Multi-material putter head and method of manufacturing same

Abstract

This disclosure relates to a multi-material putter-type golf club head having a high-density core and a low-density metallic shell configured to optimize mass distribution, feel, and performance. The core is formed from materials such as steel or tungsten, and concentrates mass centrally, while the low density and sometimes aluminum based shell encapsulates the core to create a lighter exterior and a soft yet solid impact sensation. Methods of manufacture include vacuum die casting, during which the molten shell material fills a controlled space around a pre-heated weight insert to form an integrated structure. The resulting club head provides improved moment of inertia, customizable geometry, and enhanced durability.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 892,595, filed on Oct. 2, 2025, and to U.S. Provisional Patent Application No. 63 / 751,727, filed on Jan. 30, 2025, the contents of each which are herein incorporated by reference in their entirety.FIELD

[0002] This disclosure relates generally to golf club heads and, more particularly, relates to putter-type golf club heads and the manufacture thereof.BACKGROUND

[0003] Golf club head design, particularly putter-type golf club head design, depends on club head materials and mass distribution. Putter-type golf club head design balances club head performance, which depends on the club head mass properties, with club head feel at impact, which depends on mass concentrations, overall club head weight, and the materials forming the strike face and other exterior club head surfaces.

[0004] The term “putter,” or “putter-type golf club head” can, in some embodiments, refer to a club head having a loft angle less than 10 degrees. In many embodiments, the loft angle of the putter can be between 0 and 5 degrees, between 0 and 6 degrees, between 0 and 7 degrees, or between 0 and 8 degrees. For example, the loft angle of the club head can be less than 10 degrees, less than 9 degrees, less than 8 degrees, less than 7 degrees, less than 6 degrees, or less than 5 degrees. For further example, the loft angle of the club head can be 0 degrees, 1 degree, 2 degrees, 3 degrees, 4 degrees, 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, or 10 degrees. The putter-type golf club head can be a blade-type putter club head, a mid-mallet-type putter club head, or a mallet-type putter club head.

[0005] Any one or combination of the features described herein can be applied to any putter-type golf club head. While the present disclosure focuses on a putter-type golf club head, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of golf club heads such as a wood-type golf club head (e.g., a driver-type golf club head, a fairway wood-type golf club head, a hybrid-type golf club head, and the like), an iron-type golf club head,

[0006] or a wedge-type golf club head.

[0007] The terms “first,”“second,”“third,”“fourth,” and the like, if present herein, are used

[0008] 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.

[0009] Furthermore, use of “including” and “including” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Thus, the terms “include,” and “have,” and any variations thereof, may cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that includes a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus. Further, any numerical range recited herein as between two endpoints is inclusive of those endpoints.

[0010] The terms “left,”“right,”“front,”“back,”“top,”“bottom,”“over,”“under,” and the like, if present herein, 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 disclosure described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0011] The terms “couple,”“coupled,”“couples,”“coupling,” and the like should be broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and / or otherwise. Relatedly, unless specified or limited otherwise, the terms “mounted,”“connected,”“supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a rear, top, heel-side perspective view of a golf club head according to the present disclosure.

[0013] FIG. 2 is a front, bottom, toe-side perspective view of the golf club head of FIG. 1.

[0014] FIG. 3 is another rear, top, heel-side perspective view of the golf club head of FIG. 1

[0015] with a shell shown in phantom lines.

[0016] FIG. 4 is another rear, top, heel-side perspective view of the golf club head of FIG. 1 with a shell shown in phantom lines.

[0017] FIG. 5 is a top plan view of the golf club head of FIG. 1 in an intermediate state of manufacture, with a shell shown in phantom lines.

[0018] FIG. 6 is a side elevation view of the golf club head of FIG. 1 in the intermediate state shown in FIG. 5, with a shell shown in phantom lines.

[0019] FIG. 7 is a front elevation view of the golf club head of FIG. 1 in the intermediate state shown in FIG. 5, with a shell shown in phantom lines.

[0020] FIG. 8 is a perspective view of a portion of a tool assembly used in a method for manufacturing the golf club head of FIG. 1 in an initial state.

[0021] FIG. 9 is a perspective view of the portion of the tool assembly used in a method for manufacturing the golf club head of FIG. 1 in a clamped state, prior to forming a shell around a core.

[0022] FIG. 10 is an perspective view of the portion of the tool assembly used in a method for manufacturing the golf club head of FIG. 1 in the clamped state, prior to forming a shell around the core.

[0023] FIG. 11 is a perspective view of the golf club head of FIG. 1 in a raw body state, upon removal from the tool assembly of FIG. 8 and prior to final machining.

[0024] FIG. 12 is a top plan view of the golf club head of FIG. 1 in a final state.

[0025] FIG. 13 is a front elevation view of the golf club head of FIG. 1 in a final state.

[0026] FIG. 14 is a block diagram illustrating a method for manufacturing the golf club head of FIG. 1.

[0027] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the disclosure. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numeral in different figures denotes the same element.DESCRIPTION

[0028] Before any embodiments of the present disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.

[0029] FIGS. 1-4 illustrate a multi-material club head 100, also referred to herein as a club head 100, including a body 101 defining a front 108, a rear 111 opposite the front 108, a heel 104, and a toe 106 opposite the heel 104. The body 101 includes a strike face 102 near the front 108, a crown 110 near an upper portion of the club head 100, and a sole 112 near a lower portion of the club head 100. The body 101 further includes a hosel 105 near the heel 104 for receiving a shaft or an adjustable hosel feature.

[0030] Referring to FIGS. 1 and 3-4, the club head 100 includes a multi-component body 101 including a core 120 and a shell 130. The shell 130 surrounds and at least partially encapsulates the core 120. The core 120 and the shell 130 are each formed of a suitable material (hereafter the “core material” and the “shell material,” respectively) and geometric configuration that creates a desired mass distribution. In the embodiments disclosed herein, the core 120 may be formed of a high-density material and the shell 130 may be formed of a low-density material to improve club head feel at impact. A combination of concentrated mass in the center of the club head 100 and a lighter, softer material on a club head exterior creates an impact feel that is solid, yet soft.

[0031] In some embodiments, the high-density material can be a relatively high-density metallic material, such as steel, a steel alloy, tungsten, or a tungsten alloy. In some embodiments, the high-density material can include a density between 7.0 and 20.0 g·cm3 . In some embodiments, the high-density material can include a density greater than 7.0 g·cm3, 7.5 g·cm3, 8.0 g·cm3, 8.5 g·cm3, 9.0 g·cm3, 9.5 g·cm3, 10.0 g·cm3, 10.5 g·cm3, 11.0 g·cm3, 11.5 g·cm3, 12.0 g·cm3, 12.5 g·cm3, 13.0 g·cm3, 13.5 g·cm3, 14.0 g·cm3, 14.5 g·cm3, 15.0 g·cm3, 15.5 g·cm3, 16.0 g·cm3, 16.5 g·cm3, 17.0 g·cm3, 17.5 g·cm3, 18.0 g·cm3, 18.5 g·cm3, 19.0 g·cm3, 19.5 g·cm3, or 20.0 g·cm3 . The high-density material is applied to the core 120.

[0032] In some embodiments, the low-density material can be a relatively low-density metal material, such as aluminum, an aluminum alloy, titanium, or a titanium alloy. In some embodiments, the low-density material can be a non-metallic and / or composite material. In some embodiments, the low-density material includes a density between 0.5 and 4.0 g·cm3 . In some embodiments, the low-density material can include a density less than 0.5 g·cm3, 1.0 g·cm3, 1.5 g·cm3, 2.0 g·cm3, 2.5 g·cm3, 3.0 g·cm3, 3.5 g·cm3, or 4.0 g·cm3. In some embodiments, the low-density material includes a density ranges from 0.5 and 1.0 g·cm3, 1.0 and 1.5 g·cm3, 1.5 and 2.0 g·cm3, 2.0 and 2.5 g·cm3, 2.5 and 3.0 g·cm3, 3.0 and 3.5 g·cm3, 3.5 and 4.0 g·cm3, or 4.0 and 4.5 g·cm3. The low-density material is applied to the shell 130.

[0033] The core 120 can occupy a significant portion of an overall volume of the club head. In some embodiments, the core 120 has a volume (hereafter a “core volume”) between 10 and 40 cm3. In some embodiments, the core volume can range from 20% and 50% of the total club head volume. In some embodiments, the core volume can range from 20% and 25%, 25% and 30%, 30% and 35 %, 35% and 40%, 40% and 45 %, or 45 % and 50% of the total club head volume. Similarly, the shell 130 can occupy a significant portion of the overall volume of the club head. In some embodiments, the shell 130 has a volume (hereafter a “shell volume”) between 25 and 60 cm3. In some embodiments, the shell volume can be between 50% and 80% of the total club head volume. In some embodiments, the shell volume can range from 50% and 55%, 55% and 60%, 60% and 65 %, 65% and 70%, 70% and 75 %, or 75 % and 80% of the total club head volume. Because the shell 130 at least partially encapsulates the core 120, in some embodiments the shell volume is greater than the core volume. Together, the core volume and shell volume make up the overall volume of the club head. Alternatively, the core volume and the shell volume can make up a significant majority (i.e., at least 90%) of the overall volume of the club head, with the remainder formed by inserts, sole plates, weights, and / or other components.

[0034] In some embodiments, the shell 130, made from a low density material, fully surrounds and encapsulates the core 120, as best illustrated in FIG. 3. In such embodiments, the core 120 is completely concealed from the club head exterior and forms none of the exterior surface of the body 101. Further, in such embodiments, the shell 130 can form the entirety of the club head exterior surface. For example, the shell 130 can form the entirety of the strike face 102 as well as the entirety of the exterior surfaces of the crown 110, sole 112, heel 104, toe 106, and rear 111. In other embodiments, the shell 130 may only partially encapsulate the core 120. In such embodiments, at least a portion of the core 120 may be exposed to the club head exterior. In some embodiments, the core 120 can form at least parts of the strike face 102, the crown 110, the sole 112, the heel 104, the toe 106, the rear 111, or any combination thereof.

[0035] Exterior surfaces of the strike face 102, crown 110, sole 112, heel 104, toe 106, and rear 111 can collectively form the club head exterior, and a degree to which the shell 130 encapsulates the core 120 can be described by an amount of the club head exterior formed by the shell 130. In some embodiments, the shell 130 forms 100% of the club head exterior surface area, in which case the shell 130 can be said to “fully encapsulate” the core 120. Accordingly, in such

[0036] embodiments, the core 120 forms no portion of the club head exterior. In embodiments where the shell 130 forms less than 100% of the club head exterior surface area, the shell 130 can be said to “partially encapsulate” the core 120. In embodiments where the shell 130 partially encapsulates the core 120, the shell 130 can form between 50% and 99% of the club head exterior surface area. In some embodiments, the shell can range from 50% and 55%, 55% and 60%, 60% and 65 %, 65% and 70%, 70% and 75 %, 75 % and 80%, 85% to 90%, 90%, to 95%, or 95% to 99% of the club head exterior surface area. Conversely, in embodiments wherein the shell 130 partially encapsulates the core 120, the core can form between 1% and 50%. In some embodiments, the core can range from 1% and 5%, 5% and 10%, 10% and 15%, 15% and 20%, 20% and 25 %, 25 % and 30%, 35% to 40%, 40%, to 45%, or 45% to 50% of the club head exterior surface area. In still other embodiments, even if the shell fully encapsulates the core, the shell can form less than the entire club head exterior, with the remainer formed by inserts, sole plates, weights, and / or other components.

[0037] In some embodiments, the core 120 can be shaped to approximate the overall club head shape and / or the shape of the exterior of the shell 130. For example, as illustrated in FIG. 1, the shell 130 includes a shell chassis 132 and a pair of shell legs (e.g., a heel-side shell leg 134a and a toe-side shell leg 134b) extending rearward from the shell chassis 132. Similarly, as illustrated in FIG. 3, the core 120 may include a core chassis 122 and a pair of core legs (e.g., a heel-side core leg 124a and a toe-side core leg 124b). The core chassis 122 may be encased by the shell chassis 132 and the core legs 124a, 124b may be encased by the shell legs 134a, 134b. Accordingly, the shell chassis 132 may harbor the core chassis 122, and the shell legs 134a, 134b may harbor the core legs 124a, 124b. In such embodiments, the club head center of gravity (“CG”) position can be substantially centered in the club head 100, similar to if the club head were formed of a single material. In other embodiments, the core 120 can be any shape and may not necessarily correspond to the overall club head shape. The core 120 shape and material can be selected to create a desired mass distribution. In some embodiments, the club head 100 can be any shape or style including a blade-type putter club head, a mid-mallet-type putter club head, or a mallet-type putter club head.

[0038] In some embodiments, the core 120 includes a high-density material (as described above) having a core density greater than 7.0 g·cm3, and the shell130 includes a low-density material (as described above) having a shell density less than 4.0 g·cm3. A ratio between the core density and the shell density can range from 1.5 to 40. In some embodiments, the ratio between the core density and the shell density ranges from 1.5 to 3, 3 to 5, 5 to 10, 10 to 15, 15 to 20, 20 to 25, 25 to 30, 35 to 40. As described above, the high-density core 120 concentrates mass in the

[0039] center of the club head 100, and the low-density shell 130 provides lighter, softer material around the club head exterior. This combination creates a solid, yet soft, feel at impact.

[0040] In such embodiments, the high-density core 120 may include a significant portion of the club head mass. In some embodiments, the high-density core 120 has a mass (hereafter a “core mass”) ranges from 150 and 300 grams. In some embodiments, the core mass ranges from 150 to 175 grams, 175 to 200 grams, 200 to 225 grams, 225 to 250 grams, 250 to 275 grams, or 275 to 300 grams. In such embodiments, despite accounting for a lesser volume than the shell 130, the core 120 may include a disproportionately high amount of the total club head mass. In some embodiments, the core mass can be between 40% and 80% of the total club head mass. In some embodiments, the core mass can range from 40% to 45%, 45% to 50%, 50% to 55%, 55% to 60%, 60% to 65%, 65% to 70%, 70% to 75%, or 75% to 80% of the total club head mass. In some embodiments, the core 120 may include a lower percentage of the total club head volume than the shell 130 yet a higher percentage of the total club head mass than the shell 130.

[0041] As discussed above, the shell 130 surrounds and at least partially encapsulates the core 120. The shell 130 forms a large portion of the club head exterior without significantly increasing the overall club head mass. Further, because of its lower density, the shell 130 may include a disproportionately low proportion of the club head mass (relative to its volume). In some embodiments, the shell 130 has a mass (hereafter a “shell mass”) between 50 and 175 grams. In some embodiments, the shell mass ranges from 50 to 55 grams, 55 to 60 grams, 60 to 65 grams, 65 to 70 grams, 70 to 75 grams, 75 to 80 grams, 80 to 85 grams, 85 to 90 grams, 90 to 95 grams, 95 to 100 grams, 100 to 105 grams, 105 to 110 grams, 110 to 115 grams, 115 to 120 grams, 120 to 125 grams, 125 to 130 grams, 130 to 135 grams, 135 to 140 grams, 145 to 150 grams, 150 to 155 grams, 155 to 160 grams, 160 to 165 grams, 165 to 170 grams, or 170 to 175 grams. In some embodiments, the shell mass may be between 20% and 60% of the total club head mass. In some embodiments, the shell mass may range from 20% to 25%, 25% to 30%, 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, or 55% to 60% of the total club head mass.

[0042] As illustrated in FIG. 4, some embodiments of the club head 100 include a high-density core 120 with one or more apertures 126. The apertures 126 may extend through the core 120. In some embodiments, the apertures 126 may extend from a first core surface to a second core surface (e.g., from one part of the core to another part of the core). The one or more apertures 126 provide hollowed out portions of the core 120 to improve club head mass properties and to facilitate manufacture. The apertures 126 thus remove mass from the high-density core 120, thereby creating discretionary mass that can be distributed about the club head perimeter to increase club head MOI. Further, the apertures 126 may help couple the core 120 and the shell 130. In some embodiments, additional weights can couple to the apertures to improve MOI.

[0043] In some embodiments, the core 120 and the shell 130 may be joined through an integral joining process, such as a co-molding process, a die casting process, or the like. In such embodiments, the shell 130 can be molded such that it extends through and fills the core apertures 126, thereby integrally interlocking the core 120 and shell 130. In some embodiments, as described below with reference to at least FIGS. 5-14, the core 120 and the shell 130 may be joined through a vacuum die casting process. In such embodiments, the core 120 can become encapsulated within the shell 130. The shell 130 may be anodized after manufacture of the multi-material club head 100.

[0044] Referring now to FIGS. 5-8, the core 120, according to an example method of manufacturing the multi-material club head 100 (“method”) described herein, can be prepared from a weight insert 138 which corresponds to the core 120 in the final state, as will be discussed in further detail below. In some embodiments, the weight insert 138 is formed from a high-density material, such as steel, a steel alloy such as stainless steel (e.g., SUS304), tungsten or a tungsten alloy, copper, ceramic, or the like. The weight insert 138 is initially formed with, in part, a temporary aligning member, such as a tab 140.

[0045] With reference to FIG. 8, at least a portion of the method 500 can be accomplished utilizing a die casting tool assembly 142 (or “tooling”) used in, for example, a die casting process, specifically a vacuum die casting process. The tooling 142 generally includes a first mold portion 142a and a second mold portion 142b. The first mold portion 142a may be referred to as a fixed die and / or a cover half, and the second mold portion 142b may be referred to as a moving die and / or an ejector half. The tooling 142 includes a cavity 146 to receive and support the weight

[0046] insert 138.

[0047] In some embodiments, the cavity 146 can be formed in one or more of the first mold portion 142a and the second mold portion 142b. In the illustrated embodiment, the cavity 146 is formed primarily in the first mold portion 142a. In such embodiments, one face of the weight insert 138, corresponding to the sole 112 of the core 120, can lie flush or approximately flush with a periphery 143 of the first mold portion 142a.

[0048] With continued reference to FIG. 8, the tooling 142 further includes a positioning and / or ejecting member, such as a key 148, adjacent the cavity 146 and supported by one or more of the first mold portion 142a and the second mold portion 142b. In some instances, the key 148 is dimensioned to complement a portion of the weight insert 138, for example, with a tongue 150 formed complementary to a shape of the rear 111 of the club head 100 (FIG. 1). In such instances, the key 148 can also create a temporary access space 152.

[0049] With additional reference to FIGS. 9 and 10, the first mold portion 142a, the second mold portion 142b, or a combination thereof can include a gating system 154 having fillable spaces, such as recesses, pockets, channels, or the like. In the illustrated embodiment, the gating system 154 can include one or more risers 156, runners 158, ingates 160, injection tubes 162, and / or the like, each of which is in fluid communication with the cavity 146. Similarly, the gating system 154 and the cavity 146 can be in fluid communication with an external vacuum source. In some embodiments, the gating system 154 and the cavity 146 are exposed to the vacuums source via a vacuum interface 164 formed by the first mold portion 142a and the second mold portion 142b. In other embodiments, the gating system 154 and the cavity 146 are exposed to the vacuum source via a separate designated port, channel, or the like (not shown).

[0050] Although portions of the gating system 154 can be positioned throughout the tooling 142, FIGS. 8 and 9 illustrate one example arrangement, in which the risers 156 and the runners 158 are positioned primarily in the first mold portion 142a, and the ingates 160 and the injection tube 162 are positioned primarily in the second mold portion 142b. As will be detailed below, the gating system 154 facilitates and directs fluid flow (e.g., molten material, air, oil, etc.) through the tooling 142 during the die casting process.

[0051] Referring now to FIGS. 8-11 and 14, the method of manufacturing 500 the multi-material club head 100 (“method”) will now be described in detail. In general, the method 500 begins with the preparation of different materials and components (e.g., weight insert 138, tooling 142, etc.), and the method 500 concludes with the completed club head 100.

[0052] At step 505, the weight insert 138, again which corresponds to the core 120 in the final state, may be produced by casting, metal injection molding (“MIM”), computer numerical control (“CNC”) machining, another similar approach, or a combination thereof. In some embodiments, the weight insert 138 is formed of several parts assembled together separately or during the die casting process. In the illustrated embodiment, the weight insert 138 is produced as a single monolithic body.

[0053] Next, at step 510, once the weight insert 138 has been produced, the weight insert 138 may be subjected to a cleaning and / or baking process. In some embodiments, the weight insert 138 can be baked at approximately 135-145° C. for 1.0-2.0 hours. In one example embodiment, the cleaning and / or baking process includes baking the weight insert 138 at approximately 140° C. for approximately 1.5 hours. One example purpose of the cleaning and / or baking process is to ensure the weight insert 138 has thermal compatibility with a subsequent die casting operation. Another example purpose of the cleaning and / or baking process is to minimize oxidation. Accordingly, the amount of time could be altered based on the stated or other purpose(s).

[0054] Next, at step 515, once the weight insert 138 has undergone the cleaning and / or baking process, or another equivalent process, the weight insert 138 may then undergo a pre-heating process. In some embodiments, the weight insert 138 can be pre-heated to approximately 115-125° C. and preserved at said temperature for approximately 1.5-2.5 hours. In one example embodiment, the pre-heating process includes pre-heating the weight insert 138 to approximately 120° C. and preserving said temperature for approximately 2.0 hours.

[0055] Simultaneously with step 515, at step 520, the tooling 142 may also undergo a pre-heating process. In some embodiments, the tooling 142 can be pre-heated to approximately 180-200° C. and preserved at said temperature for a desired amount of time. One example purpose of the pre-heating processes in step 515 and step 520 is to ensure optimal material flow and adhesion. Another example purpose of the pre-heating processes in step 515 and step 520 is to inhibit thermal shock.

[0056] Next, at step 525, as illustrated, for example, in FIG. 8, the pre-heated weight insert 138 may be positioned within the pre-heated tooling 142. More specifically, the weight insert 138 is positioned within the cavity 146 and aligned therein by the tab 140, which bears against a defining surface of the cavity 146. Subsequently, the key 148 may be operated (e.g., moved into the cavity) to position and / or secure the weight insert 138 in the cavity 146 and ensure a predefined material fillable space surrounding all or a majority portion of the weight insert 138 and, if surrounding a majority portion of the weight insert 138, not surrounding a minority portion of the weight insert 138, which may correspond generally to the tab 140. The fillable space produces a predefined material thickness around all or a majority portion of the weight insert 138. In some embodiments, the material thickness may range from 1.5-3.5 mm. In some embodiments, the material thickness may be approximately 2.5 mm, i.e., approximately 2.5 mm continuously around all or a majority portion of the weight insert 138. One example purpose of the material thickness is to ensure structural integrity and avoid visible flow marks on the final club head 100.

[0057] Once the weight insert 138 is secured in the cavity 146, the method proceeds to step 530, as illustrated in FIG. 9, in which the first mold portion 142a and the second mold portion 142b are joined together to enclose the weight insert 138 entirely within the tooling 142. In the illustrated embodiment, the first mold portion 142a and the second mold portion 142b are brought together to form the vacuum interface 164, thereby allowing some gas communication, but not material migration, out of the cavity 146. In other configurations in which the vacuum port or connection or channel is elsewhere relative to the cavity 146, the interface 164 simply serves to enclose and seal the cavity 146.

[0058] Next, step 535 proceeds with vacuum die casting, which includes, for example, evacuating air and gases from within the cavity 146 via the vacuum interface 164 or other designated channel and injecting molten material, such as aluminum alloy (e.g., 6061 aluminum) into the cavity 146 via the gating system 154, as shown in FIG. 10. In general, some example purposes of the gating system 154 are to optimize and promote uniform filling, reduce turbulence, minimize porosity, prevent defects (e.g., cold shuts, incomplete filling, or the like), and improve adhesion between the molten material and the weight insert 138. In some embodiments, the tooling 142 is fitted with cooling channels to further achieve these purposes and regulate temperature during vacuum die casting.

[0059] In some embodiments, vacuum die casting includes heating the molten material to approximately 800-900° C. and injecting said material at a pressure of approximately 50-80 MPa, with a flow speed of approximately 0.1-1.1 m / s. In some embodiments, vacuum die casting includes heating the molten material to approximately 850-900° C. and injecting said material at a pressure of approximately 65-75 MPa, with a flow speed of approximately 0.55-0.75 m / s. In some embodiments, vacuum die casting further includes maintaining a flow time of the material for, or limiting a flow time of the material to, less than approximately 0.3-0.7 seconds and holding the pressure for approximately 2.5-6 seconds. In some embodiments, vacuum die casting further includes maintaining a flow time of the material for, or limiting a flow time of the material to, less than approximately 0.5-0.75 seconds and holding the pressure for approximately 3-4 seconds. One example goal of these listed parameters is to inhibit thermal shock between different materials.

[0060] One example purpose of the vacuum die casting parameters of step 535 is to ensure the cavity 146 fills completely and the material solidifies fully around the weight insert 138, thereby forming the raw body 178 as illustrated in, for example, FIGS. 10 and 11. In other words, the die casting process in step 535 encapsulates the weight insert 138 within the aluminum to form the shell 130 and thereby form the multi-component / material structure referred to herein. Accordingly, in step 540, the raw body 178 is formed and simultaneously allowed to cool (e.g., solidify).

[0061] Next, at step 545, after solidification, the raw body 178 may be removed from the tooling 142 (e.g., demolded), which may include retracting the second mold portion 142b from the first mold portion 142a to expose the raw body 178. At the same time, the key 148 may be operated to loosen the raw body 178. In some instances, moving the key 148 more simply exposes the access space 152 between the raw body 178 and the tooling 142 to assist with removing the raw body 178.

[0062] In general, as best illustrated in FIGS. 10 and 11, due to the molten material filling the cavity 146 and the gating system 154, the raw body 178 has formed thereon temporary gate members, including legs 168, knobs 172, mounts 176, and the like, in particular legs 168 formed in the ingates 160, knobs 172 formed in the risers 156, and the mount 176 formed in the runners 158 and / or injection tube 162. Accordingly, as best illustrated in FIG. 11, the raw body 178 is made up of solidified material covering the weight insert 138 and the temporary gate members 168, 172, 176, but not the tab 140, though in some embodiments, the solidified material can cover a portion or all of the tab 140.

[0063] Next, at step 550, the excess material (e.g., members 168, 172, 176) may be trimmed away, as illustrated, for example, in FIG. 12, thereby turning the raw body 178 into the shell 130.

[0064] Similarly, at step 555, as illustrated, the tab 140 is removed from the weight insert 138 to accommodate coupling (e.g., affixing, attaching, mounting, etc.) of the strike face 102 (further detailed herein). Removal of tab 140 transforms the weight insert 138 into the core 120. In other words, the weight insert 138 is a temporary component comprised of the core 120 and the tab 140.

[0065] In some embodiments, the core 120 and shell 130 combination, except for the strike face 102, may then undergo a series of finishing operations, including (i) polishing to remove tooling lines and oxide layers, (ii) additional machining to remove excess material therefrom and / or apply surface textures, (iii) cleaning and / or baking to prepare the club head 100 for anodizing, (iv) sandblasting to achieve a uniform or desired surface finish, and (v) anodizing to provide corrosion resistance and allow for various color finishes.

[0066] In the illustrated embodiment, step 560 may include polishing, step 565 may include additional machining, step 570 may include cleaning and / or baking prior to anodizing, step 575 may include sandblasting for surface finishing purposes, and step 580 may include anodizing. In some embodiments, anodizing is used, for example, with aluminum alloys to improve the natural aluminum oxide corrosion-resistant finish by forming a stronger aluminum oxide layer that increases durability, permits coloring options, and potentially improves adhesion of any additional surface coatings. In some embodiments, control of the precise composition of the aluminum alloy can improve the quality of the oxide layer, e.g., an aluminum alloy with reduced silicon content.

[0067] At step 585, following anodization, the strike face 102 in the form of rubber or other suitable material may be affixed according to the structure outlined above. Next, in step 590, any artwork or branding may be painted and / or baked onto the strike face 102 or another portion of the club head 100. Finally, in step 595, the finished club head 100 may then be subjected to inspection for dimensional accuracy, surface quality, and proper integration of the weight insert 138.

[0068] Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.

[0069] Before any embodiments of the present disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.

[0070] Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and / or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and / or limitations in the claims under the doctrine of equivalents.

Claims

1. A putter-type golf club head comprising:a multi-component body includinga core made of a core material including a core material density greater than 7.0 g·cm3, the core accounting for between 20% and 50% of a total club head volume and between 40% and 80% of a total club head mass, anda shell made of a shell material including a shell material density less than 4.0 g·cm3, the shell material being a metallic material, and the shell accounting for between 50% and 80% of the total club head volume and between 20% and 60% of the total club head mass.

2. The putter-type golf club head of claim 1, wherein one or more apertures extend through the core from a first core surface to a second core surface.

3. The putter-type golf club head of claim 1, wherein the core material is formed of steel or a steel alloy and the shell material is formed of aluminum or an aluminum alloy.

4. The putter-type golf club head of claim 1, wherein the core has a volume between 10 and 40 cubic centimeters and the shell has a volume between 25 and 60 cubic centimeters.

5. The putter-type golf club head of claim 1, wherein the shell fully encapsulates the core.

6. The putter-type golf club head of claim 1, the multi-component body including a crown region, a sole region, a heel region, a toe region, a rear region, and a front region, and further including a strike face near the front region, and wherein the shell fully encapsulates the core excepting the strike face.

7. The putter-type golf club head of claim 1, wherein the multi-component body has an exterior surface configured in a shape corresponding to any of a blade-type putter club head, a mid-mallet-type putter club head, or a mallet-type putter club head.

8. A method of manufacturing a multi-material club head, the method comprising:heating a weight insert, the weight insert formed from a steel alloy;heating a mold having a cavity configured to receive the weight insert;positioning the weight insert within the mold such that a predetermined fillable space remains surrounding a majority portion of the weight insert and not surrounding a minority portion of the weight insert;evacuating gases from the cavity;injecting aluminum alloy in a molten state into the predetermined fillable space;after solidification of the aluminum alloy, removing the aluminum alloy and the weight insert from the mold;removing the minority portion of the weight insert; andanodizing the aluminum alloy.

9. The method of claim 8, wherein positioning the weight insert within the mold includes disposing an ejecting member into an orientation relative to the weight insert such that a portion of the ejecting member complements a portion of the weight insert.

10. The method of claim 8, wherein prior to heating the weight insert, the method further includes heating the weight insert for one to two hours at a temperature of at least 135 degrees C.

11. The method of claim 8, wherein heating the weight insert comprises heating the weight insert to a temperature between 115 and 125 degrees C. for 1.5 to 2.5 hours.

12. The method of claim 8, wherein the predetermined fillable space corresponds to between 1.5 mm and 3.5 mm of material thickness around the majority portion.

13. The method of claim 8, wherein the predetermined fillable space corresponds to approximately 2.5 mm of material thickness around the majority portion.

14. The method of claim 8, wherein injecting the aluminum alloy into the predetermined fillable space includes pressurizing the aluminum alloy at 50-80 MPa for 2.5 to 6 seconds.

15. The method of claim 8, wherein injecting the aluminum alloy into the predetermined fillable space comprises injecting aluminum alloy at a flow speed of 0.1 to 1.1 meters per second.

16. The method of claim 8, wherein injecting the aluminum alloy into the predetermined fillable space comprises limiting a flow time of the aluminum alloy to less than 0.5 seconds.

17. An apparatus for manufacturing a putter-type golf club head, having a weight insert corresponding to a core that is configured to be at least partially encased within a metallic material, the apparatus comprising:a first mold portion;a second mold portion selectively joinable with the first mold portion to define a cavity therebetween, the cavity configured complementary to an exterior surface of the core;a key mechanism operable to at least one of position or secure the weight insert within the cavity thereby to define a fillable space around at least a portion of the weight insert;a vacuum interface in communication with the cavity and configured to evacuate gases therefrom; anda gating system in fluid communication with the cavity and configured to direct the metallic material, in a molten state, into the fillable space, thereby to form a shell at least partially encapsulating the core.

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