the casing walls. In the illustrated embodiment, casing 130 comprises a heel end reinforcement 126a surrounding the heel wall 152 and a toe end reinforcement 126b surrounding the toe wall 154. The end reinforcements 126a, 126b are concentrations of club head mass with a substantially greater thickness TER than the surrounding casing walls. As illustrated in FIG. 5, the toe end reinforcement 126b can comprise an end reinforcement thickness TER measured between the casing toe wall 154 and an outer surface of the toe end reinforcement 126b, the measurement taken perpendicularly to the casing toe wall 154. Similarly, the heel end reinforcement 126a can comprise an end reinforcement thickness TER measured between the casing heel wall 152 and an outer surface of the heel end reinforcement 126a, the measurement taken perpendicularly to the casing heel wall 152. In some embodiments, the end reinforcement thickness TER can be between 0.25 inch and 0.75 inch. In some embodiments, the end reinforcement thickness TER can be greater than 0.25 inch, greater than 0.30 inch, greater than 0.35 inch, greater than 0.40 inch, greater than 0.45 inch, greater than 0.50 inch, greater than 0.55 inch, greater than 0.60 inch, greater than 0.65 inch, or greater than 0.70 inch. In some embodiments the end reinforcement thickness TER is between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, or between 0.65 and 0.70 inch, between 0.70 and 0.75 inch.

[0131] Similar to the reliefs 128, 129, the end reinforcements 126a, 126b reduce stress concentrations occurring in the heel wall 152 and the toe wall 154, respectively, thereby increasing overall casing durability. Although the end reinforcements 126a, 126b are concentrations of club head mass located on the casing walls, they are located towards the heel 104 and the toe 106 and thus do not hinder strike face deflection. In the illustrated embodiment, the end reinforcements 126a, 126b are generally circular in shape. In other embodiments, the end reinforcements 126a, 126b can be any suitable shape for reducing stress near the heel wall 152 and the toc wall 154. The end reinforcements 126a, 126b can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. The illustrated embodiment includes both a heel end reinforcement 126a and a toe end reinforcement 126b. In other embodiments, the casing 130 can comprise a heel end reinforcement 126a, a toe end reinforcement 126b, or both. Specific relief geometries and dimensions are discussed in further detail below.

[0132] In some embodiments, the casing 130 can further comprise one or more front wall reinforcements 139, as best illustrated in FIG. 10. The front wall reinforcements 139 can be thickened portions of casing front wall 132. In the illustrated embodiment, the casing 130 comprises a front wall reinforcement 139 located in the casing center region 131. The front wall reinforcements 139 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. Similar to the end reinforcements 126a, 126b, the front wall reinforcements 139 reduce stress concentrations occurring in the front wall 132, thereby increasing overall casing 130 durability. In the illustrated embodiment, a single front wall reinforcement 139 is generally located in the center region 131. In other embodiments, the front wall reinforcements 139 can be located in the heel region 135, in the toe region 137, or in any combination of central, heel, and toe regions 131, 135, 137. The front wall reinforcements 139 can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. Specific front wall reinforcement 139 geometries and their relation to the overall front wall thickness FWT are discussed in further detail below.

[0133] In many embodiments, the casing 130 comprises a casing recess 182 that retains the insert 170 and increases strike face deflection. In the illustrated embodiment of FIG. 11, the casing recess 182 is located at the rear wall base 143. The casing recess 182 includes a seating surface 184 that is inset from an exterior surface 109 of the sole 112 by a rising surface 183. The casing recess 182 can be in direct communication with the aperture 140. The casing recess 182 forms a lap joint configured to receive one or more portions of the insert 170, as described in further detail below. Although the casing recess 182 of the illustrated embodiment is located only at the rear wall base 143, in other embodiments, the casing recess 182 can also be formed at the front wall base 133. In some embodiments, the casing recess 182 extends around and entirely circumscribes the aperture 140.

[0134] The casing recess 182 removes mass from the rear wall base 143, thereby increasing the amount the rear wall 142 and the sole 112 bend at impact. In some embodiments, the casing recess 182 defines a recess depth DR measured between the exterior surface of the sole 112 and the seating surface 184. Increasing the recess depth DR will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, increasing the recess depth DR also potentially increases stress in the casing 130. The recess depth DR can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the recess depth DR can be between 0.1 and 0.75 inch. For example, in some embodiments, the recess depth DR can be between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, between 0.20 and 0.25 inch, between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, between 0.65 and 0.70 inch, or between 0.70 and 0.75 inch.

[0135] In alternative embodiments, rather than a lap joint configuration including a rising surface and a seating surface, the casing recess 182 can comprise a bevel. As best illustrated in FIG. 12, the casing recess 182 defines a beveled surface 185 that gradually slopes between the exterior surface 109 of the sole 112 and the rear wall front surface 144 and / or the front wall rear surface 136. Rather than a recess depth, the beveled surface 185 can comprise a bevel angle αB defined between the exterior surface 109 of the sole 112 and the beveled surface 185. A greater bevel angle αB, will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, a greater bevel angle αB also potentially increases stress in the casing 130. The bevel angle αB can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the bevel angle αB can be between 5 and 60 degrees. For example, in some embodiments, the bevel angle αB can be between 5 and 10 degrees, between 10 and 16 degrees, between 16 and 21 degrees, between 21 and 27 degrees, between 27 and 32 degrees, between 32 and 38 degrees, between 38 and 43 degrees, between 43 and 49 degrees, between 49 and 54 degrees, or between 54 and 60 degrees.

[0136] In some embodiments, the casing can form one or more retainers configured to engage the insert without restricting strike face flexure. In some embodiments, the retainers can be one or more tabs 4545, as best illustrated in FIG. 13. The tabs 4545 are part of the casing 4530 and are configured to engage the insert 4550 and facilitate installation of the insert 4550 to the proper location within the aperture 4540, without contributing significant mass. In the illustrated embodiment, the tabs 4545 are small, distinct protrusions that extend rearward from the casing front wall 4532 into the aperture 4540. The tabs 4545 overhang at least part of the aperture 4540 and terminate at cantilevered ends that are suspended in or overhang the aperture 4540. As illustrated in FIG. 14, the tabs 4545 extend over and overlap at least a portion of the insert 4550. When the insert 4550 is installed from the sole 4512, the tabs 4545 create a mechanical stop that engages the insert top surface 4588 and prevents the insert 4550 from being pushed through the aperture 4540 and into the interior cavity.

[0137] In some embodiments, referring to FIG. 14, the tabs 4545 can protrude above the front wall top surface 4538 and rearward over at least a portion of the aperture 4540. The tabs 4545 can each comprise a tab underside surface 4549 that is substantially flush with the front wall top surface 4538. In such embodiments, the tabs 4545 do not extend into the aperture 4540 itself, but rather overhang the aperture 4540. In some embodiments, one or more tabs 4545 can extend forward from the casing rear wall 4542 into the aperture 4540, rather than extending from the casing front wall 4532.

[0138] As described above, the one or more tabs 4545 are small, distinct protrusions that do not contribute a significant amount of mass to the casing walls, nor do they prohibit strike face deflection. Referring to FIG. 15, the tabs 4545 can comprise a tab width WT measured between lateral surfaces of the tab 4545 in a direction parallel to the front wall rear surface 4536. In some embodiments, the tab width WT can be between 0.05 inch and 0.25 inch. In some embodiments, the tab width WT can be between 0.05 and 0.10 inch, between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, or between 0.20 and 0.25 inch. The tabs 4545 can also comprise a tab depth DT measured perpendicularly from the front wall rear surface 4536 to the end of the tab 4545. The tab depth Dr represents the amount the tab 4545 extends across the aperture 4540. The tabs 4545 extend only partially across the aperture 4540. In some embodiments, the tab depth DT can be between 0.05 inch and 0.25 inch. In some embodiments, the tab depth Dr can be between 0.05 and 0.10 inch, between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, or between 0.20 and 0.25 inch.

[0139] Additionally, in some embodiments, the insert 4550 can also comprise one or more retainers configured to engage the tabs 4545 and more precisely locate the insert 4550 in its intended position. The insert 4550 can comprise one or more pockets 4594 recessed into the insert top surface 4588. The pockets 4594 can be shaped complementarily to the tabs 4545 such that when the insert 4550 engages the tabs 4545, the tabs 4545 fit into the corresponding pockets 4594 and align the insert 4550. The pockets 4594 improve insert retention over the tabs that simply rest on the insert top surface 4588 by preventing lateral insert movement within the aperture 4540. In such embodiments, rather than overhanging the aperture 4540, the tabs 4545 can extend into the aperture 4540 itself to engage the insert 4550 disposed therein. In some embodiments, as illustrated in FIG. 15, the tabs 4545 may not extend above the front wall top surface 4538. Instead, each of the tabs 4545 can comprise a tab upper surface 4547 that is flush with the front wall top surface 4538.

[0140] The tabs 4545 can provide unique advantages over other solutions for mechanically the insert 4550. For example, some embodiments of lap joints or bevels form mechanical stops by removing mass from the casing walls. In some of these embodiments, this mass removal can potentially create stress concentrations that require other portions of the casing walls to be thickened, thereby diminishing strike face deflection and creating an uneven response in the IRM. In contrast, the tabs 4545 are freely suspended in or over the aperture 4540 and thus are configured such that they do not significantly affect casing wall deflection.

[0141] In some embodiments, the faceplate 114 comprises one or more return portions that are used in combination with the IRM 120 to increase strike face deflection. The return portions are portions of the faceplate 114 that wrap over the strike face perimeter and form other forward portions of the club head 100, such as forward portions of the crown 110, sole 112, heel 104, or toe 106. The return portions replace these portions of the club head 100, which typically experience high impact stresses and would otherwise be formed of the body material, with the high-strength faceplate material. This allows these areas of the club head 100 to be thinned without sacrificing durability, thereby increasing strike face deflection.

[0142] The one or more return portions can be described in relation to the faceplate perimeter 155, which is the outermost edge of the faceplate 114 that couples to the body 101 and / or other club head components. Referring to FIG. 17, in some embodiments, the faceplate 114 comprises a crown return 115 that wraps over the transition from the strike face 102 to the crown 110, thereby to form a forward portion of the crown 110. In embodiments comprising a crown return 115, the faceplate top edge 160 is located on the crown 110 and not on the strike face 102. Similarly, in other embodiments such as that illustrated in FIG. 19, the faceplate 114 can comprise a toe return 161, wrapping over the transition between the strike face 102 and the toe 106, thereby to form a forward portion of the toe 106. In embodiments comprising a toe return 161, the faceplate toe edge 159 is located on the toe 106 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a sole return (discussed in further detail below) that wraps over the leading edge 103 and forms a forward portion of the sole 112, wherein the faceplate bottom edge 157 is located on the sole 112 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a heel return (discussed in further detail below) that wraps over the transition between the strike face 102 and the heel 104, thereby to form a forward portion of the heel 104, wherein the faceplate heel edge 158 is located on the heel 104 and not on the strike face 102. The faceplates described herein can comprise a crown return, a heel return, a toe return, or any combination thereof. Specific return combinations and configurations are discussed in detail below.

[0143] In some embodiments, the club head 100 can comprise a “reverse L-cup” faceplate 114, as best illustrated in FIGS. 17 and 18. The reverse L-cup faceplate 114 can comprise a crown return 115 yet be devoid of a sole return. As such, the reverse L-cup faceplate 114 comprises a faceplate top edge 160 that is located on the crown 110. The faceplate bottom edge that is located on the strike face 102, above the leading edge 103. The reverse L-cup faceplate 114 does not extend to or wrap over the leading edge 103, nor does the reverse L-cup faceplate 114 form any portion of the sole 112. Due to the absence of a sole return, the body 101 of the illustrated embodiment forms a forward portion of the sole 112 as well as the entire casing 130.

[0144] The crown return increases durability and performance by reinforcing (via the high-strength faceplate material) the transition between the strike face 102 and the crown 110 and forward portions of the crown 110, which are both areas that experience impact stresses. Further, the reverse L-cup faceplate 114 simplifies manufacture. The lack of a sole return in the reverse L-cup faceplate 114 enables the complex casing geometries to be easily cast out of body material. The IRM 120 and the crown return 115 work in conjunction to increase strike face deflection without sacrificing durability. In particular, the IRM 120 increases sole flexibility, whereas the crown return 115 increases crown flexibility.

[0145] In some embodiments, such as the illustrated embodiment of FIGS. 17 and 18, the reverse L-cup faceplate 114 comprises a crown return 115, but no heel return or toe return. However, in other embodiments, the reverse L-cup faceplate 114 can further comprise a toe return 161, as illustrated in FIG. 19. In such embodiments, the faceplate toe edge 159 is located on the toe 106. The toe return 161 further increases durability by reinforcing the transition between the strike face 102 and the toe 106. The toe return 161 thereby allows portions of the toc 106 to be thinned without exceeding the yield strength of the high-strength faceplate material. The reverse L-cup faceplate 114 with both a crown return 115 and a toe return 161 increases strike face deflection over a reverse L-cup faceplate 114 with only a crown return 115. In some embodiments, referring to FIG. 19, the faceplate toe edge 159 can run substantially parallel to the strike face 102. In other embodiments, as best illustrated in FIG. 20, the faceplate toe edge 159 can be divided into a toe edge sole segment 159a that extends in a substantially horizontal direction parallel to the sole 112 and a toe edge crown segment 159b that extends in a substantially vertical direction perpendicular to the sole 112. This configuration simplifies manufacture by smoothing the transition between the toe edge sole segment 159a and the faceplate bottom edge 157 and the transition between the toe edge crown segment 159b and the faceplate top edge 160.

[0146] The IRM 120 delofts the strike face 102 at impact. This delofting effect reduces stress in the crown 110, thereby allowing the crown 110 to be thinned without sacrificing durability. In some embodiments, as shown in FIGS. 21 and 22, the crown return 115 further comprises an indentation 141. The indentation 141 is recessed into an interior surface of the crown return 115. The indentation 141 is a region of reduced thickness relative to the remainder the crown return 115. In the illustrated embodiment, the indentation 141 is isolated within the crown return 115, such that the indentation perimeter 194 is located entirely within the bounds of the crown return 115. The indentation 141 increases strike face deflection without compromising faceplate durability. The indentation 141 can increase ball speed by upwards of 0.5 mph (without compromising durability) over a club head comprising a crown return without an indentation. Specifically, the indentation 141 strategically weakens the forward portion of the crown 110, thereby increasing the amount the crown 110 deflects upward at impact. This increased upward crown deflection in turn increases the amount of strike face deflection. Because the indentation 141 is isolated within the crown return 115, this additional deflection can occur without exceeding the yield strength of the high-strength faceplate material.

[0147] The indentation 141 comprises an indentation thickness TI that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indentation thickness TI can be between 0.005 and 0.020 inch, whereas the crown return thickness TCR can be between 0.020 and 0.050 inch. In some embodiments, the indentation thickness TI can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return 115 can comprise an indentation thickness ratio TI / TCR defined as the indentation thickness TI divided by the crown return thickness TCR. In some embodiments, the indentation thickness ratio TI / TCR can be less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1.

[0148] In the illustrated embodiment, the indentation 141 is located approximately in the center of the crown return 115 and extends in a generally heel-toe direction. In other embodiments, the indentation can be offset towards to the toe 106 or towards the heel 104. In the illustrated embodiment, the indentation 141 has an approximately rectangular shape. In other embodiments, the indentation 141 can have other shapes such as an elongated oval or an arcuate shape.

[0149] The casing embodiments described herein can comprise one or more of the casing features described above. In particular, any casings formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof can include any combination of reliefs, end reinforcements, casing recesses, or returns.IV. Impact Response Modulator with High-Strength Material Reinforcement

[0150] As described above, a high-strength component forms at least part of the casing. In some embodiments, the faceplate forms part or all of the casing, whereas in other embodiments, a separate, high-strength material component (such as a cartridge or an appendage) forms part or all of the casing. The high-strength material reinforces the casing, increasing strike face deflection without compromising durability. Specifically, design choices that increase strike face deflection, such as decreasing front wall offset, increasing the casing length, or shortening or thinning the front wall, can be implemented without exceeding the high-strength material's yield strength, thereby maintaining durability.

[0151] The club heads described below include an IRM having high-strength material while improving or simplifying manufacture. In general, high-strength components with complex geometries are difficult to manufacture, particularly by forging. In general, a monolithically forged component can have no more than two “bends” in a given cross-section, wherein a “bend” refers to adjacent surfaces or portions of the component being significantly angled relative to each other. For example, a monolithically forged faceplate can have no more than two bends in a vertical (i.e., crown-to-sole) cross section and no more than two bends in a horizontal (i.e., heel-to-toe) cross section. Components with more than two bends in given cross section may not provide sufficient clearance for a forging tool to be removed post-manufactured.

[0152] As described above, in some embodiments, the faceplate can comprise a crown return, a heel return, or a toe return to reinforce portions of the crown, heel, or toe, respectively, to improve strike face deflection. However, due to the manufacturing constraints discussed above, it can be difficult or impossible to monolithically forge a faceplate with a crown return, heel return, or toe return if the faceplate also forms a sole return and one or more casing geometries. Such an embodiment would exceed the maximum number of two bends in a single cross-section. Some embodiments of the IRM described herein comprise faceplates and / or other high-strength material components having complex geometries that are capable of being manufactured by forging or other processes by selectively placing high-strength material and strategically combining monolithic faceplate geometries (i.e., crown returns, sole returns, toe returns, heel returns, and casing geometries).A. Body and Faceplate Forming the Casing

[0153] In some embodiments, the faceplate and the body combine to form the casing. The embodiments described below with reference to FIGS. 23-30 include a faceplate that combines with the body to form the casing and reinforce the casing with high-strength faceplate material (having a yield strength above 175 ksi). The faceplate reduces stress in the casing walls, allowing the casing walls to have reduced thickness, reduced length, or being located closer to the strike face, thereby increasing strike face deflection without compromising durability. The embodiments described below increase strike face deflection while maintaining sufficient club head durability and overall manufacturability. The faceplates have relatively simple designs (including two or less bends in a given cross-section) that are suitable for monolithic forging while still reinforcing areas of the casing. Any other complex casing geometries can be cast out of the body material.

[0154] In some embodiments, the club head 700 can comprise an “L-cup” faceplate 714 that reinforces the casing 730. As best illustrated in FIG. 23, the L-cup faceplate 714 comprises a sole return 716 that extends rearward from the strike face 702 and forms a forward portion of the sole 712. The sole return 716 is coupled to the body 701 at a sole return rear edge 757. The sole return 716 terminates at the front wall base 733, such that the sole return rear edge 757 is forward of the casing front wall 732. The L-cup faceplate 714, therefore, does not form any portion of the casing front wall 732 or the casing rear wall 742, nor does it form any portion of the aperture 740. In the illustrated embodiment, both the casing front wall 732 and the casing rear wall 742 are integral with the body 701. The body 701 therefore encapsulates and defines the entire aperture 740.

[0155] In some embodiments, the sole return 716 can extend along the entirety of the casing front wall 732. In other embodiments, the sole return 716 can extend along less than the entirety length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 40%, between 30% and 45%, between 35% and 50%, between 40% and 55%, between 45% and 60%, between 50% and 65%, between 55% and 70%, between 60% and 75%, between 65% and 80%, between 70% and 85%, between 75% and 90%, between 80% and 95%, or between 85% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 is located only in the casing center region to locally reinforce areas of the casing 730 that typically experience the greatest deflection and the highest impact stresses.

[0156] The L-cup faceplate 714 is readily manufacturable and reinforces the casing 730. The sole return 716 reinforces high-stress areas of the sole 712 immediately in front of the casing front wall 732 with high-strength material. The L-cup faceplate 714 is easily forged, because it does not include any of the complicated casing wall geometries. The L-cup faceplate 714 comprises only a single bend in the vertical cross-section, located at the juncture between the strike face 702 and the sole return 716. The casing walls, which are integral with the body 701, can be easily cast out of the body material. At impact, the L-cup faceplate 714, specifically the sole return 716, deflects with the portion of the sole 712 immediately in front of the casing front wall 732, which in turn increases strike face deflection.

[0157] In some embodiments, the club head 800 can comprise a “J-cup” faceplate 814 that reinforces the casing front wall 832. As best illustrated in FIG. 24, the J-cup faceplate 814 comprises a sole return 816 that extends rearward from the strike face 802. In comparison to the sole return 716 of the L-cup faceplate 714, which only forms a forward portion of the sole 712, the sole return 816 forms both a forward portion of the sole 812 and the casing front wall 832. The J-cup faceplate 814, forms no portion of the casing rear wall 842. As such, the casing front wall 832 can be integral with the J-cup faceplate 814, whereas the casing rear wall 842 can be integral with the body 801. In this configuration, the J-cup faceplate 814 and the body 801 combine to form the aperture 840 therebetween.

[0158] In some embodiments, the sole return 816 can form the entire casing front wall 832. In other embodiments, the sole return 816 forms only a portion of the casing front wall 832. As best illustrated in FIG. 25, the casing front wall 832 comprises a support segment 868 that is integral with the J-cup faceplate 814 and a core segment 869 that is integral with the body 801. The support segment 868 is the portion of the casing front wall 832 formed by the J-cup faceplate 814, whereas the core segment 869 is the portion of the casing front wall 832 formed by the body 801.

[0159] In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall front surface 834. For example, in some embodiments, the support segment 868 can form between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 834. In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall rear surface 836. For example, in some embodiments, the support segment 868 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall rear surface 836.

[0160] In some embodiments, such as the illustrated embodiment of FIG. 25, support segment 868 is located primarily in the casing center region 831, and the core segment 869 is located primarily in the casing heel region 835 and the casing toe region 837. In the present configuration, the sole return 816 locally reinforces the casing center region 831, where the greatest deflection and highest impact stresses typically occur. In other embodiments, the support segment 868 and the core segment 869 can have alternate configurations. For example, the support segment 868 can be located primarily in the casing center region 831, the casing heel region 835, the casing toe region 837, or any combination thereof.

[0161] In embodiments where the sole return 816 forms only a portion of the casing front wall 832, the sole return 816 can span a lesser distance in a heel-to-toe direction than the aperture 840. As illustrated in FIG. 25, the sole return 816 comprises a sole return width WSR measured in a heel-to-toe direction from the sole return heel edge 858 to the sole return toe edge 859. In some embodiments, the sole return width WSR is less than the total length TL of the aperture 840 (defined below).

[0162] The J-cup faceplate 814 is readily manufacturable and reinforces the casing 830. The sole return 816 reinforces high-stress areas of the casing front wall 832 with high-strength material. In some embodiments, the J-cup faceplate 814 can be monolithically forged, because it does not include any overly complicated geometries. Referring to FIG. 24, the J-cup faceplate 814 comprises only two bends in the vertical cross-section. The J-cup faceplate 814 comprises a first bend at the juncture between the strike face 802 and the sole return 816 and a second bend at the juncture between the sole 812 and the casing front wall 832. In the illustrated embodiment, the J-cup faceplate 814 is devoid of a crown return. The introduction of a crown return to the J-cup faceplate 814 would add a third bend at the juncture between the strike face 802 and the crown 810, making the J-cup faceplate geometry too complicated for monolithic forging. At impact, the J-cup faceplate 814, specifically the sole return 816, deflects with the casing front wall 832, which in turn increases strike face deflection.

[0163] In some embodiments, the club head 900 can comprise a “partial J-cup” faceplate 914 that reinforces the casing front wall 932. As best illustrated in FIG. 26, the partial J-cup faceplate 914 comprises a sole return 916 that extends rearward from the strike face 902. The sole return 916 forms both a forward portion of the sole 912 and a portion of the casing front wall 932. Specifically, the sole return 916 forms the front wall front surface 934 of the casing 930, but not the front wall rear surface 936. In contrast to the J-cup faceplate 814, which forms the entire casing front wall 832, the partial J-cup faceplate 914 forms only a portion of the front wall thickness FWT. The front wall front surface 934 is therefore integral with the partial J-cup faceplate 914. Similar to the J-cup faceplate 814 illustrated in FIG. 24, the partial J-cup faceplate 914 forms no portion of the casing rear wall 942. As such, both the front wall rear surface 936 and the rear wall 942 of the casing 930 can be integral with the body 901. The partial J-cup faceplate 914 therefore forms no portion of the aperture 940 and the aperture 940 is entirely encapsulated within the body 901.

[0164] In some embodiments, the sole return 916 can form the entire front wall front surface 934 of the casing 930. In other embodiments, the sole return 916 forms only a portion of the front wall front surface 934. As best illustrated in FIG. 27, The casing front wall 932 comprises a support segment 968 that is integral with the partial J-cup faceplate 914 and a core segment 969 that is integral with the body 901. The support segment 968 is the portion of the casing front wall 932 formed by the partial J-cup faceplate 914, whereas the core segment 969 is the portion of the casing front wall 932 formed by the body 901.

[0165] In some embodiments, the support segment 968 forms between 25 and 100% of a surface area of the front wall front surface 934. For example, in some embodiments, the support segment 968 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 934. In some embodiments, the support segment 968 forms no portion of the front wall rear surface 936. In contrast to the core segment 869 of the J-cup faceplate 814, which only forms portions of the front wall rear surface 836, the core segment 969 of the partial J-cup faceplate 914 forms the entire front wall rear surface 936.

[0166] In some embodiments, such as the illustrated embodiment of FIG. 27, support segment 968 is located primarily in the casing center region 931. In such embodiments, the core segment 969 forms the entire casing front wall 932 in the casing heel region 935 and the casing toe region 937. In the present configuration, the sole return 916 locally reinforces the casing center region 931, where the greatest deflection and high impact stresses typically occur. In other embodiments, the support segment 968 and the core segment 969 can have alternate configurations. For example, the support segment 968 can be located primarily in the casing center region 931, the casing heel region 935, the casing toe region 937, or any combination thereof.

[0167] In embodiments where the sole return 916 forms only a portion of the casing front wall 932, the sole return 916 can span a lesser distance in a heel-to-toe direction than the aperture 940. As illustrated in FIG. 27, the sole return width WSR is less than the total length TL of the aperture 940 (defined below).

[0168] The partial J-cup faceplate 914 is readily manufacturable and reinforces the casing 930. The sole return 916 reinforces high-stress areas of the casing front wall 932 with high-strength material. In some embodiments, the partial J-cup faceplate 914 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 26, the partial J-cup faceplate 914 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814, the partial J-cup faceplate 914 comprises a first bend at the juncture between the strike face 902 and the sole return 816 and a second bend at the juncture between the sole 912 and the casing front wall 932. In the illustrated embodiment, the partial J-cup faceplate 914 is devoid of a crown return. The introduction of a crown return to the partial J-cup faceplate 914 would add a third bend at the juncture between the strike face 902 and the crown, making the partial J-cup faceplate geometry too complicated for monolithic forging. At impact, the partial J-cup faceplate 914, specifically the sole return 916, deflects with the front wall front surface 934, which in turn increases strike face deflection. This contrasts to the J-cup faceplate 814 described above, which deflects with the entire casing front wall 832.

[0169] In some embodiments, the club head 1100 can comprise an “underlapping J-cup” faceplate 1114 that reinforces the casing front wall 1132. As best illustrated in FIG. 28, the underlapping J-cup faceplate 1114 comprises a sole return 1116 that extends rearward from the strike face 1102. The sole return 1116 forms both a forward portion of the sole 1112 and a portion of the casing front wall 1132. The sole return 1116 comprises a faceplate lap 1118 that extends upwards at the rear end of the sole return 1116 to form the front wall rear surface 1136. The body 1101 comprises a body lap 1119 that overlaps the faceplate lap 1118 and forms the front wall front surface 1134. Together, the faceplate lap 1118 and the body lap 1119 combine to form the casing front wall 1132. The underlapping J-cup faceplate 1114 therefore forms only a portion of the front wall thickness. The front wall rear surface 1136 is integral with the underlapping J-cup faceplate 1114, whereas the front wall front surface 1134 is integral with the body 1101. As such, the underlapping J-cup faceplate 1114 contrasts with the partial J-cup faceplate 914, which forms the front wall front surface 934 but not the front wall rear surface 936. Similar to the J-cup faceplate 814 illustrated in FIG. 24, the casing rear wall 1142 is integral with the body 1101, and the underlapping J-cup faceplate 1114 forms no portion of the casing rear wall 1142. As such, both the front wall front surface 1134 and the rear wall 1142 of the casing 1130 can be integral with the body 1101. In this configuration, the underlapping J-cup faceplate 1114 and the body 1101 combine to form the aperture 1140 therebetween.

[0170] In some embodiments, the sole return 1116 can form the entire front wall rear surface 1136 of the casing 1130. In other embodiments, the sole return 1116 forms only a portion of the front wall rear surface 1136. For example, in some embodiments, as illustrated in FIG. 28, the body lap 1119 includes a cap 1117 that covers the top end of the faceplate lap 1118. The cap 1117 thereby forms the entire front wall top surface 1138 and an upper end of the front wall rear surface 1136. Further, in some embodiments, the faceplate lap 1118 does not extend along the entirety of the front wall rear surface 1136. As best illustrated in FIG. 29, the casing front wall 1132 comprises a support segment 1168 that is integral with the underlapping J-cup faceplate 1114 and a core segment 1169 that is integral with the body 1101. The support segment 1168 is the portion of the casing front wall 1132 formed by the underlapping J-cup faceplate 1114, whereas the core segment 1169 is the portion of the casing front wall 1132 formed by the body 1101.

[0171] In some embodiments, the support segment 1168 forms between 25 and 100% of a surface area of the front wall rear surface 1136. For example, in some embodiments, the support segment 1168 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall rear surface 1136. In some embodiments, the support segment 1168 forms no portion of the front wall front surface 1134. The core segment 1169 of the underlapping J-cup faceplate 1114 forms the entire front wall front surface 1134. This contrasts with the core segment 969 of the partial J-cup faceplate 914 described above, which forms the entire front wall rear surface 1136.

[0172] In some embodiments, such as the illustrated embodiment of FIG. 29, support segment 1168 is located primarily in the casing center region 1131. In such embodiments, the core segment 1169 forms the entire casing front wall 1132 in the casing heel region 1135 and the casing toe region 1137. In the present configuration, the sole return 1116 locally reinforces the casing center region 1131, where the greatest deflection and high impact stresses typically occur. In other embodiments, the support segment 1168 and the core segment 1169 can have alternate configurations. For example, the support segment 1168 can be located primarily in the casing center region 1131, the casing heel region 1135, the casing toe region 1137, or any combination thereof.

[0173] In embodiments where the sole return 1116 forms only a portion of the casing front wall 1132, the sole return 1116 can span a lesser distance in a heel-to-toe direction than the aperture 1140. As illustrated in FIG. 22, the sole return width WsR is less than the total length TL of the aperture 1140.

[0174] The underlapping J-cup faceplate 1114 is readily manufacturable and reinforces the casing 1130. The sole return 1116 reinforces high-stress areas of the casing front wall 1132 with high-strength material. In some embodiments, the underlapping J-cup faceplate 1114 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 21, the underlapping J-cup faceplate 1114 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814 and the partial J-cup faceplate 914, the underlapping J-cup faceplate 1114 comprises a first bend at the juncture between the strike face 1102 and the sole return 1116 and a second bend at the juncture between the sole 1112 and the faceplate lap 1118. In the illustrated embodiment, the underlapping J-cup faceplate 1114 is devoid of a crown return. The introduction of a crown return to the underlapping J-cup faceplate 1114 would add a third bend at the juncture between the strike face 1102 and the crown, making the underlapping J-cup faceplate geometry too complicated for monolithic forging. At impact, the underlapping J-cup faceplate 1114, specifically the faceplate lap 1118, deflects with the front wall rear surface 1136, which in turn increases strike face deflection. This contrasts with the partial J-cup faceplate 914, which deflects with the front wall front surface 1134.

[0175] In some embodiments, the club head 1200 comprises a faceplate 1214 with one or more bridges 1249 that further reinforce the casing 1230 without compromising strike face deflection. As best illustrated in FIG. 30, the faceplate 1214 comprises a sole return 1216 that extends rearward from the strike face 1202. The sole return 1216 forms both a forward portion of the sole 1212 as well as the casing front wall 1232. As such, the casing front wall 1232 is integral with the faceplate 1214. The faceplate 1214 further comprises one or more bridges 1249 that span the aperture 1240 in a face-to-rear direction. The bridges 1249 connect the front wall 1232 and the rear wall 1242 of the casing 1230. In the illustrated embodiment, the bridges 1249 connect the front wall top surface 1238 and the rear wall top surface 1244. In other embodiments, the bridges 1249 can connect other portions of the front wall 1232 and the rear wall 1242. In some embodiments, the bridges can connect the front wall base 1233 to the rear wall base 1243. In other embodiments, the bridges 1249 can connect portions of the front wall 1232 and the rear wall 1242 in between the top surfaces 1238, 1244 and the bases 1233, 1243. The faceplate 1214 can comprise any suitable number of bridges 1249 for reinforcing the casing walls 1232, 1242. In some embodiments, the faceplate can comprise one, two, three, four, five, six, seven, eight, nine, or any suitable number of bridges 1249. In some embodiments, the bridges 1249 are monolithically formed with the faceplate 1214. In other embodiments, the bridges 1249 can be separately formed from the faceplate 1214 and subsequently attached thereto, such as by welding.

[0176] The bridges 1249 can be located at strategic locations to locally reinforce the casing 1230. In some embodiments, the bridges 1249 are located within the casing center region 1231. For center strikes, the greatest deflection and highest impact stresses occur within the casing center region 1231. Placing one or more bridges 1249 in the casing center region 1231 reinforces the casing 1230 in these high-stress areas to improve durability without hindering strike face deflection.

[0177] In the illustrated embodiment, the casing front wall 1232 and the bridges 1249 are both integral with the faceplate 1214, and the casing rear wall 1242 is integral with the body 1201. In such embodiments, the bridges 1249 can be welded or otherwise coupled to the body 1201. In such embodiments, the faceplate 1214 and the body 1201 combine to form the aperture 1240. In other embodiments, the casing front wall 1232, the bridges 1249 and the casing rear wall 1242 are all integral with the faceplate 1214. In such embodiments, the faceplate 1214 entirely encapsulates the aperture 1240. At impact, the faceplate 1214 with one or more bridges 1249 bends with the casing 1230. Specifically, the sole return 1216 bends with the casing front wall 1232. As the casing walls bend towards each other, the bridges 1249 are compressed by the casing walls and return a stiffening force back to the casing walls. The stiffening force allows the casing walls to bend further than they otherwise would in the absence of bridges, thereby increasing strike face deflection.B. Cartridge Forming the Casing

[0178] In some embodiments, the club head 1400 comprises a component separate from the faceplate and body, such as a cartridge 1450, that integrally forms at least a portion of the casing 1430. Referring to FIGS. 31 and 32, the cartridge 1450 is a component distinct from the faceplate 1414 that is attached to the faceplate 1414, the body 1401, or both. Although the cartridge 1450 and the faceplate 1414 are both high-strength material components, they are not the same component. The cartridge 1450 integrally forms at least a portion of the casing 1430, including the front wall 1432 and the rear wall 1442. The cartridge 1450 is formed of a high-strength cartridge material that is more durable than the body material. As such, the cartridge 1450 reinforces the IRM 1420 and increases strike face deflection without compromising durability. In some embodiments, the cartridge 1450 houses and forms the entire casing 1430. In other embodiments, the cartridge 1450 forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 but may not form the entire casing 1430. In such embodiments, the cartridge 1450 locally reinforces the casing 1430 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1431 experiences greater deflection and higher impact stresses than the casing heel region 1435 or the casing toc region 1437. In such embodiments, the cartridge 1450 may form and reinforce the casing center region 1431. The casing heel region 1435 and the casing toe region 1437 may not require the same level of reinforcement and can therefore be formed by the body 1401, which comprises a lower-strength material.

[0179] The cartridge 1450 reinforces the IRM 1420 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1430, the cartridge 1450 is a separate, high-strength material component that forms and reinforces the casing 1430. Because the faceplate 1414 does not form any part of the complicated casing geometry, the cartridge 1450 can be combined with a faceplate 1414 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration not only reinforces the IRM 1420 but also reinforces other portions of the club head 1400 to further increase strike face deflection, as the returns (i.e., the crown return, sole return, heel return, or sole return) can have a reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process, (such as welding) between the cartridge 1450 and the faceplate 1414 or body 1401 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0180] In some embodiments, the separately formed cartridge 1450 is attached to both the faceplate 1414 and the body 1401 and houses at least a portion of the casing 1430. In the illustrated embodiment of FIG. 25, the cartridge 1450 is located in a forward portion of the sole 1412. The cartridge 1450 comprises a cartridge perimeter 1455 that includes a cartridge forward edge 1456 that couples to the faceplate 1414 and a cartridge rear edge 1457 that couples to the body 1401. In some embodiments, as illustrated in FIG. 32, the faceplate 1414 comprises a sole return 1416 extending rearward from the strike face 1402 and the cartridge forward edge 1456 couples to the sole return 1416. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the sole 1412. The cartridge 1450 is thereby located entirely within the sole 1412.

[0181] In alternative configurations, rather than the cartridge 1450 being located entirely within the sole 1412, the cartridge 1450 can partially extend onto the strike face 1402, as best illustrated in FIG. 33. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the strike face 1402. The faceplate 1414 can be devoid of a sole return 1416 and the cartridge 1450 can wrap over the leading edge 1403 and form a lower portion of the strike face 1402. In both embodiments, the cartridge 1450 forms at least a portion of the sole 1412.

[0182] In the embodiment illustrated in FIGS. 31 and 32, the cartridge 1450 houses the entire casing 1430, thereby reinforcing the entire casing 1430 with high-strength material. The cartridge perimeter 1455 is continuously attached to either the faceplate 1414 or the body 1401 in this embodiment, such that there are no unattached cartridge edges. In such embodiments, the cartridge 1450 forms and encases the entire aperture 1440. In other embodiments, the cartridge 1450 is coupled to both the faceplate 1414 and the body 1401 and forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 yet may not form the entire casing 1430. In some embodiments, the front wall 1432 and / or rear wall 1442 can comprise a support segment formed by the cartridge 1450 and a core segment formed by the body 1401, as described in further detail below. In such embodiments, the aperture 1440 is formed by a combination of the cartridge 1450 and the body 1401.

[0183] In some embodiments, the separately formed cartridge 1550 is attached only to the body 1501 and is not directly coupled to the faceplate 1514. The cartridge perimeter 1555 can be continuously coupled to the body 1501. As illustrated in FIGS. 34-36, both the cartridge forward edge 1556 and the cartridge rear edge 1557 are coupled to the body 1501, such that the cartridge 1550 is entirely housed by and isolated within the body 1501. This configuration can be especially useful in embodiments comprising face inserts, in which the faceplate 1514 is confined within an opening located on the strike face 1502. Further, in some cases, stresses concentrate near the casing front wall 1532, but not in the forwardmost portion of the sole 1512 or near the leading edge 1503. In such cases, the leading edge 1503 and the portion of the sole 1512 in front of the casing 1530 may not require high-strength reinforcement.

[0184] The cartridge 1550 can be located entirely within the sole 1512, as illustrated in FIGS. 34-36. In such embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the sole 1512. Further, the body 1501 forms a forward sole segment 1513 interposed between the cartridge forward edge 1556 and the leading edge 1503. In other embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the strike face 1502. In such embodiments, the cartridge 1550 can wrap over the leading edge 1503 and form a lower portion of the strike face 1502. In both embodiments, the cartridge 1550 forms at least a portion of the sole 1512.

[0185] In the embodiment illustrated in FIGS. 34-36, the cartridge 1550 only partially forms the casing 1530. The portion(s) of the casing walls formed by the cartridge 1550 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1501 can be referred to as core segments. In the illustrated embodiment, the front wall 1532 comprises a front wall support segment 1568a formed by the cartridge 1550 and a rear wall core segment 1569b formed by the body 1501. Similarly, the rear wall 1542 comprises a rear wall support segment 1568b formed by the cartridge 1550 and a rear wall core segment 1569b formed by the body 1501. In the illustrated embodiment, the respective support segments 1568a, 1568b are in the casing center region 1531 and extend into the casing toe region 1537, whereas the respective core segments 1569a, 1569b are primarily located in the casing heel region 1535. The cartridge 1550 comprises a cartridge heel edge 1558 that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b. Because the body 1501 and the cartridge 1550 combine to form the aperture 1540, the cartridge heel edge 1558 can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge heel edge 1558.

[0186] In other embodiments, the support segments 1568a, 1568b and core segments 1569a, 1569b can have alternative configurations. For example, the support segments 1568a, 1568b can be primarily in the casing center region 1531. In such embodiments, the core segments 1569a, 1569b are located in both the casing heel region 1535 and the casing toe region 1537. In such embodiments, the cartridge 1550 further comprises a cartridge toe edge that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b near the casing toe region 1537. As similarly described above, the cartridge toe edge in such embodiments can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge toe edge.

[0187] The front wall 1532 and rear wall 1542 can have combinations or configurations of support segments 1568a, 1568b and core segments 1569a, 1569b to produce a desired strike face deflection. The cartridge 1550 can form at least portions of the casing front wall 1532 and the casing rear wall 1542. In some embodiments, the front wall height of the casing can be greater in the front wall core segment 1569a than in the front wall support segment 1568a. The high-strength cartridge material allows the front wall height in the support segment 1568a to be reduced (thereby increasing strike face deflection) without compromising durability.

[0188] In other embodiments, by being coupled only to the body 1501 and not the faceplate 1514, the cartridge 1550 can house the entire casing 1530, thereby increasing IRM reinforcement. The cartridge perimeter 1555 is continuously attached to the body 1501 in such embodiments, such that there are no unattached or interrupted cartridge edges.

[0189] In the club head 1400 comprising a cartridge 1450, the faceplate 1414 forms no portion of the casing 1430. Instead, the casing 1430 is formed entirely by the cartridge 1450 or a combination of the cartridge 1450 and the body 1401, as described above. Similarly, the faceplate 1414 forms no portion of the aperture 1440. The cartridge 1450 separates the faceplate 1414 from the aperture 1440 and is either formed completely by the cartridge 1450 or by a combination of the cartridge 1450 and the body 1401.

[0190] As described above, manufacturing (and in particular forging) unitary, high-strength material components is limited by the number of bends the unitary component can have in a single direction (i.e., vertical, horizontal, etc.). In general, a single high-strength component can only be forged with a maximum of two bends in a single direction. The cartridge 1450 improves manufacture by forming the complex casing geometries separately from the faceplate 1414. Because the casing 1430 is separate from the faceplate 1414, the casing 1430 does not factor into the maximum number of faceplate bends. As such, the faceplate 1414 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1414 integrally forms the casing 1430. For example, the separately formed faceplate 1414 can comprise both a crown return 1415 and a sole return 1416 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1414 comprises a first bend at the juncture between the strike face 1402 and the crown return 1415 and a second bend at the juncture between the strike face 1402 and the sole return 1416. The cartridge 1450 can thereby be combined with a faceplate 1414 comprising a crown return 1415, a sole return 1416, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing key areas of the club head 1400 on the crown 1410, sole 1412, heel 1404, and toe 1406.

[0191] The cartridge 1450 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1401 or the faceplate 1414. In some embodiments, the cartridge 1450 is welded to the faceplate 1414 or the body 1401. In other embodiments, the cartridge 1450 can be coupled to the faceplate 1414 or the body 1401 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the cartridge 1450 is coupled to the body 1401 and the faceplate 1414 through a permanent fixing means. In some embodiments, the attachment means between the cartridge 1450 and the body 1401 is the same as the attachment means between the cartridge 1450 and the faceplate 1414. In other embodiments, the cartridge 1450 is coupled to both the body 1401 and the faceplate 1414 by identical means.

[0192] As described above, the cartridge 1450 is formed of a high-strength cartridge material. For example, in some embodiments, the cartridge material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0193] In other embodiments, the cartridge material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fc-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the cartridge material can be a high-strength composite or carbon fiber material.

[0194] Generally, the cartridge material is stronger than the body material. In some embodiments, the cartridge material is the same as the faceplate material. In other embodiments, the cartridge material and the faceplate material are different. The high-strength cartridge material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the cartridge material has a yield strength value of at least 175 ksi or more. In some embodiments, the cartridge material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises a cartridge strength ratio comparing the yield strength of the cartridge material to the yield strength of the body material. In some embodiments, the cartridge strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.C. Body and Appendage Forming the Casing

[0195] In some embodiments, the club head 1600 comprises an appendage 1650 that integrally forms at least a portion of the casing 1630. Referring to FIGS. 37-40, the appendage 1650 is a separate component attached to the faceplate 1614 and the body 1601. Although the appendage 1650 and the faceplate 1614 are both high-strength material components, they are not the same component. The appendage 1650 integrally forms at least a portion of the casing front wall 1632. The appendage 1650 is formed of a high-strength appendage material that is more durable than the body material. As such, the appendage 1650 reinforces the IRM 1620 and increases strike face deflection without compromising durability. In some embodiments, the appendage 1650 forms the entire front wall 1632. In other embodiments, the appendage 1650 forms only a portion of the front wall 1632 rather than the entire front wall 1632. In such embodiments, the appendage 1650 locally reinforces the casing 1630 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1631 experiences greater deflection and higher impact stresses than the casing heel region 1635 or the casing toe region 1637. In such embodiments, the appendage 1650 may form and reinforce the casing center region 1631. The casing heel region 1635 and the casing toe region 1637 may not require the same level of reinforcement and can therefore be formed by the body 1601, which comprises a lower-strength material.

[0196] The appendage 1650 reinforces the IRM 1620 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1630, the appendage 1650 is a separate, high-strength material component that forms and reinforces the casing 1630. Because the faceplate 1614 does not have to form any part of the complicated casing geometry, the appendage 1650 can be combined with a faceplate 1614 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration allows for high-strength material reinforcement of not only the IRM 1620 but also other portions of the club head 1600 to further increase strike face deflection, because the returns (i.e., the crown return, sole return, heel return, or sole return) can have reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process (such as welding) between the appendage 1650 and the faceplate 1614 or body 1601 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0197] In some embodiments, the separately formed appendage 1650 is attached to both the faceplate 1614 and the body 1601 and integrally forms at least a portion of the casing front wall 1632. In the illustrated embodiment of FIG. 38, the appendage 1650 is located in a forward portion of the sole 1612. The appendage 1650 comprises an appendage perimeter 1655 that includes an appendage forward edge 1656 that couples to the faceplate 1614. The appendage perimeter 1655 further includes an appendage heel edge 1658 and an appendage toe edge 1659 each coupled to the body 1601. While the appendage 1650 forms at least a portion of the front wall 1632, the body 1601 forms the rear wall 1642. The aperture 1640 is thereby formed between the body 1601 and the appendage 1650.

[0198] In some embodiments, the appendage 1650 is located entirely within the sole 1612. As illustrated in FIGS. 30-31, the faceplate 1614 comprises a sole return 1616 extending rearward from the strike face 1602, and the appendage forward edge 1656 couples to the sole return 1616. In such embodiments, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the sole 1612. In alternative configurations, rather than the appendage 1650 being located entirely within the sole 1612, the appendage 1650 can partially extend on to the strike face 1602. In such embodiments, as best illustrated in FIG. 39, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the strike face 1602. In such embodiments, the faceplate 1614 can be devoid of a sole return 1616 and the appendage 1650 can wrap over the leading edge 1603 and form a lower portion of the strike face 1602. In both embodiments, the appendage 1650 forms at least a portion of the sole 1612.

[0199] In some embodiments, the appendage 1650 forms entities of both the front wall front surface 1634 and front wall rear surface 1636 of the casing 1630. This configuration increases high-strength material reinforcement along the entire front wall 1632. In some embodiments, the appendage 1650 can extend laterally past the extent of the aperture 1640. Such embodiments increase heel wall 1652 and toe wall 1654 reinforcement, where stress often pools within the casing 1630. In such embodiments, the appendage forward edge 1656 can be coupled to both the faceplate 1614 and the body 1601, because the appendage 1650 extends past the extent of the faceplate 1614 and / or the sole return 1616.

[0200] In other embodiments, such as that illustrated at FIG. 38, the appendage 1650 forms only a portion of the front wall 1632 and only a portion of the front wall rear surface 1636. The portion(s) of the casing walls formed by the appendage 1650 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1601 can be referred to as core segments. As illustrated in FIG. 40, the front wall 1632 comprises a support segment 1668 formed by the appendage 1650 and a core segment 1669 formed by the body 1601. In the illustrated embodiment, the support segment 1668 occupies the casing center region 1631 whereas the respective core segment 1669 primarily occupies the casing heel region 1635 and the casing toe region 1637. The appendage heel edge 1658 and the appendage toe edge 1659 couple to the body 1601 at the junctures between the support segment 1668 and the core segment 1669. The support segment 1668 locally reinforces high-stress areas in the front wall 1632.

[0201] In other embodiments, the support segment 1668 and core segment 1669 can have alternative configurations. For example, in some embodiments, the support segment 1668 can extend from the casing center region 1631 into either the casing heel region 1635 or the casing toe region 1637. The front wall 1632 and rear wall 1642 can have any configuration of the support segment 1668 and the core segment 1669 to produce a desired strike face deflection. The appendage 1650 can form any amount or portion of the casing front wall 1632. In some embodiments, the front wall height of the casing 1630 can be greater in the core segment 1669 than in the support segment 1668. The high-strength appendage material allows the front wall height FWH in the support segment 1668 to be reduced (thereby increasing strike face deflection) without compromising durability.

[0202] The appendage 1650 can define an appendage length LA measured in a heel-to-toe direction between the heelmost and toemost extent of the appendage 1650. In embodiments wherein the appendage 1650 forms less than the entirety of the front wall 1632, the appendage length LAP can be less than the total length TL of the aperture 1640 (defined below). In such embodiments, strike face deflection and club head durability are improved without excess high-strength material being required to form the appendage 1650.

[0203] In the club head 1600 comprising an appendage 1650, the faceplate 1614 forms no portion of the casing 1630. Instead, the casing 1630 is formed entirely by a combination of the appendage 1650 and the body 1601, as described above. Similarly, because the casing 1630 forms the aperture 1640, the faceplate 1614 also forms no portion of the aperture 1640. The appendage 1650 separates the faceplate 1614 from the aperture 1640. Instead, the aperture 1640 is formed completely by a combination of the appendage 1650 and the body 1601 within the casing 1630.

[0204] As described above, manufacturing (particularly forging) high-strength material components is limited by the number of bends the unitary component can have in a single direction. The appendage 1650 improves manufacture by allowing the complex casing geometries to be forged separately from the faceplate 1614. Because the appendage 1650 is separate from the faceplate 1614, the front wall geometry does not factor into the maximum number of faceplate bends. As such, the faceplate 1614 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1614 integrally forms the front wall. For example, the separately formed faceplate 1614 can comprise both a crown return and a sole return 1616 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1614 comprises a first bend at the juncture between the strike face 1602 and the crown return and a second bend at the juncture between the strike face 1602 and the sole return 1616. The appendage 1650 thereby separately forms a third bend at the juncture between the sole 1612 and the front wall 1632. The appendage 1650 can thereby be combined with a faceplate 1614 comprising a crown return, a sole return 1616, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing areas of the club head 1600 on the crown 1610, sole 1612, heel 1604, and toe 1606.

[0205] The appendage 1650 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1601 and the faceplate 1614. In some embodiments, the appendage 1650 is welded to the faceplate 1614 or the body 1601. In other embodiments, the appendage 1650 can be coupled to the faceplate 1614 or the body 1601 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the appendage 1650 is coupled to the body 1601 and the faceplate 1614 through a permanent fixing means. In some embodiments, the attachment means between the appendage 1650 and the body 1601 is the same as the attachment means between the appendage 1650 and the faceplate 1614. In other embodiments, the appendage 1650 is coupled to both the body 1601 and the faceplate 1614 by identical means.

[0206] As described above, the appendage 1650 is formed of a high-strength appendage material. For example, in some embodiments, the appendage material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0207] In other embodiments, the appendage material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fc-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9Al-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fc (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the appendage material can be a high-strength composite or carbon fiber material.

[0208] Generally, the appendage material is stronger than the body material. In some embodiments, the appendage material is the same as the faceplate material. In other embodiments, the appendage material and the faceplate material are different. The high-strength appendage material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the appendage material has a yield strength value of at least 175 ksi or more. In some embodiments, the appendage material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises an appendage strength ratio comparing the yield strength of the appendage material to the yield strength of the body material. In some embodiments, the appendage strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.V. Casing Parameters and Performance Ratio

[0209] In one embodiment of a golf club head, the casing comprises various shapes, geometries, and dimensions described below that improve the performance and durability of the IRM when implemented in a fairway wood type club head. In the current embodiment, the IRM is formed entirely within a body of the club head, and the club head further comprises an adjustable shaft-receiving mechanism (described in further detail below). The IRM includes a check-marked shaped casing such that the casing walls form a toe relief. The club head further comprises a faceplate that forms a crown return. The specific values and relationships between the casing shapes, geometries, and dimensions are particularly advantageous for a fairway wood type club head, as described in greater detail below.

[0210] The main parameters that alter the performance of the casing of this specific fairway wood embodiment are the total length TL of the aperture, the offset distance OD of the casing the front wall thickness FWT of the casing, and the front wall height FWH of the casing, as shown in FIGS. 41-46. These four parameters can be balanced to increase strike face deflection while maintaining sufficient durability. The relationship between these parameters can be expressed by a performance ratio defined below. The performance coefficient PC in the equation accounts for the change in strike face deflection and durability per unit change in each of the individual parameters and may alter or change between embodiments.X⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤Y⁢ in-2

[0211] As shown in the performance ratio above, the numerator comprises total length TL because as the total length TL increases, the performance increases. Conversely, the denominator comprises the product of offset distance OD, front wall thickness FWT, and front wall height FWH because as each of those three parameters increases, performance decreases. Accordingly, the numerator (total length TL) has an inverse relationship with the denominators (offset distance OD, front wall thickness FWT, front wall height FWH) such that if the total length increases, some combination of the offset distance OD, front wall thickness FWT, and / or front wall height FWH will also have to increase to maintain the performance ratio. Similarly, if any one of the denominators increases, at least one of the other remaining denominators will decrease to maintain the performance ratio.

[0212] The performance ratio is expressed as an inequality ranging between 14 in−2 and 18 in−2. If the performance ratio falls below 14 in−2, the IRM / casing will underperform and / or be over durable. Conversely, if the performance ratio goes above 18 in−2, the casing will be overly flexible and not sufficiently durable. The performance ratio and inequality having a range between 14-18 in−2 is especially applicable to the fairway wood type club head comprising an adjustable hosel and a casing having walls forming a check-mark shape with a toe return wherein the casing is formed with the body.

[0213] The performance coefficient PC, as described above, accounts for a change in strike face deflection and durability per unit change in each of the individual parameters. The performance coefficient PC is unique to individual embodiments. In this particular embodiment as described above, the performance coefficient can range from 0.028 to 0.035. For example, the performance coefficient can be 0.028, 0.029, 0.030, 0.031, 0.032, 0.033, 0.034, or can be 0.035.

[0214] In other embodiments of club heads comprising an IRM, the boundaries of the performance inequality and the performance coefficient may be different than the performance inequality and the performance coefficient of the above described embodiment. The parameters (OD, TL, FWT, FWH) used in the inequality may have different effects on the durability and performance of the club head.

[0215] The parameters, total length TL, offset distance OD, front wall thickness FWT, and front wall height FWH, are measurements based off of the casing front wall 132. To better define the parameters, the construction / structure of the front wall 132 must be defined first. The front wall 132 has a front wall front surface 134, a front wall top surface 138, and a front wall rear surface 136, as illustrated in FIG. 41. The front wall front surface 134 and the front wall top surface 138 connect to form a top front edge 121. The front wall top surface 138 and the front wall rear surface 136 connect to form a top rear edge 122. The front wall rear surface 136 and the sole 112 connect to form a bottom rear edge 123. An interior sole surface 125 and the front wall front surface 134 connect to form a bottom front edge 124. In some embodiments, the adjoining surfaces may have fillets or chamfers. In these embodiments, the edges described above can be defined at the intersection of the adjoining surface projections.

[0216] The total length TL of the aperture is measured from an absolute heel point (AHP) to an absolute toe point (ATP), parallel to the X-axis 40, as illustrated in FIG. 46. This length can be selected to balance between either increasing strike face deflection and decreasing durability, or decreasing strike face deflection and increasing durability. The absolute heel point AHP is located at the heel most point of the aperture 140. The absolute toe point ATP is located at the toe most point of the aperture 140. The total length TL can be increased to increase strike face deflection but decrease durability. Similarly, the total length TL of the aperture can be decreased to decrease strike face deflection but increase durability. Similar to a fixed beam, a longer casing will experience more deflection for the same amount of load. As such, the longer the aperture 140 (and therefore the longer the casing 130), the more flexible the casing 130 becomes. The potential max total length TL of the aperture is affected whether or not an adjustable shaft-receiving mechanism or a fixed shaft receiving mechanism is utilized in the club head, which is described in further detail below.

[0217] The total length TL to be used in the above performance inequality can range between 2.00 and 2.05 inches, 2.05 and 2.10 inches, 2.10 and 2.15 inches, 2.15 and 2.20 inches, 2.20 and 2.25 inches, 2.25 and 2.30 inches, 2.30 and 2.35 inches, 2.35 and 2.40 inches, 2.40 and 2.45 inches, 2.45 and 2.50 inches, 2.50 and 2.55 inches, 2.55 and 2.60 inches, 2.60 and 2.65 inches, 2.65 and 2.70 inches, or between 2.70 and 2.75 inches. In the specific embodiment described above, the total length TL is approximately 2.359 inches.

[0218] The offset distance OD generally quantifies the location of the aperture relative to the strike face and is defined as the distance from the leading edge 103 to the front wall bottom rear edge 123, parallel to the Z-axis 60, in the YZ plane. As mentioned above, the offset distance OD can be selected to either increase strike face deflection and decrease durability or decrease strike face deflection and increase durability. Specifically, as the offset distance OD increases (i.e., the casing 130 is further away from the strike face 102) the strike face deflection decreases and the durability increases. Similarly, as the offset distance OD decreases (i.e., the casing 130 is positioned closer to the strike face 102), the strike face deflection increases and the durability decreases. A reduced offset distance OD of the aperture increases the deflection of the casing 130 by moving the aperture 140 closer to the strike face 102 and experiences higher deflection. When the casing 130 experiences an increase in deflection, the casing 130 flexes more and increases energy returned back to the strike face 102 and the golf ball.

[0219] The offset distance OD can range between 0.225 and 0.230 inch, 0.230 and 0.235 inch, 0.235 and 0.240 inch, 0.240 and 0.245 inch, 0.245 and 0.250 inch, 0.250 and 0.255 inch, 0.255 and 0.260 inch, 0.260 and 0.265 inch, 0.265 and 0.270 inch, 0.270 and 0.275 inch, 0.275 and 0.280 inch, 0.280 and 0.285 inch, 0.285 and 0.290 inch, 0.290 and 0.295 inch, or between 0.295 and 0.300 inch. In the specific embodiment described above, the offset distance OD is approximately 0.245 in.

[0220] The front wall thickness FWT is measured as the distance between front wall front surface 134 and the front wall rear surface 136, in the YZ plane. As mentioned above, the front wall thickness FWT can be selected to either increase strike face deflection and decrease durability or to decrease strike face deflection and increase durability. Specifically, the front wall thickness FWT can be increased (i.e., made thicker) to decrease strike face deflection but increase durability. Alternatively, the front wall thickness FWT can be decreased (i.e., made thinner) to increase strike face deflection but decrease durability.

[0221] The front wall thickness FWT can range between 0.065 and 0.070 inch, 0.070 and 0.075 inch, 0.075 and 0.080 inch, 0.080 and 0.085 inch, 0.085 and 0.090 inch, 0.090 and 0.095 inch, 0.095 and 0.100 inch, 0.100 and 0.105 inch, 0.105 and 0.110 inch, or between 0.110 and 0.115 inch. In the specific embodiment described above, the front wall thickness FWT is approximately 0.0851 inch.

[0222] The front wall height FWH, as used above, is measured as the distance between the front wall bottom rear edge 123 and the front wall top rear edge 122, along the front wall rear surface 136, in the YZ plane. As mentioned above, the front wall height FWH can be selected to either increase strike face deflection and decrease durability, or to decrease strike face deflection and increase durability. Specifically, increasing the front wall height FWH (i.e., providing a taller front wall 132) decreases strike face deflection but increases durability. Similarly, as the front wall height FWH decreases (i.e., providing a shorter front wall 132), the strike face deflection increases but the durability decreases. The front wall height FH can be constant along the length of the casing 130, or the front wall height FWH can vary along the length of the casing 130.

[0223] The front wall height FWH can range between 0.200 and 0.205 inch, 0.205 and 0.210 inch, 0.210 and 0.215 inch, 0.215 and 0.220 inch, 0.220 and 0.225 inch, 0.225 and 0.230 inch, 0.230 and 0.235 inch, 0.235 and 0.240 inch, 0.240 and 0.245 inch, or between 0.245 and 0.250 inch. In the specific embodiment described above, the front wall height FWH is approximately 0.221 in.

[0224] The above-described parameters and ranges are particularly advantageous for the fairway wood type club head comprising a casing with walls that are formed in a check-mark shape that increases strike face deflection while maintaining a sufficient durability. In other embodiments of club heads, variation can occur for the performance ratio and / or ranges of parameters. For example, a casing in a hybrid type club head may have different parameters that result in a similar increase in strike face deflection while maintaining sufficient durability. Furthermore, in other embodiments, a club head can comprise one or more additional parameters measured at various positions along the length of the casing.

[0225] The additional parameters can be better understood with reference to certain reference planes, as shown in FIGS. 42-47. The reference planes are located at various positions along the length of the casing, from the heel end to the toe end. The reference planes are also used to define various cross-sectional views to visualize other specific casing geometries. For example, the casing can comprise a front wall thickness that is measured in a heel plane, a toe plane, and an XY plane. The front wall thickness can be different in each of these planes (cross-sections), or the front wall thickness can be the same in each of the planes (cross-sections). The front wall thickness, heel plane, toe plane, and XY plane are discussed below.

[0226] The casing comprises a heel plane HP that is perpendicular to the leading edge plane LEP and the ground plane GP and intersects the front wall rear surface 136 at the heel end where the front wall rear surface 136 deviates to the heel relief, or heel wall, as illustrated in FIG. 47. The front wall rear surface 136 deviates to the heel relief, or heel wall, where the radius of curvature of the front wall 132 changes. The heel plane HP creates a heel plane HP cross-section, as shown in FIG. 43.

[0227] The casing comprises a toe plane TP that is perpendicular to the leading edge plane LEP and the ground plane GP and intersects the front wall rear surface 136 at the toe end where the front wall rear surface 136 deviates to the toe relief, or toe wall, as illustrated in FIG. 47. The front wall rear surface 136 deviates to the toe relief, or toe wall, where the radius of curvature of the front wall 132 changes. The toe plane TP creates a toe plane TP cross-section, as shown in FIG. 44.

[0228] The casing comprising various shapes, geometries, and dimensions described above, such as total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT, that improve the performance and durability of the IRM when implemented in a fairway wood type club head having an adjustable hosel, a faceplate with a crown return, and a check-marked shaped IRM.A. Offset Distance

[0229] In some embodiments, the offset distance OD can vary along the length of the casing to either increase deflection or durability of a specific area of the casing. In other embodiments, the offset distance OD can be constant along the length of the casing. In some embodiments, the offset distance OD can be greatest in the casing center region and smallest in the casing heel region and the casing toe region. In other embodiments, the offset distance OD can be smallest in the casing center region and greatest in the casing heel region and the casing toe region.

[0230] The offset distance OD can be measured at three different locations along the length of the casing in a center, heel, and toe portions of the casing. The first offset distance OD1 is measured in the YZ plane, as shown in FIG. 42. The second offset distance OD2 is measured in the heel plane HP, as shown in FIG. 43. The third offset distance OD3 is measured in the toe plane TP, as shown in FIG. 44. The offset distances OD1,2,3 can be equal or in other embodiments, the offset distances OD1,2,3 can be different such that the offset distances OD1,2,3 vary across the length of the casing. Each offset distance OD1,2,3 can be adjusted individually to alter the performance and durability of the casing.

[0231] Each of the casing offset distances OD1,2,3 can range from 0.075 to 1.00 inch. For example, the casing offset distance OD1,2,3 can range from 0.075-0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, 0.40 to 0.50 inch, 0.50 to 0.60 inch, 0.60 to 0.70 inch, 0.70 to 0.80 inch, 0.80 to 0.90 inch, or from 0.90 to 1.00 inch. In some embodiments, the casing offset distance OD1,2,3 can be 0.075 inch, 0.080 inch, 0.085 inch, 0.090 inch, 0.095 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, or 1.0 inch. In one embodiment, the offset distance OD1 is 0.177 inch, the offset distance OD2 is 0.170 inch, and the offset distance OD3 is 0.140 inch. In other embodiments, the offset distances OD1,2,3 can be equal.B. Total Length

[0232] The aperture comprises a total length TL, measured from an absolute heel point (AHP) to an absolute toe point (ATP), parallel to the X-axis 40, as illustrated in FIG. 46, that can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. The total length TL can be increased to increase strike face deflection, but decrease durability. Similarly, the total length TL of the casing can be decreased to decrease strike face deflection, but increase durability. Similar to a fixed beam, a longer casing will experience more deflection for the same amount of load. As such, the longer the casing, the casing is more flexible. The potential maximum total length TL of the casing is affected whether or not an adjustable shaft-receiving mechanism or a fixed shaft-receiving mechanism is utilized in the club head. This is described in further detail below.

[0233] Furthermore, the aperture comprises an effective length EL measured from the heel plane HP to the toe plane TP parallel to the X-axis, as illustrated in FIG. 46. The effective length EL is a measurement of the length of the aperture not including the reliefs and / or rounded ends. The effective length EL can be increased to increase strike face deflection, but decrease durability. Similarly, the effective length EL of the casing can be decreased to decrease strike face deflection, but increase durability. In the embodiments that do not have a heel relief or a toe relief, the effective length EL will be the same as the total length TL.

[0234] The total length TL can range from 0.50 to 4.0 inches. For example, the total length TL can range from 0.50 to 1.0, 1.0 to 2.0 inches, 2.0 to 3.0 inches, or 3.0 to 4.0 inches. In some embodiments, the total length can be 0.5 inches, 0.75 inches, 1.0 inches, 1.25 inches, 1.50 inches, 1.75 inches, 2.00 inches, 2.25 inches, 2.50 inches, 2.75 inches, 3.00 inches, 3.25 inches, 3.50 inches, 3.75 inches, or 4.00 inches. In one embodiment, the total length TL is 2.681 inches.

[0235] The effective length EL can range from 0.50 to 4.0 inches. For example, the total length TL can range from 0.50 to 1.0, 1.0 to 2.0 inches, 2.0 to 3.0 inches, or 3.0 to 4.0 inches. In some embodiments, the total length can be 0.5 inches, 0.75 inches, 1.0 inches, 1.25 inches, 1.50 inches, 1.75 inches, 2.00 inches, 2.25 inches, 2.50 inches, 2.75 inches, 3.00 inches, 3.25 inches, 3.50 inches, 3.75 inches, or 4.00 inches. In one embodiment, the effective length EL is 1.998 inches.

[0236] The casing comprises a toe effective length TEL, measured as the distance from the toe plane TP to the YZ plane parallel to the X-axis 40. The toe effective length TEL can range from 0.25 to 2.0 inches. For example, the toe effective length TEL can range from 0.25 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or 1.5 to 2.0 inches.

[0237] The casing comprises a heel effective length HEL, measured as the distance from the heel plane HP to the YZ plane parallel to the X-axis 40. The heel effective length HEL can range from 0.25 to 2.0 inches. For example, the toe effective length HEL can range from 0.25 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or 1.5 to 2.0 inches.

[0238] In some embodiments, the toe effective length TEL can be greater than the heel effective length HEL. In other embodiments, the heel effective length HEL can be greater than the toe effective length TEL. In some embodiments, the toe effective length TEL can be equal to the heel effective length HEL.C. Relief Angle

[0239] In the embodiments where the casing comprises reliefs, the reliefs comprise relief angles, defined below. As mentioned above, the relief angles can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, increasing the relief angle (i.e., angling the relief more rearwardly), decreases strike face deflection but increases durability. Similarly, decreasing the relief angle (i.e., angling the relief more flat or parallel to the length of the casing), increases strike face deflection but decreases durability. The use of a fixed shaft-receiving mechanism or an adjustable shaft-receiving mechanism can affect whether or not the casing includes a heel relief. An adjustable shaft-receiving structure comprises a heel recess or indentation for a mechanical fastener. The heel recess prevents the casing from extending into the heel thereby preventing the casing from including a heel relief.

[0240] In some embodiments, the casing can comprise a heel relief 129, a toe relief 128, or both. In some embodiments, the heel relief angle HRA can be the same as the toe relief angle TRA. In other embodiments, the heel relief angle HRA can be different than the toe relief angle TRA.

[0241] The casing comprises a heel relief angle HRA measured as the angle between a line that extends between the intersection of the heel plane HP and the front wall bottom rear edge 123 to the absolute heel point AHP and the leading edge plane LEP, as illustrated in FIG. 47. The heel relief angle HRA can range between 2 and 75 degrees. The heel relief angle HRA can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the heel relief angle HRA is 53 degrees.

[0242] The casing comprises a toe relief angle TRA measured as the angle between a line that extends between the intersection of the toe plane TP and the front wall bottom rear edge 123 to the absolute toe point ATP and the leading edge plane LEP, as illustrated in FIG. BQ. The toe relief angle TRA can range between 2 and 75 degrees. The toe relief angle TRA can range between 2 and 10 degrees, 10 and 15 degrees, 15 and 20 degrees, 20 and 25 degrees, 25 and 30 degrees, 30 and 35 degrees, 35 and 40 degrees, 40 and 45 degrees, 45 and 50 degrees, 50 and 55 degrees, 55 and 60 degrees, 60 and 65 degrees, 65 and 70 degrees, or between 70 and 75 degrees. In one embodiment, the toe relief angle is 53.38 degrees.D. Relief Length

[0243] In the embodiments where the casing comprises on or more reliefs, the reliefs comprise a relief length on the heel and / or toe ends. The relief lengths can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, increasing the relief length (i.e., lengthening the relief) increases strike face deflection but decreases durability. Similarly, decreasing the relief length (i.e., shortening the relief) decreases strike face deflection but increases durability. The relief angle, defined above, can change the effective factor of the relief length.

[0244] The casing can comprise a toe relief length TRL, measured as the distance from the toe plane TP to the absolute toe point ATP. The toe relief length TRL can range from 0.1 to 0.5 inch. In some embodiments, the toe relief length TRL can range from 0.1 to 0.2 inch, 0.2 to 0.3 inch, 0.3 to 0.4 inch, or from 0.4 to 0.5 inch.

[0245] The casing can comprise a heel relief length HRL, measured as the distance from the heel plane HP to the absolute heel point AHP. The heel relief length HRL can range from 0.1 to 0.5 inch. In some embodiments, the toe relief length HRL can range from 0.1 to 0.2 inch, 0.2 to 0.3 inch, 0.3 to 0.4 inch, or from 0.4 to 0.5 inch.

[0246] In some embodiments, the toe relief length TRL is the same as the heel relief length HRL. In other embodiments, the toe relief length TRL can be different than the heel relief length HRL. For example, the toe relief length TRL can be longer than the heel relief length HRL, or the toe relief length TRL can be shorter than the heel relief length HRL.E. Front Wall Height

[0247] The front wall height FWH can be measured at three different locations along the length of the casing. The first front wall height FWH1 is measured in the YZ plane, defined above. The second front wall height FWH2 is measured in the heel plane HP, defined above. The third front wall height FWH3 is measured in the toe plane TP, defined above.

[0248] The front wall heights FWH1,2,3 can range from 0.050 to 0.50 inch. In some embodiments, the front wall heights FWH1,2,3 can range from 0.050 to 0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, or from 0.40 to 0.50 inch. In some embodiments, the first front wall height FWH1 is greater than both the second front wall height FWH2 and the third front wall height FWH3. In other embodiments, the first front wall height FWH1 is equal to both the second front wall height FWH2 and third front wall height FWH3. In other embodiments, the first front wall height FH1 is less than both the second front wall height FWH2 and the third front wall height FWH3. In other embodiments, the second front wall height FWH2 is greater than both the first front wall height FWH1 and the third front wall height FWH3. In other embodiments, the second front wall height FWH2 is less than both the first front wall height FWH1 and the third front wall height FWH3. In other embodiments, the third front wall height FWH3 is greater than both the first front wall height FWH1 and the second front wall height FWH2. In other embodiments, the third front wall height FWH3 is less than both the first front wall height FWH1 and the second front wall height FWH2.F. Front Wall Thickness

[0249] As mentioned above, the front wall thickness can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, the front wall thickness can be increased (i.e., thickening the front wall) to decrease strike face deflection, but increase durability.

[0250] In some embodiments, the front wall thickness is constant along the length of the casing. In other embodiments, the front wall thickness varies along the length of the casing. For example, in some embodiments, the front wall thickness is greater in the YZ plane than in the heel plane and toe plane. As such, the front wall thickness can be measured at three different locations along the length of the casing. The first front wall thickness FWT1 is measured in the YZ plane, defined above. The second front wall thickness FWT2 is measured in the heel plane HP, defined above. The third front wall thickness FWT3 is measured in the toe plane TP, defined above.

[0251] The front wall thicknesses FWT1,2,3 can range from 0.010 to 0.175 inch. In some embodiments, the front wall thickness FWT1,2,3 can range from 0.010 to 0.025 inch, 0.025 to 0.050 inch, 0.050 to 0.075 inch, 0.075 to 0.100 inch, 0.100 to 0.125 inch, 0.125 to 0.150 inch, or from 0.150 to 0.175 inch.

[0252] The front wall thickness FWT can also be expressed as a cross-sectional area within the YZ plane. As illustrated in FIG. BP, the cross-sectional area can be the area defined by the front wall top surface, the front wall front surface, the front wall rear surface, the exterior sole surface, and the forward surface extension 127. The forward surface extension 127 is an imaginary line that is co-planar to the front wall front surface and extends downward towards the exterior sole surface. The front wall 132 can have a variable cross-sectional area along the length of the casing.

[0253] The front wall 132 can comprise one or more front wall reinforcements 139. The front wall reinforcements 139 are areas of increased thickness to strategically reduce stress in specific regions. The front wall reinforcements 139 can protrude from the front wall front surface 134 towards the strike face, or the front wall reinforcements 139 can protrude from the front wall rear surface 136 towards the rear of the club head, as illustrated in FIG. 10.G. Forward Sole Thickness

[0254] The club head comprises a forward sole thickness FST which is the thickness of the sole in front of the front wall. Or in other words, the forward sole thickness is the thickness of the forward sole region 166, described above, measured from an interior sole surface to an exterior sole surface, as illustrated in FIGS. 42-44. As mentioned above, the forward sole thickness FST can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, the forward sole thickness FST can be increased (i.e., thickened) to decrease strike face deflection but increase durability. Similarly, the forward sole thickness FST can be decreased (i.e., thinned) to increase strike face deflection but decrease durability. The forward sole thickness FST can be constant along the length of the casing or can vary along the length of the casing. Similarly, the forward sole thickness FST can be constant in a front-back direction or can vary.

[0255] The forward sole thickness FST can be measured at three different locations along the length of the casing. The first forward sole thickness FST1 is measured in the YZ plane, defined above. The second forward sole thickness FST2 is measured in the heel plane HP, defined above. The third forward sole thickness FST3 is measured in the toe plane TP, defined above.

[0256] The forward sole thicknesses FST1,2,3 can range from 0.010 to 0.175 inch. In some embodiments, the forward sole thicknesses FST1,2,3 can range from 0.010 to 0.025 inch, 0.025 to 0.050 inch, 0.050 to 0.075 inch, 0.075 to 0.100 inch, 0.100 to 0.125 inch, 0.125 to 0.150 inch, or from 0.150 to 0.175 inch. In some embodiments, the first forward sole thickness FST1 is greater than both the second forward sole thickness FST2 and the third forward sole thickness FST3. In other embodiments, the first forward sole thickness FST1 is equal to both the second forward sole thickness FST2 and third forward sole thickness FST3. In other embodiments, the first forward sole thickness FST1 is less than both the second forward sole thickness FST2 and the third forward sole thickness FST3. In other embodiments, the second forward sole thickness FST2 is greater than both the first forward sole thickness FST1 and the third forward sole thickness FST3. In other embodiments, the second forward sole thickness FST2 is less than both the first forward sole thickness FST1 and the third forward sole thickness FST3. In other embodiments, the third forward sole thickness FST3 is greater than both the first forward sole thickness FST1 and the second forward sole thickness FST2. In other embodiments, the third forward sole thickness FST3 is less than both the first forward sole thickness FST1 and the second forward sole thickness FST2.

[0257] In some embodiments, the golf club head can comprise a patch in the forward sole region 166. The patch is an area of increased thickness to improve durability in the high stress region. In one embodiment, the patch is located in front of the casing center region.H. End Conditions

[0258] The shape and size of the casing toe wall and the casing heel wall, where the front wall transitions to the rear wall, affect strike face deflection and durability. Generally speaking, abrupt changes in geometry, such as corners with small radii of curvature, experience greater stresses than smooth transitions between geometries, such as rounded fillets or chamfers. The same applies to the casing heel wall and the casing toe wall. As mentioned above, the radius of curvature, or shape, can be selected to either increase strike face deflection and decrease durability, or decrease strike face deflection and increase durability. Specifically, as the radius of curvature of the heel wall and / or the toe wall decreases (i.e., providing a sharper transition between the front wall and rear wall), the strike face deflection increases, but the durability decreases. Similarly, as the radius of curvature of the heel wall and / or toe wall increases (i.e., providing a more rounded / smooth transition from the front wall to the rear wall), the strike face deflection decreases, but the durability increases.

[0259] In some embodiments, the heel wall and the toe wall are rounded with a constant radius of curvature. In other embodiments, the heel wall and the toe wall can have other shapes with varying or multiple radii of curvature. The relief angle RA and the relief length RL defined above, can change the effective factor of the end conditions. The radius of curvature in the toe end and the heel end can range from 0.075 inch to 2 inches. For example, the radius of curvature can range from 0.075 to 0.10 inch, 0.10 to 0.50 inch, 0.50 to 1.0 inch, 1.0 to 1.5 inches, or from 1.5 to 2.0 inches.VI. Insert

[0260] The IRM further comprises an insert for closing off the aperture to prevent migration of debris into the interior chamber. Additionally, the insert may further modify performance of the IRM and increase durability of the club head. The insert may be primarily formed of a flexible, polymeric material that is configured to engage the casing walls, thereby securing the insert within the casing. The material composition, overall construction, optional use of hybrid materials, and geometry of the insert can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert and the casing can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert within the casing, even after repeated, violent impacts. FIGS. 48-50 illustrate various exemplary embodiments of inserts and casings comprising corresponding geometrics.A. Z-Shaped and U-Shaped Inserts

[0261] An insert having an Z-shaped cross-section is illustrated in FIG. 48. The Z-shaped insert blocks access to the interior cavity, preventing water and debris from entering, while still allowing the IRM. The Z-shaped insert further uses complementary geometry to secure it to the club head and provide durability to the IRM. The insert 3170 of FIG. 48 can comprise an insert base 3172 and an insert front wall 3174. The base 3172 can extend along the sole of the club head from the casing front wall 3132 to the casing rear wall 3142 to cover the aperture 3140. The base 3172 can cover the entirety of the aperture 3140, such that the insert 3170 seals the interior cavity 3107 from the club head exterior thereby preventing water or debris from entering the interior cavity 3107. In general, the base 3172 extends approximately from the casing front wall rear surface 3136 to the rear wall front surface 3144. In some embodiments, the base 3172 can be substantially flush with the surrounding sole surface, creating a continuous sole appearance. The Z-shaped insert 3170 further comprises a rear extension 3178 extending rearward of the base 3172 (i.e. away from the strike face). The rear extension 3178 can extend rearward of the casing rear wall 3142, engaging a casing recess 3182 defined by the rear wall 3142, and terminating at a casing rising surface 3183. The rear wall 3142 and rear extension 3178 form a lap joint for bonding the insert 3170 to the club head. More specifically, the rear wall 3142 resists any external force applied to the insert 3170 that would otherwise push the insert 3170 into the interior cavity 3107. Further, the casing rear wall 3142 at the recess 3182 provides a mechanical stop preventing the Z-shaped insert 3170 from being pushed into the interior cavity 3107.

[0262] The insert front wall 3174 extends upward from a front end 3186 of the insert base 3172, towards the interior cavity 3107. The insert front wall 3174 comprises an insert front wall bottom end 3187 integral to a front end 3186 of the base, and an insert front wall top end 3188 opposite the insert front wall bottom end 3187. The insert front wall 3174 can be configured to abut the casing front wall 3132. The insert front wall 3174 can be shaped complementarily to the casing front wall 3132. In some embodiments, the insert front wall 3174 can be adhesively coupled to the casing front wall 3132. In other embodiments, the insert front wall 3174 can be spring loaded to be pressed and expanded as an interference fit with the casing front wall 3132. In some embodiments, the insert front wall 3174 comprises a similar height to the casing front wall 3132 to increase the bonding area between the insert front wall 3174 and the casing front wall 3132. In other embodiments, the insert front wall 3174 can be taller or shorter than the casing front wall 3132. In some embodiments, the insert front wall height can vary along the casing length L. The insert front wall height is measured as the distance between the base 3172 to the front wall top end 3188. The insert front wall height can range from 0.050 to 0.50 inch. In some embodiments, the insert front wall height can range from 0.050 to 0.10 inch, 0.10 to 0.20 inch, 0.20 to 0.30 inch, 0.30 to 0.40 inch, or from 0.40 to 0.50 inch.

[0263] The Z-shaped insert 3170 in FIG. 48 can further comprise a front flange 3181 extending from the insert front wall top end 3188. The front flange 3181 can extend forward towards the strike face and overlap the top end of the casing front wall 3138. In some embodiments, the front flange 3181 can be adhesively coupled to the top end of the casing front wall 3138. The front flange 3181 provides a mechanical stop preventing the insert 3170 from exiting the casing and being pushed out to the club head exterior. The top end of the casing front wall 3132 exerts a force against the front flange 3181 that opposes any outward forces applied to the insert 3170. The front flange 3181 and casing front wall 3132 thereby secure the insert 3170 within the casing. In some embodiments, the front flange 3181 extends along the entire length of the casing front wall 3132. In other embodiments, the front flange 3181 may comprise one of more discrete flange sections located along the casing length. For example, in some embodiments, the front flange 3181 can be located only in a central portion of the casing, only in the heel portion of the casing, only in the toe portion of the casing, or any combination thereof. In such examples, the front flange 3181 can secure the insert 3170 within the casing without adding unnecessary mass.

[0264] In the installed configuration illustrated in FIG. 48, the insert 3170 only fills a portion of the casing, and a gap 3171 is formed between the base 3172, the insert front wall 3174, and the casing rear wall 3142. As illustrated, in some embodiments, the gap 3171 can be open to the interior cavity 3107. The gap 3171 provides space for the insert 3170 to deform during installation. Once installed, the insert front wall 3174 can engage the casing front wall 3132, mechanically interlocking the insert 3170 within the casing. Further, once fully installed, the gap permits the insert 3170 to flex with the casing walls.

[0265] FIG. 49 illustrates an embodiment of a U-shaped insert 3570 and a casing 3530 comprising corresponding geometries. The insert 3570 is similar to the insert 3170 illustrated in FIG. 48. The insert 3570 of FIG. 49 comprises a base 3572 configured to seal the casing exterior opening, a rear extension 3578 configured to engage a casing recess 3582, and an insert front wall 3574 configured to abut and couple to the casing front wall 3532. Further, the U-shaped insert 3570 in FIG. 49 can comprise an insert rear wall 3576 extending upwards from a rear end 3589 of the base, towards the interior cavity 3507, and a rear flange 3580 configured to overlap a top end 3548 of the casing rear wall 3542. The insert rear wall 3576 comprises an insert rear wall bottom end 3591 coupled to a base rear end 3589, and an insert rear wall top end 3592 opposite the insert rear wall bottom end 3591. The insert rear wall 3576 can be configured to abut the casing rear wall 3542. The insert rear wall 3576 can be shaped complementarily to the casing rear wall 3542. In some embodiments, the insert rear wall can be adhesively coupled to the casing rear wall 3542. In some embodiments, the insert rear wall 3576 comprises a similar height to the casing rear wall 3542 to increase the bonding area between the insert rear wall 3576 and the casing rear wall 3542. In other embodiments, the insert rear wall 3576 can be taller or shorter than the casing rear wall 3542. In some embodiments, the insert rear wall height can vary along the casing length. In some embodiments, the insert rear wall height can differ from the insert front wall height. In other embodiments, the insert rear wall height can be equivalent to the insert front wall height.

[0266] The U-shaped insert 3570 can further comprise a rear flange 3580 extending from the insert rear wall top end 3592. The rear flange 3580 can extend rearward and away from the face and overlap the top end 3548 of the casing rear wall. In some embodiments, the rear flange 3580 can be adhesively coupled to the top end 3548 of the casing rear wall. The rear flange 3580 acts as a mechanical stop preventing the insert 3570 from exiting the casing 3530 and being pushed out to the club head exterior. The top end 3548 of the casing rear wall exerts a force against the rear flange 3580 that opposes outward forces applied to the insert 3570. The rear flange 3580 and casing rear wall 3542 thereby secure the insert 3570 within the casing 3530. In some embodiments, the rear flange 3580 extends along the entire length of the casing rear wall 3542. In other embodiments, the rear flange 3580 can be localized along a certain portion of the casing length. For example, in some embodiments, the rear flange 3580 can be located only in a central portion of the casing 3530, only in the heel portion of the casing 3530, only in the toe portion of the casing 3530, or any combination thereof. In such examples, the rear flange 3580 can secure the insert 3570 within the casing 3530 without using any unnecessary mass.

[0267] The rear wall 3542 at the casing recess 3582 provides a bonding surface to which the rear extension 3578 can be coupled, thereby to form a lap joint. Further, the casing recess 3582 acts as a mechanical stop preventing the insert 3570 from exiting the casing and being pushed into the interior cavity 3507. The rear wall 3542 resists outward forces applied to the insert 3570. The rear extension 3578 and casing recess 3582 thereby secure the insert 3570 within the casing.

[0268] As illustrated in FIG. 49, the insert 3570 only fills a portion of the casing 3530, and a gap 3571 is formed between the base 3572, the insert front wall 3574, and the insert rear wall 3576. In some embodiments, the gap 3571 can be open to the interior cavity 3507. The gap 3571 provides space for the U-shaped insert 3570 to deform during installation so that the rear flange 3580 can fit through both the casing exterior opening and the casing interior opening. Once installed, the insert walls can engage the casing walls and the rear flange 3580 can engage the top end 3548 of the casing rear wall, mechanically interlocking the insert 3570 within the casing 3530. Further, once fully installed, the gap 3571 permits the insert 3570 to flex with the casing walls.

[0269] In some embodiments, as illustrated in FIG. 50, the U-shaped insert comprises both a front flange 3781 and a rear flange 3780. The front flange 3781 and the rear flange 3780 can both be similar to those described, in that the front flange 3781 overlaps the casing front wall 3732 and the rear flange 3780 overlaps the casing rear wall 3742. Similar to the insert illustrated in FIG. 49, a gap 3771 is formed between the base 3772, the insert front wall 3774, and the insert rear wall 3776. The gap 3771 can be sufficiently large to allow both the front flange 3781 and the rear flange 3780 to fit through both the casing exterior opening and the casing interior opening. Once installed, the insert front wall 3774 can engage the casing front wall 3732, the insert rear wall 3776 can engage the casing rear wall 3742, the front flange 3781 can engage the top end 3738 of the casing front wall, and the rear flange 3780 can engage the top end 3748 of the casing rear wall, mechanically interlocking the insert 3770 within the casing 3730. Further, once fully installed, the gap 3771 permits the insert 3770 to flex with the casing walls, thereby increasing ball speed over a solid insert filling the entire casing.

[0270] FIG. 51 illustrates an embodiment of a U-shaped insert 3670 having an expansive rear flange 3680 and rear extension 3678 configured to engage the casing rear wall 3642. The insert 3670 is substantially similar to the insert 3570 illustrated in FIG. 49, in that the insert 3670 comprises a base 3672, an insert front wall 3674 configured to couple to the casing front wall 3632, an insert rear wall 3676 configured to couple to the casing rear wall 3642, a rear extension 3678 configured to engage a casing recess 3682, and a rear flange 3680 configured to overlap a top end of the casing rear wall 3642. As illustrated, the insert 3670 further comprises a lip 3693 extending soleward from the end of the rear flange. The lip 3693 can engage a backside surface 3646 of the casing rear wall. In some embodiments, the lip 3693 can be adhesively coupled to the backside surface 3646 of the casing front wall. The lip 3693 acts as a mechanical stop preventing the insert 3670 moving in a front-to-rear direction during use. The backside surface 3646 of the casing rear wall 3642 exerts a force against the lip 3693 that opposes forces acting on the insert 3670 from the rear. This prevents the insert rear wall 3676 from deforming into the casing 3630 and disengaging the insert 3670 from the casing 3630.

[0271] Similar to the insert illustrated in FIGS. 49, a gap 3671 is formed between the base 3672, the insert front wall 3674, and the insert rear wall 3676. The gap 3671 can be sufficiently large to allow the rear flange 3680 and the lip 3693 to fit through both the casing exterior opening and the casing interior opening. Once installed, the insert front wall 3674 can engage the casing front wall 3632, the insert rear wall 3676 can engage the casing rear wall 3642, the rear flange 3680 can engage the top end of the casing rear wall, and the lip 3693 can engage the backside surface 3646 of the casing rear wall, mechanically interlocking the insert 3670 within the casing 3630. Further, once fully installed, the gap 3671 permits the insert 3670 to flex with the casing walls. Although FIG. 51 illustrates a rear flange 3680 and lip 3693 extending from the insert rear wall, it should be noted that in other embodiments, a similar flange and lip can be formed by the insert front wall. In such embodiments, the insert can form a front flange similar to those described above, wherein the lip extends soleward from the end of the front flange and engages a frontside surface of the casing front wall.B. Materials

[0272] The insert can be formed of a flexible, polymeric material, such as a polymer matrix composite. The polymer matrix composite can comprise a glass-filled elastomer, a stainless steel-filled elastomer, a tungsten-filled elastomer, a thermoplastic polyurethane (TPU) composite, a thermoplastic elastomer (TPE) composite, or any other elastomer matrix composite, a Kevlar® (aramid) fiber-reinforced polymer, a carbon-fiber reinforced polymer, rubber, ethylene-vinyl acetate foam, polymer-based foam, any combination of a suitable resin and a suitable reinforcing fiber, or any combination of the above materials.

[0273] In many embodiments, the insert can comprise a material density between 0.75 and 2.0 g / cm3. In many embodiments, the insert can comprise a material density between 0.75 and 1.0 g / cm3, between 1.0 and 1.25 g / cm3, between 1.25 and 1.5 g / cm3, between 1.5 and 1.75 g / cm3, or between 1.75 and 2.0 g / cm3.

[0274] In many embodiments, the insert can comprise a material durometer between shore 30A and shore 90D. In some embodiments, the material hardness of the insert can be between shore 30A and shore 50A, between shore 50A and shore 70A, between shore 70A and shore 90A, between shore 10D and shore 30D, between shore 30D and shore 50D, between shore 50D and shore 70D, or between shore 70D and shore 90D.

[0275] In many embodiments, the effective density of the insert can be between 0.35 and 1.0 g / cm3. In many embodiments, at least a portion of the insert can have an effective density between 0.35 and 0.50 g / cm3, between 0.40 and 0.55 g / cm3, between 0.45 and 0.60 g / cm3, between 0.50 and 0.65 g / cm3, between 0.55 and 0.70 g / cm3, between 0.60 and 0.75 g / cm3, between 0.65 and 0.80 g / cm3, between 0.70 and 0.85 g / cm3, between 0.75 and 0.90 g / cm3, between 0.80 and 0.95 g / cm3, or between 0.85 and 1.0 g / cm3.VII. Shaft-Receiving Mechanism

[0276] Strike face deflection and club head durability are affected by the presence or absence of an adjustable shaft-receiving mechanism and said mechanism's relationship to the IRM. The adjustable shaft-receiving mechanism can adjust the loft angle 20 and / or the lie angle 25 to better fit a given player and improve launch characteristics. However, adjustable shaft-receiving mechanisms often include a lower opening located on the sole (discussed in further detail below), near the strike face, and therefore in close proximity to the IRM. Accordingly, the presence of an adjustable shaft-receiving mechanism can limit the area of the sole available for the IRM to occupy. In embodiments including an adjustable shaft-receiving mechanism, the IRM size can be reduced or the IRM profile can be tailored to improve strike face deflection while retaining loft angle and lie angle adjustability, all without sacrificing club head durability.

[0277] The adjustable shaft-receiving mechanism can be similar to those described in U.S. patent application Ser. No. 15 / 003,494, filed on Jan. 21, 2016, now U.S. Pat. No. 9,868,035, granted on Jan. 16, 2018; and U.S. patent application Ser. No. 17 / 304,836, filed on Jan. 25, 2021, now U.S. Pat. No. 11,607,590, granted on Mar. 21, 2023; which are both incorporated fully herein by reference.

[0278] The adjustable shaft-receiving mechanism, as best illustrated in FIG. 52, comprises a shaft sleeve 5026 configured to receive a golf club shaft and retained within the hosel 5005 by a fastener 5027. The shaft sleeve 5026 and the hosel 5005 comprise complementary geometries that allow the shaft sleeve 5026 to be removably rotated into a plurality of different configurations. Rotating the shaft sleeve 5026 between different configurations will adjust a loft angle 20 and / or a lie angle 25 of the golf club head 5000.

[0279] In some embodiments, as best shown in FIGS. 52 and 53, the golf club head 5000 can comprise a lightweight shaft-receiving mechanism 5025 that creates discretionary mass. The shaft-receiving structure 5025 has reduced structural mass. At least a portion of the shaft sleeve 5026 is exposed to the interior cavity 5007. In the present embodiment, rather than being retained by an internal structure such as an interior hosel tube or hosel wall, the shaft sleeve 5026 is retained and supported in the golf club head 5000 by structures that also form at least a portion of the exterior of the body 5001. In many embodiments, the shaft-receiving mechanism 5025 comprises an upper end 5038A and a lower end 5038B. In the present embodiment, the shaft sleeve 5026 is secured only at the upper end 5038A and the lower end 5038B. The shaft sleeve 5026 is inserted through a hosel bore opening 5039 and retained at the upper end 5038A by the hosel 5005. The shaft sleeve 5026 can be secured to the golf club head 5000 by a fastener 5027. The fastener 5027 can extend through a lower opening 5022 formed in the sole 5012 and couple to a bottom end of the shaft sleeve 5026. The fastener 5027 can releasably couple the shaft sleeve 5026 to the hosel 5005.

[0280] The IRM 5020 can be configured to accommodate the adjustable shaft-receiving mechanism and provide loft angle and lie angle adjustability while improving strike face deflection. Referring to FIG. 54, the casing 5030 can comprise a “checkmark” shape, wherein the casing toe region 5037 comprises a toe relief 5028 and the casing heel region 5035 is truncated. In such embodiments, the casing heel region 5035 does not comprise a heel relief. The casing comprises a toe length LT measured from the absolute toe point (ATP) to the YZ plane and a heel length LH measured from the absolute heel point (AHP) to the YZ plane. In the illustrated embodiment, the toe length LT is greater than the heel length LH.

[0281] The checkmark shape having a truncated casing heel region 5035 allows for room between the casing 5030 and the lower opening 5022 of the adjustable shaft-receiving mechanism 5025. The checkmark shape improves club head durability, because if the absolute heel point (AHP) is too close to the lower opening 5022, excessive stress can pool in the casing heel region 5035 or in the adjustable shaft-receiving mechanism 5025. Referring to FIG. 54, the club head defines a heel region offset OH, measured as a heel-to-toe distance between the absolute heel point (AHP) and the lower opening 5022. In some embodiments, the heel region offset OH can be between 0.1 and 0.5 inch. In some embodiments, the heel region offset OH can be greater than 0.1 inch, greater than 0.2 inch, greater than 0.3 inch, greater than 0.4 inch, or greater than 0.5 inch. In some embodiments, the heel region offset OH can be less than 0.5 inch, less than 0.4 inch, less than 0.3 inch, less than 0.2 inch, or less than 0.1 inch. The heel region offset OH influences the heel length LH and balances strike face deflection with club head durability by either increasing or decreasing the total length (TL) of the casing 5030.

[0282] The adjustable shaft-receiving mechanism 5125 can be combined with an IRM 5120 reinforced by one or more of the high-strength components described herein (i.e., cartridge, appendage, etc.). In some embodiments, the high-strength component can form one or more portions of the adjustable shaft-receiving mechanism 5125, as best illustrated in FIG. 55. In the illustrated embodiment, the club head 5100 comprises a cartridge 5150 that integrally forms the lower opening 5122. The cartridge heel edge 5158 is disposed heelward of the lower opening 5122. The cartridge 5150 integrally forms both the casing 5130 and the lower opening 5122. This configuration removes the need for a weld line between the casing 5130 and the lower opening 5122. The heel region offset OH can thereby be reduced without danger of a heat affected zone compromising the durability of the casing 5130 or the portion of the sole 5112 forming the lower opening 5122. Accordingly, the casing heel region 5135 can be lengthened further towards the heel 5104 to increase strike face deflection.

[0283] In some embodiments, strike face deflection may be prioritized over loft angle and lie angle adjustability. In such embodiments, the club head 5200 can comprise a fixed shaft-receiving mechanism 5225 that combines with the IRM 5220 to improve strike face deflection. As best illustrated in FIG. 56, the hosel 5205 comprises a hosel side wall 5241 and a hosel bottom wall 5244 at least partially bounding a hosel bore 5245. The hosel bore 5245 is configured to receive a golf shaft through a hosel opening 5239 at the upper end of the hosel 5005. The hosel side wall 5241 is tubular in shape and circumscribes the hosel axis 30. As illustrated in FIG. 56, the hosel bottom wall 5244 is located within the interior cavity 5207 and spaced from the sole 5212. The hosel bottom wall 5244 separates the hosel bore 5245 from the interior cavity 5207 such that the hosel opening 5239 is the only opening into the hosel bore 5245.

[0284] The dimensions of the fixed shaft-receiving mechanism 5225, particularly how far the hosel side wall 5241 and the hosel bottom wall 5244 extend into the interior cavity 5207, can allow the casing 5230 to be lengthened further towards the heel 5204, thereby increasing strike face deflection. The hosel 5205 can comprise a hosel bore depth DHB measured from the hosel bore opening 5039 to the hosel bottom wall 5244, parallel to the hosel axis 30, of less than about 1.25 inches. In some embodiments, the hosel bore depth DHB can be less than 1.20, less than 1.15, or less than 1.10 inches.

[0285] In some embodiments, extending the casing 5230 towards the heel 5204 places the casing walls 5232, 5242 closer to the fixed shaft-receiving mechanism 5225. The hosel bottom wall 5244 can be spaced away from the casing walls 5232, 5242 by a hosel offset distance OHS, measured perpendicularly from the hosel bottom wall 5244 to the closest point of the casing front wall 5432 or the casing rear wall 5242. In some embodiments, the hosel offset distance OHS is less than 0.5 inches. For example, in some embodiments, the hosel offset distance OHS is less than 0.5 inches, less than 0.45 inches, less than 0.40 inches, less 0.35 inch, less than 0.30 inch, less than 0.25 inch, or less than 0.20 inch.

[0286] The combination of a shallow hosel bore depth DHB (i.e., less than about 1.25 inches) and a hosel offset distance OHS less than 0.50 inches creates space for the casing walls to extend toward the heel 5204, underneath the hosel bottom wall 5244. The lesser the hosel offset distance OHS and the shallower the hosel bore depth DHB, the further towards the heel 5204 the aperture 5240 can be extended without the casing walls 5232,5242 running into the hosel walls. The casing walls 5232, 5242 can therefore be designed with the desired heights and thicknesses to increase strike face deflection without interfering with the hosel walls.

[0287] Because the fixed shaft-receiving mechanism does not facilitate adjustment of loft and lie angles, there is no need to releasably couple the shaft to the club head body. Rather, the shaft can be permanently attached to the hosel 5205 through adhesives or epoxy. Accordingly, the fixed shaft-receiving mechanism does not have a fastener and is free of a lower opening. In the fixed system, the absence of a lower opening allows the aperture 5240 to be lengthened, thereby increasing strike face deflection. In some embodiments, as illustrated in FIG. 57, the club head 5200 with a fixed shaft-receiving mechanism can be combined with a U-shaped casing 5230 that includes both a toe relief 5228 and a heel relief 5229. The U-shaped casing 5230 expands further towards the heel 5204 than the checkmark shaped casing discussed above, because there is no lower opening interfering with the casing heel region 5235.VIII. Additional FeaturesA. Variable Face Thickness

[0288] In some embodiments, the club head 5400 can further comprise a strike face 5402 with a variable face thickness (hereafter “VFT”). The VFT can comprise a profile as described in U.S. patent application Ser. No. 18 / 981,336, filed on Dec. 13, 2024, entitled “Golf Club Heads Comprising a Variable Face Thickness.” Referring to FIG. 58, the VFT profile can include at least a central region 5424, a first transition region 5429, and an intermediate region 5436 formed into the strike face rear surface 5417. The central region 5424 can be located proximate the face center (FC) and can comprise the maximum strike face thickness of the club head 5400. In some embodiments, the central region 5424 comprises a constant thickness. In some embodiments, the strike face thickness in the central region 5424 can be between 0.060 and 0.150 inch.

[0289] The strike face thickness can depend on the club type. For example, for driver-type club heads, the strike face thickness in the central region 5424 can be between 0.100 and 0.150 inch. In some embodiments, the strike face thickness in the central region 5424 for a driver-type club head can be between 0.100 and 0.125 inch, between 0.105 and 0.130 inch, between 0.110 and 0.135 inch, between 0.115 and 0.140 inch, between 0.120 and 0.145 inch, or between 0.125 and 0.150 inch.

[0290] For fairway wood and hybrid-type club heads, the strike face thickness in the central region 5424 can be between 0.060 and 0.110 inch. In some embodiments, the strike face thickness in the central region 5424 for a fairway wood or hybrid-type club head can be between 0.060 and 0.085 inch, between 0.065 and 0.090 inch, between 0.070 and 0.095 inch, between 0.075 and 0.100 inch, between 0.080 and 0.105 inch, or between 0.085 and 0.110 inch.

[0291] The intermediate region 5436 at least partially surrounds the central region 5424 and comprises a minimum thickness of the strike face 5402. In some embodiments, the intermediate region 5436 comprises a constant thickness. In some embodiments, the strike face thickness in the intermediate region 5436 can be between 0.040 and 0.090 inch. As described above, the strike face thickness can depend on the club type. For example, for driver-type club heads, the strike face thickness in the intermediate region 5436 can be between 0.055 and 0.090 inch. In some embodiments, the strike face thickness in the central region 5424 for a driver-type club head can be between 0.055 and 0.070 inch, between 0.060 and 0.075 inch, between 0.065 and 0.080 inch, between 0.070 and 0.085 inch, or between 0.075 and 0.090 inch.

[0292] For fairway wood and hybrid-type club heads, the strike face thickness in the intermediate region 5436 can be between 0.040 and 0.075 inch. In some embodiments, the strike face thickness in the central region 5424 for a fairway wood or hybrid-type club head can be between 0.040 and 0.055 inch, between 0.045 and 0.060 inch, between 0.050 and 0.065 inch, between 0.055 and 0.070 inch, or between 0.060 and 0.075 inch.

[0293] The first transition region 5429 connects the central region 5424 to the intermediate region 5436 and comprises a varying thickness that decreases as it extends from the central region 5424 the intermediate region 5436. In some embodiments, the strike face thickness in the first transition region can vary between the strike face thicknesses in the central region 5424 and the intermediate region 5436, as described above.

[0294] In some embodiments, such as the driver embodiment illustrated in FIG. 58, the VFT profile can include a central region 5424, a first transition region 5429, an intermediate region 5436, a second transition region 5442, and an outer region 5446. In such embodiments, the outer region 5446 can at least partially surround the intermediate region 5436 and can comprise a thickness greater than that of the intermediate region 5436. Further, in such embodiments, the second transition region 5442 connects the intermediate region 5436 to the outer region 5446 and comprises a varying thickness that increases as it extends from the intermediate region 5436 to the outer region 5446. In other embodiments, such as the hybrid embodiment illustrated in FIG. 59, the VFT profile comprises only a central region 5524, a first transition region 5529, and an intermediate region 5536. In such embodiments, the club head 5200 can be devoid of a second transition region or an outer region.

[0295] The VFT profile can be configured to complement the strike face deflection benefits of the IRM. In some cases, the IRM can lower CT value low on the strike face 5402. As such, the VFT can reduce the strike face thickness near the sole 5412, thereby increasing strike face deflection and ball speed, particularly on low shots. In some embodiments, because the lower portion of the strike face 5402 does not require additional thickness to keep CT within conformance limits, the central region 5424 can be biased towards the crown 5410. Referring to FIG. 58, the central region 5424 can comprise a central region center point 5425 located at a geometric center of the central region 5424, on the strike face rear surface 5417. In some embodiments, the central region center point 5425 can be above the face center (FC). The club head 5400 can comprise a central region center height HCR measured between the face nadir (FN) and the central region center point 5425, in a direction parallel to the loft plane 15 and the YZ plane.

[0296] In some driver embodiments, the central region center height HCR can be between 0.700 and 1.200 inch. In some driver embodiments, the central region center height HCR can be between 0.700 and 0.850 inch, between 0.750 and 0.900 inch, between 0.800 and 0.950 inch, between 0.850 and 1.000 inch, between 0.900 and 1.050 inch, between 0.950 and 1.100 inch, between 1.000 and 1.150 inch, or between 1.200 inch. In some driver embodiments, the central region center height HCR can be greater than 0.700 inch, greater than 0.750 inch, greater than 0.800 inch, greater than 0.850 inch, greater than 0.900 inch, greater than 0.950 inch, greater than 1.000 inch, greater than 1.050 inch, greater than 1.100 inch, greater than 1.150 inch, or greater than 1.200 inch.

[0297] In some fairway wood and hybrid embodiments, the central region center height HCR can be between 0.500 and 1.000 inch. In some fairway wood and hybrid embodiments, the central region center height HCR can be between 0.500 and 0.600 inch, between 0.550 and 0.650 inch, between 0.600 and 0.700 inch, between 0.650 and 0.750 inch, between 0.700 and 0.800 inch, between 0.750 and 0.850 inch, between 0.800 and 0.900 inch, or between 0.900 and 1.000 inch. In some fairway wood and hybrid embodiments, the central region center height HCR can be greater than 0.500 inch, greater than 0.550 inch, greater than 0.600 inch, greater than 0.650 inch, greater than 0.700 inch, greater than 0.750 inch, greater than 0.800 inch, greater than 0.850 inch, greater than 0.900 inch, greater than 0.950 inch, or greater than 1.000 inch. The central region center point 5425 can be located in the upper half of the strike face rear surface 5417. The club head 5400 can comprise a central region center ratio defined as the central region center height HCR divided by the strike face height HSF. In some embodiments, the central region center ratio can be between 0.40 and 0.75. In some embodiments, the central region center ratio can be between 0.40 and 0.55, between 0.45 and 0.60, between 0.50 and 0.65, between 0.55 and 0.70, or between 0.60 and 0.75. In some embodiments, the central region center ratio can be greater than 0.40, greater than 0.45, greater than 0.50, greater than 0.55, greater than 0.60, greater than 0.65, greater than 0.70, or greater than 0.75.

[0298] Further, to reduce the strike face thickness near the sole 5612, the bottom of the VFT profile can be truncated. Referring to FIG. 60, the transition region 5629 comprises a transition region perimeter 5633 including a transition region nadir 5634 at a sole-most point of the transition region perimeter 5633 and a transition region apex 5635 at the crown-most point of the transition region perimeter 5633. In some embodiments, the transition region 5629 is truncated such that the distance between the transition region nadir 5634 and the central region center point 5625 is less than the distance between the transition region apex 5635 and the central region center point 5625, as measured parallel to the YZ plane (YZ).

[0299] The transition region perimeter 5633 can be raised away from the leading edge 5603. This configuration increases the area of the intermediate region 5636 to reduce the strike face thickness near the sole 5612. The club head 5600 comprises a transition region nadir height HTN measured between the face nadir (FN) and the transition region nadir 5634, in a direction parallel to the loft plane 15 and the YZ plane. In some driver embodiments, the transition region nadir height HTN can be between 0.030 and 0.050 inch. In some driver embodiments, the transition region nadir height HTN can be between 0.030 and 0.035 inch, between 0.035 and 0.040 inch, between 0.040 and 0.045 inch, between 0.045 and 0.050 inch, between 0.050 and 0.055 inch, between 0.055 and 0.060 inch, between 0.060 and 0.065 inch, or between 0.065 and 0.070 inch. In some driver embodiments, the transition region nadir height HTN can be greater than 0.030 inch, greater than 0.035 inch, greater than 0.040 inch, greater than 0.045 inch, greater than 0.050 inch, greater than 0.055 inch, greater than 0.060 inch, greater than 0.065 inch, greater than 0.070 inch, greater than 0.075 inch, or greater than 0.080 inch. In some fairway wood and hybrid embodiments, the transition region nadir height HTN can be between 0.200 and 0.400 inch. In some fairway wood and hybrid embodiments, the transition region nadir height HTN can be between 0.200 and 0.250 inch, between 0.225 and 0.275 inch, between 0.250 and 0.300 inch, between 0.275 and 0.325 inch, between 0.300 and 0.350 inch, between 0.325 and 0.375 inch, between 0.350 and 0.400 inch, or between 0.375 and 0.425 inch. In some fairway wood embodiments, the transition region nadir height HTN can be greater than 0.200 inch, greater than 0.225 inch, greater than 0.250 inch, greater than 0.275 inch, greater than 0.300 inch, greater than 0.325 inch, greater than 0.350 inch, greater than 0.375 inch, greater than 0.400 inch, greater than 0.425 inch, or greater than 0.450 inch.

[0300] Further, the club head 5600 can comprise a transition region nadir ratio defined as the transition region nadir height HTN divided by the strike face height HSF. In some embodiments, the transition region nadir ratio can be between 0.20 and 0.50. In some embodiments, the transition region nadir ratio can be between 0.20 and 0.35, between 0.25 and 0.40, or between 0.35 and 0.50. In some embodiments, the central region center ratio can be greater than 0.20, greater than 0.25, greater than 0.30, greater than 0.35, greater than 0.40, greater than 0.45, or greater than 0.50.B. Weighting Features

[0301] In some embodiments, the club head further comprises one or more weights that complement the IRM to improve club head performance. The one or more weights can create a desirable CG position that, in combination with the strike face deflection created by the IRM, increases ball speed and reduces spin rate. The one or more weights can be integral with the club head body, such as one or more internal mass pads, or one or more separate weight members such as a removable weight member or a sole plate.

[0302] In many embodiments, the club head can comprise one or more internal mass pads control the club head CG location. Referring to FIG. 61, the club head 5700 comprises a mass pad 5751 formed integrally with the club head body 5701, located on the sole 5712, and within the interior cavity 5707. The mass pad 5751 is a region of increased thickness surrounding regions of the sole 5712. The mass pad 5751 can be rearward of the aperture 5740. In some embodiments, the mass pad 5751 is integral with a portion of the casing 5730. In the illustrated embodiment, the mass pad 5751 is integral with the casing rear wall 5742. In such embodiments, the mass pad top surface 5753 can abut the rear wall rear surface 5746. In some embodiments, such as the illustrated embodiment of FIG. 61, the mass pad top surface 5753 can be lower than the rear wall top surface 5748, such that at least a portion of the rear wall 5742 extends above the mass pad 5751. In other embodiments, the mass pad top surface 5753 and the rear wall top surface 5748 can be flush. In such embodiments, mass pad 5751 essentially forms the rear wall 5742 and thereby bounds at least a portion of the aperture 5740. In other embodiments, the mass pad 5751 and the casing 5730 can be separated. In such embodiments, the mass pad 5751 can be spaced rearward of the casing rear wall 5742 such that the mass pad 5751 does not contact the casing rear wall 5742.

[0303] Any IRM geometry or faceplate configuration can be combined with any mass pad embodiment described herein. One or more mass pads can be integrally formed by the faceplate, the body, a cartridge, an appendage, or any combination thereof. The combination of high-strength material reinforcement and one or more mass pads further increases strike face deflection without compromising durability.

[0304] In some embodiments, the club head comprises an IRM 5820 and a large, high-density sole pod 5866 that lowers the club head CG and improves performance characteristics, as best illustrated in illustrated in FIGS. 62 and 63. In some embodiments, the sole pod can be similar to the sole insert as described in U.S. application Ser. No. 18 / 665,424, filed on May 15, 2024, which is fully incorporated herein by reference. The sole pod 5866 comprises a sole pod material with a higher density than that of the body material. The sole pod 5866 can reside within a sole pod recess 5867 formed into the exterior surface of the sole 5812. In some embodiments, the sole pod 5866 forms a portion of the sole 5812. The sole pod 5866 concentrates mass near the sole 5812, thereby lowering CG. The low-CG complements the strike face deflection benefits of the IRM 5820 to further increase ball speed and lower spin.

[0305] The sole pod 5866 is a large and heavy weight member. The sole pod 5866 can be made of a relatively high-density material, such as tungsten or a tungsten alloy. In some embodiments, the sole pod 5866 can comprise a sole pod mass between 50 and 100 grams. In some embodiments, the sole pod mass can be greater than 50 grams, greater than 60 grams, greater than 70 grams, greater than 80 grams, greater than 90 grams, or greater than 100 grams. Any one or combination of club head embodiments described herein can comprise a high-density sole pod 5866.

[0306] In some embodiments, the sole pod 5866 can be located immediately rearward of the casing 5830. This forward positioning of the sole pod 5866 moves the CG forward to increase ball speed and reduce spin without hindering strike face deflection. Referring to FIG. 63, the club head 5800 can comprise a sole pod offset OSI, defined as the front-to-back distance between the casing front wall 5832 and a sole pod forward edge 5868. The sole pod offset OSI can be substantially small. As such, the sole pod 5866 moves the CG forward while still allowing the IRM 5820 to flex. In some embodiments, the sole pod offset OSI can be between 0.2 and 1.0 inch. In some embodiments, the sole pod offset OSI can be less than 1.0 inch, less than 0.9 inch, less than 0.8 inch, less than 0.7 inch, less than 0.6 inch, less than 0.5 inch, less than 0.4 inch, or less than 0.3 inch. The combination of IRM 5820 performance benefits and the CG position provided by the sole pod 5866 creates a high performing club head.

[0307] The sole pod 5866 can be secured within the sole pod recess 5867 by mechanical means, adhesive means, welding, or a combination thereof. In some embodiments, the sole pod 5866 is secured within the sole pod recess 5867 by one or more external threaded fasteners 5871.

[0308] Any IRM geometry or faceplate configuration can be combined with a sole pod as described above. For example, a sole pod can be combined with a club head comprising a reverse L-cup faceplate, an L-cup faceplate, a J-cup faceplate, a partial J-cup faceplate, an underlapping J-cup, an appendage, a cartridge, or any other faceplate configuration described herein.

[0309] Further, as illustrated in FIG. 63, the club head 5800 can comprise one or more removable weights 5869 located in and removably coupled to a rearward portion of the sole 5812. The removable weight 5869 can be used for swing weighting, by selecting a removable weight mass that will result in the desired club head mass. In some embodiments, the removable weight mass can be between 1 and 35 grams. In some embodiments, the removable weight mass can be between 1 and 5 grams, between 5 and 10 grams, between 10 and 15 grams, between 15 and 20 grams, between 20 and 25 grams, between 25 and 30 grams, or between 30 and 35 grams. In some embodiments, the removable weight mass can be greater than 1 gram, greater than 5 grams, greater than 10 grams, greater than 15 grams, greater than 20 grams, greater than 25 grams, greater than 30 grams, greater than 35 grams, or greater than 40 grams.

[0310] Similar to the sole pod 5866, the removable weight 5869 can lower the club head CG, thereby improving launch characteristics. Further, the removable weight 5869 can be located in a rear portion of the sole 5812 to increase club head MOI. Although the removable weight 5869 is illustrated in combination with the sole pod 5866, the removable weight 5869 can be provided in any embodiment described herein.

[0311] Any IRM geometry or faceplate configuration can be combined with a removable weight as described above. For example, a removable weight can be combined with a club head comprising a reverse L-cup faceplate, an L-cup faceplate, a J-cup faceplate, a partial J-cup faceplate, an underlapping J-cup, an appendage, a cartridge, or any other faceplate configuration described herein.EXAMPLESA. Example 1—Ball Flight Performance of Golf Club Head with IRM

[0312] The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head, but was devoid of an Impact Response Modulator entirely.

[0313] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club head and the control club head. The ball flight results of the player test are displayed in Table 1 below.TABLE 1Player Test Ball Flight CharacteristicsBall SpeedLaunch AngleSpin RateCarry DistanceClub Head(mph)(degrees)(rpm)(yards)Exemplary155.510.43547252.1Control154.510.33911248.7

[0314] As displayed in Table 1 above, the exemplary club head exhibited an increase in ball speed of 1.0 mph and a decrease in spin rate of 364 rpm in comparison to the control club head, with a similar launch angle. The decreased spin rate created a more piercing ball flight that cuts through the air and travels further. These improved ball flight characteristics increased carry distance by 3.4 yards on average.

[0315] In addition to the performance results obtained through player testing, robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 3 displays the results of the robotic testing at each location, as well as the averages over all locations.TABLE 2Robotic Testing Ball Flight CharacteristicsBall SpeedSpin RateCarry DistanceClub HeadLocation(mph)(rpm)(yards)ExemplaryFace Center151.93203249.00.1 inch low151.63383244.00.2 inch low150.63265235.40.3 inch low150.73070221.3Average151.23230237.4ControlFace Center150.53714240.00.1 inch low149.83916237.70.2 inch low149.43835231.30.3 inch low149.83543220.2Average149.93752232.3

[0316] At the face center (FC), the exemplary club head exhibited an increase in ball speed of 1.4 mph and a decrease in spin of 511 rpm, which creates a more piercing ball flight that cuts through the air and travels further. These improvements resulted in an increase in carry distance of 9.0 yards. On average across all locations, the exemplary club head exhibited an increase in ball speed of 1.3 mph and a decrease in spin of 522 rpm in comparison to the control club head, resulting in an increase in carry distance of 5.1 yards. Overall, results of both the player test and the robotic test illustrate the benefits of the IRM. The IRM increased strike face deflection in the exemplary club head, which improved ball speed, spin rate, and distance.B. Example 2—Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0317] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a cartridge located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The casing also wrapped over the leading edge and formed a lower portion of the strike face, similar to the casing illustrated in FIG. 26. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had a front wall height FWH of 0.274 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.192 inch due to the high-strength material reinforcement. The offset distance OD from the casing front wall to the strike face in the control club head was 0.24 inch, whereas the exemplary club head had a reduced offset distance OD of 0.177 inch. The reduced front wall height FWH and offset distance OD each increase the amount the casing bends at impact, thereby increasing strike face deflection.

[0318] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 3 below.TABLE 3Ball Flight CharacteristicsBall SpeedLaunch AngleSpin RateClub Head(mph)(degrees)(rpm)Exemplary144.711.552532Control141.511.42919

[0319] As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph compared, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength cartridge allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. The example demonstrates that reinforcing the casing with a high-strength component, such as the exemplary cartridge, results in measurable performance benefits. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the exemplary and control club heads of the present example. Similar ball speed and spin rate improvements are expected for the exemplary club head.C. Example 3—Ball Flight Performance of Club Head Comprising IRM and Fixed Shaft-Receiving Mechanism

[0320] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator and a fixed shaft-receiving mechanism were compared to those of a first control club head comprising an Impact Response Modulator and an adjustable shaft-receiving mechanism and a second control club head devoid of an Impact Response Modulator. The exemplary club head comprised a U-shaped casing extending across the majority of the sole and comprising both a heel relief and a toe relief. The exemplary club head had no lower opening on the sole to accommodate an adjustable shaft-receiving mechanism, because the exemplary shaft-receiving mechanism was fixed. The first control club head comprised a lower opening on a heel side of the sole that received a fastener to secure the shaft sleeve to the hosel. The lower opening blocked the IRM of the control club head from extending all the way towards the heel. As such, the control casing had a truncated checkmark shape with a toe relief but no heel relief. The second control club was devoid of an IRM altogether but included an adjustable shaft-receiving mechanism similar to that of the first control club head.

[0321] Robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club heads. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 4 displays the results of the robotic testing averaged over all the impact locations. Table 5 displays the results of the robotic testing averaged only over the three “low” locations (i.e., 0.1 inch, 0.2 inch, and 0.3 inch below face center (FC)).TABLE 4Ball Flight Characteristics, All LocationsClub HeadBall Speed (mph)Spin Rate (rpm)Exemplary151.62278First Control150.82959Second Control150.43197TABLE 5Ball Flight Characteristics, Low LocationsClub HeadBall Speed (mph)Spin Rate (rpm)Exemplary152.42286First Control150.83135Second Control149.63673As illustrated by Tables 4 and 5, the club heads comprising an IRM (i.e., the exemplary club head and the first control club head) exhibited significant gains over second control club head, which was devoid of an IRM. In particular, the exemplary club head and the first control club head each exhibited increased ball speed and decreased spin rate in comparison to the second control club head, both on low strikes and across all locations. Further, the exemplary club head exhibited significant gains over the first control club head. On average across all locations, the exemplary club head increased ball speed by 0.8 mph and reduced spin rate by 681 rpm. Specifically, regarding low strikes, the exemplary club head increased ball speed by 1.6 mph and reduced spin by 849 rpm.

[0323] The results of the robotic test illustrate the possible ball flight characteristic advantages of combining the IRM with a fixed shaft-receiving mechanism. As discussed above, removing the need for a lower opening associated with the adjustable shaft-receiving mechanism allows the casing to be lengthened and improves strike face flexibility, thereby leading to the improvements displayed in the above tables. However, in some cases, providing an adjustable shaft-receiving mechanism can outweigh the raw ball speed and spin rate benefits of the fixed shaft-receiving mechanism. For certain players, the ability to adjust the loft angle and / or lie angle can optimize said player's launch conditions and improve ball speed and spin rate over a fixed system.D. Example 4—Performance Ratio Comparison

[0324] The performance of an exemplary club head comprising an IRM with the above disclosed geometries and parameters, that satisfies the inequality below, is compared to two control club heads comprising IRMs with altered geometries / dimensions that do not satisfy the following inequality:14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2

[0325] The exemplary club head is a fairway wood type club head comprising a strike face with a crown return, an adjustable hosel, and an IRM formed in the body. The two control club heads are identical to the exemplary club head except that the two control club heads had different total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT than the exemplary club head.TABLE 6ExemplaryControl 1Control 2Total Length (TL)2.359in2.538in2.550inOffset Distance (OD)0.245in0.277in0.247inFront Wall Height0.221in0.238in0.235in(FWH)Front Wall Thickness0.0851in0.096in0.0753in(FWT)Performance Value16.38in−212.83in−218.66in−2Ball Speed+0.7mph+0.2mph+1.0mphSpin−250rpmnegligible−350rpmDurability2000hits2996hits1792hits

[0326] As illustrated in Table 6 above, control club head 1 and control club head 2 had altered geometries that do not satisfy a performance inequality. The performance inequality of the present disclosure ranges between 14 and 18 in−2 while control club head 1 had a performance value of 12.83 in−2 and control club head 2 had a performance value of 18.66 in−2. The Exemplary embodiment has a performance value of 16.38 in−2. These performance values were based on the performance inequality having a performance coefficient PC of 0.032.

[0327] Control club head 1 and control club head 2 were physically tested for performance and durability by a robotic test and an air cannon test, respectively. Each test compared the results of the control club head to a baseline club head without an IRM or an aperture. Control club head 1 had a 0.2 mph gain in ball speed and negligible spin difference compared to the club head without an IRM and had. Control club head 2 had a 1.0 mph gain in ball speed and reduction of 350 rpms compared to the club head without an IRM. These results show that control club head 1, which had a performance value below 14 in−2, was over durable and had minimal improvements on performance. Conversely, the results show that control club head 2, which had a performance ratio above 18 in−2, was overly flexible and resulted in a large increase in performance but insufficient durability with less than 2000 hits to failure.

[0328] The Exemplary club head is expected to exhibit, based on a Finite Element Analysis study, a 0.7 mph gain in ball speed and a 250 rpm spin reduction compared to the club head without an IRM while achieving a sufficient durability of at least 2000 hits to failure. This will be due to the balance of the four parameters (total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT) that result in a performance value of 16.38 in−2. Specifically, the total length TL was decreased relative to control 1 and control 2, the offset distance OD was decreased relative to control 1 and control 2, the front wall height FWH was decreased relative to control 1 and control 2, and the front wall thickness FWT was increased relative to control 2 but less than control 1. Accordingly, this resulted in the exemplary club head having a performance value of 16.38 in−2.Clauses

[0329] Clause 1. A golf club head, comprising a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, and a coordinate system centered about a face center comprising: an x-axis extending in a heel-to-toe direction parallel to a ground plane; a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; and a z-axis extending in a front-to-rear direction and orthogonal to both the x-axis and y-axis; the golf club head further comprising an Impact Response Modulator (IRM) including a casing having: a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface; a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a toe relief portion angled rearwardly away from the strike face; and an insert disposed within the aperture; wherein the IRM satisfies the following inequality: 14 in−2≤PC (TL) / (OD) (FWT) (FWH)≤18 in−2, wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing, wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge, wherein FWT is a front wall thickness measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface, wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, and wherein PC is a performance coefficient equal to 0.032.

[0330] Clause 2. The golf club head of clause 1, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

[0331] Clause 3. The golf club head of clause 2, wherein the central region comprises a central region center point located above a face center of the strike face.

[0332] Clause 4. The golf club head of clause 1, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

[0333] Clause 5. The golf club head of clause 1, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

[0334] Clause 6. The golf club head of clause 1, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

[0335] Clause 7. The golf club head of clause 1, wherein the casing further comprises: a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; and a toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

[0336] Clause 8. The golf club head of clause 1, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

[0337] Clause 9. A golf club head, comprising a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, a crown panel formed of a composite material having a toe wrap and a heel wrap, and a coordinate system centered about a face center comprising: an x-axis extending in a heel-to-toe direction parallel to a ground plane; a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; and a z-axis extending in a front-to-rear direction and orthogonal to both the x-axis and y-axis; the golf club head further comprising an Impact Response Modulator (IRM) including a casing having: a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface; a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; a toe relief portion angled rearwardly away from the strike face; and an insert disposed within the aperture; wherein the IRM satisfies the following inequality: 14 in−2≤PC (TL) / (OD) (FWT) (FWH)≤18 in−2, wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing, wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge, wherein FWT is a front wall thickness measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface, wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, and wherein PC is a performance coefficient between 0.030 and 0.034.

[0338] Clause 10. The golf club head of clause 9, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

[0339] Clause 11. The golf club head of clause 10, wherein the central region comprises a central region center point located above a face center of the strike face.

[0340] Clause 12. The golf club head of clause 9, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

[0341] Clause 13. The golf club head of clause 9, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

[0342] Clause 14. The golf club head of clause 9, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

[0343] Clause 15. The golf club head of clause 9, wherein the casing further comprises: a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; and a toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

[0344] Clause 16. The golf club head of clause 9, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

[0345] Clause 17. The golf club head of clause 9, wherein the casing further comprises one or more tabs that extend rearward from the front wall and overhang at least a portion of the aperture, and wherein the one or more tabs are configured to engage the insert.

Examples

examples

A. Example 1—Ball Flight Performance of Golf Club Head with IRM

[0312]The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head, but was devoid of an Impact Response Modulator entirely.

[0313]Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club h...

example 2

B. Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0317]The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a cartridge located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The casing also wrapped over the leading edge and formed a lower portion of the strike face, similar to the casing illustrated in FIG. 26. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had...

example 4

D. Performance Ratio Comparison

[0324]The performance of an exemplary club head comprising an IRM with the above disclosed geometries and parameters, that satisfies the inequality below, is compared to two control club heads comprising IRMs with altered geometries / dimensions that do not satisfy the following inequality:

14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2

[0325]The exemplary club head is a fairway wood type club head comprising a strike face with a crown return, an adjustable hosel, and an IRM formed in the body. The two control club heads are identical to the exemplary club head except that the two control club heads had different total length TL, offset distance OD, front wall height FWH, and front wall thickness FWT than the exemplary club head.

TABLE 6ExemplaryControl 1Control 2Total Length (TL)2.359in2.538in2.550inOffset Distance (OD)0.245in0.277in0.247inFront Wall Height0.221in0.238in0.235in(FWH)Front Wall Thickness0.0851in0.096in0.0753in(FWT)Performance Value16.38in−212...

Claims

1. A golf club head, comprising:a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, and a coordinate system centered about a face center comprising:an x-axis extending in a heel-to-toe direction parallel to a ground plane;a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; anda z-axis extending in a front-to-rear direction and is orthogonal to both the x-axis and y-axis;the golf club head further comprising an Impact Response Modulator (IRM) including a casing having:a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface;a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface;a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture;a toe relief portion angled rearwardly away from the strike face; andan insert disposed within the aperture;wherein the IRM satisfies the following inequality:14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing,wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge,wherein FWT is a front wall thickness is measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface,wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, andwherein PC is a performance coefficient that is equal to 0.032.

2. The golf club head of claim 1, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

3. The golf club head of claim 2, wherein the central region comprises a central region center point located above a face center of the strike face.

4. The golf club head of claim 1, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

5. The golf club head of claim 1, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

6. The golf club head of claim 1, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

7. The golf club head of claim 1, wherein the casing further comprises:a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; anda toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

8. The golf club head of claim 1, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

9. A golf club head, comprising:a body, a faceplate at least partially forming a strike face and having a crown return, a sole, an adjustable shaft-receiving mechanism, a club head volume between 160 and 200 cc, a body depth between 3.0 and 4.0 inches, a body height between 1.25 and 1.75 inches, a crown panel formed of a composite material having a toe wrap and a heel wrap, and a coordinate system centered about a face center comprising:an x-axis extending in a heel-to-toe direction parallel to a ground plane;a y-axis extending in a crown-to-sole direction and orthogonal to both the x-axis and the ground plane; anda z-axis extending in a front-to-rear direction and is orthogonal to both the x-axis and y-axis;the golf club head further comprising an Impact Response Modulator (IRM) including a casing having:a front wall having a front wall front surface, a front wall rear surface, a front wall bottom rear edge, a front wall top surface, and a front wall top edge rear edge that is a junction between the front wall rear surface and the front wall top surface;a rear wall having a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface;a toe wall and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture;a toe relief portion angled rearwardly away from the strike face; andan insert disposed within the aperture;wherein the IRM satisfies the following inequality:14⁢ in-2≤PC⁢(TL)(OD)⁢(FWT)⁢(FWH)≤18⁢ in-2wherein L is a length of the casing measured parallel to the x-axis between an absolute heel point of the casing and an absolute toe point of the casing,wherein OD is an offset distance of the casing measured parallel to the z-axis, in a midplane, between a leading edge and the front wall bottom rear edge,wherein FWT is a front wall thickness is measured in a YZ plane, that extends vertically along the y-axis and z-axis, as a distance between the front wall front surface and the front wall rear surface,wherein FWH is a front wall height measured within the YZ plane and along the front wall rear surface, between the front wall bottom edge to the front wall top rear edge, andwherein PC is a performance coefficient between 0.030 and 0.034.

10. The golf club head of claim 9, further comprising a variable face thickness having a central region comprising a maximum thickness of the strike face and an intermediate region at least partially surrounding the central region and comprising a minimum thickness of the strike face.

11. The golf club head of claim 10, wherein the central region comprises a central region center point located above a face center of the strike face.

12. The golf club head of claim 9, further comprising a weight removably coupled to a rearward portion of the sole, the weight having a mass between 1 and 35 grams.

13. The golf club head of claim 9, wherein the insert comprises an insert base that extends from the front wall to the rear wall of the casing, an insert front wall that extends upward from the insert base, and an insert front flange that extends from a top end of the insert front wall towards the strike face.

14. The golf club head of claim 9, wherein the front wall is separated from the strike face by a forward sole region, and wherein the forward sole region has a forward sole thickness less than 0.080 inch measured as the distance from an interior sole surface to an exterior sole surface.

15. The golf club head of claim 9, wherein the casing further comprises:a toe plane that is perpendicular to the leading edge plane and the ground plane and intersects the front wall rear surface at the toe end where the front wall rear surface deviates to the toe relief; anda toe relief angle measured as an angle between a line that extends between an intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and a leading edge plane.

16. The golf club head of claim 9, wherein the body further comprises a body material and the faceplate further comprises a faceplate material that has a higher yield strength than the body material.

17. The golf club head of claim 9, wherein the casing further comprises one or more tabs that extend rearward from the front wall and overhang at least a portion of the aperture, and wherein the one or more tabs are configured to engage the insert.

Images