Golf club head with composite faceplate

Abstract

Golf club heads have a composite faceplate having an Impact Response Modulator disposed in the sole to improve ball flight characteristics. The Impact Response Modulator (IRM) includes a casing with a plurality of casing walls that form an aperture therebetween. The faceplate structurally reinforces the IRM by forming the casing walls out of high-strength material, thereby improving faceplate deflection while maintaining sufficient durability.

Description

Docket No. KMC-24-021-D-X1-PCTGOLF CLUB HEAD WITH COMPOSITE FACEPLATECROSS REFERNCE TO RELATED APPLICATIONS

[0001] This is a continuation-in-part of U.S. Patent Application No. 19 / 339,232, filed on September 24, 2025, which claims the benefit of U.S. Provisional Application No. 63 / 699,398, filed on September 26, 2024, U.S. Provisional Application No. 63 / 784,868, filed on April 7, 2025, and U.S. Provisional Application No. 63 / 874,540, filed on September 2, 2025. This further claims the benefit of U.S. Provisional Application No. 63 / 728,589, filed on December 5, 2024, which is incorporated in its 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 golfball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. More deflection will increase 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 to the golfball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air increasing 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. To counter those stresses, conventional golf club heads employ build-ups, increased thicknesses, or other structural features adjacent the flexure to improve durability, at the sacrifice of performance. Consequently, conventional golf club heads fail to increase strike face deflection without compromising club head durability.Docket No. KMC-24-021-D-X1-PCT

[0004] Conventional flexure features are typically formed of the same material as the body. Consequently, conventional clubs employ build-ups, increased thicknesses, or other structural features adjacent the flexure to improve durability, at the sacrifice of performance.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. l is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0006] FIG. 2 is a bottom, front, toe-side perspective view of the golf club head of FIG. 1.

[0007] FIG. 3 is a front, elevation view of the golf club head of FIG. 1.

[0008] FIG. 4 is a toe-side, elevation view of the golf club head of FIG. 1.

[0009] FIG. 5 is a rear, toe-side perspective view of a golf club head according to the present invention.

[0010] FIG. 6 is a bottom view of a golf club head according to the present invention.

[0011] FIG. 7 is a rear, toe-side perspective view of a golf club head according to the present invention.

[0012] FIG. 8 is a detailed, plan view of the golf club head of FIG. 1, in cross-section.

[0013] FIG. 9 is a toe-side, detailed, elevation view of the golf club head of FIG. 1, in crosssection.

[0014] FIG. 10 is a heel-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0015] FIG. 11 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0016] FIG. 12 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.Docket No. KMC-24-021-D-X1-PCT

[0017] FIG. 13 a detailed, plan view of the golf club head of FIG. 12, in cross-section.

[0018] FIG. 14 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0019] FIG. 15 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0020] FIG. 16 is a bottom, front, toe-side perspective view of the golf club head of FIG. 15.

[0021] FIG. 17 is an exploded, bottom, front, toe-side perspective view of the golf club head of FIG. 15.

[0022] FIG. 18 is a bottom, front, toe-side perspective view of a composite faceplate of the golf club head of FIG. 15.

[0023] FIG. 19 an exploded, plan view of the golf club head of FIG. 15.

[0024] FIG. 20 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

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

[0026] FIG. 22 is a toe-side elevation view of a golf club head of the present invention, in cross-section.

[0027] FIG. 23 is a toe-side elevation view of the golf club head of FIG. 22, in cross-section.

[0028] FIG. 24 is a rear, toe-side perspective view of a golf club head according to the present invention, in cross-section.

[0029] FIG. 25 is a front, toe-side perspective view of the golf club head of FIG. 24.

[0030] FIG. 26 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.Docket No. KMC-24-021-D-X1-PCT

[0031] FIG. 27 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0032] FIG. 28 is a rear, toe-side perspective view of a golf club head according to the present invention, in cross-section.

[0033] FIG. 29 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0034] FIG. 30 is a plan view of the golf club head of FIG. 29, in cross-section.

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

[0036] FIG. 32 is a plan view of the golf club head of FIG. 31, in cross-section.

[0037] FIG. 33 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0038] FIG. 34 a plan view of the golf club head of FIG. 33, in cross-section.

[0039] FIG. 35 is a detailed, plan view of the golf club head of FIG. 20, in cross-section.

[0040] FIG. 36 is a plan view of a golf club head of the present invention.

[0041] FIG. 37 is a rear, toe-side perspective view of the golf club head of FIG. 36, in crosssection.

[0042] FIG. 38 is a top, rear, toe-side perspective view of a composite faceplate.

[0043] FIG. 39 is a front view of the composite faceplate of FIG. 38.

[0044] FIG. 40 is a toe-side, detailed, elevation view of a golf club head of the present invention, in cross-section.Docket No. KMC-24-021-D-X1-PCT

[0045] FIG. 41 is a rear, toe-side perspective view of the golf club of FIG.40, in crosssection.

[0046] FIG. 42 is a bottom, front, toe-side perspective view of a composite faceplate from the golf club head of FIG. 40.

[0047] FIG. 43 is a toe-side elevation view of a golf club head according to the present invention, in cross-section.

[0048] FIG. 44 is a bottom plan view of a golf club head according to the present invention.

[0049] FIG. 45 is a bottom plan view of a golf club head according to the present invention.

[0050] FIG. 46 is a bottom plan view of a golf club head according to the present invention.

[0051] FIG. 47 is a toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0052] FIG. 48 is a rear, toe-side perspective view of a golf club head according to the present invention.

[0053] FIG. 49 is a toe-side elevation view of the golf club head of FIG. 48, in cross-section.

[0054] FIG. 50 is a bottom plan view of the golf club head of FIG. 48.

[0055] FIG. 51 is a rear, toe-side perspective view of a golf club head according to the present invention.

[0056] FIG. 52 is a toe-side elevation view of the golf club head of FIG. 51, in cross-section.

[0057] FIG. 53 is a bottom plan view of the golf club head of FIG. 51.

[0058] FIG. 54 is a toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0059] FIG. 55 is a top plan view of the golf club head of FIG. 54.Docket No. KMC-24-021-D-X1-PCT

[0060] FIG. 56 is a block diagram of a method of fabricating a golf club head according to the present invention.

[0061] FIG. 57 is a plan view of a composite faceplate in an intermediate state.

[0062] FIG. 58 is a plan view of a composite faceplate in an intermediate state.

[0063] FIG. 59 is a plan view of a composite faceplate in an intermediate state.

[0064] FIG. 60 is a top, rear, toe-side, perspective view of a composite faceplate in a final state.

[0065] FIG. 61 is a block diagram of a method of fabricating a golf club head according to the present invention.

[0066] FIG. 62 is a plan view of a composite faceplate in an intermediate state.

[0067] FIG. 63 is a top, rear, toe-side perspective view of a composite faceplate in a final state.

[0068] FIG. 64 is a top, rear, toe-side, perspective view of the composite faceplate of the golf club head of FIG. 36.

[0069] FIG. 65 is a bottom, front, toe-side perspective view of the composite faceplate of the golf club head of FIG. 36.

[0070] FIG. 66 is a bottom plan view of the golf club head composite faceplate of FIG. 36.

[0071] FIG. 67 is a top, rear, toe-side, perspective view of the composite faceplate of the golf club head of FIG. 38.

[0072] FIG. 68 is a front view of the composite faceplate of the golf club head of FIG. 38.

[0073] FIG. 69 is a plan view of the composite faceplate of the golf club head of FIG. 38.Docket No. KMC-24-021-D-X1-PCT

[0074] FIG. 70 is a rear perspective view of the composite faceplate of the golf club head of FIG. 22.

[0075] FIG. 71 is a plan view of the composite faceplate of FIG. 24, in an intermediate state.

[0076] FIG. 72 is a top, rear, toe-side perspective view of the composite faceplate of FIG. 24, in an intermediate state.

[0077] FIG. 73 is a top, rear, toe-side perspective view of the composite faceplate of FIG. 24, in a final state.

[0078] FIG. 74 is a toe-side, detailed, elevation view of a golf club head with an insert according to the present invention, in cross section.

[0079] FIG. 75 is a toe-side, detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0080] FIG. 76 is a toe-side, detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0081] FIG. 77 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0082] FIG. 78 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0083] FIG. 79 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0084] FIG. 80 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0085] FIG. 81 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.Docket No. KMC-24-021-D-X1-PCT

[0086] FIG. 82 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0087] FIG. 83 is a toe-side detailed, elevation view of the golf club head of FIG. ATA, in cross-section.

[0088] FIG. 84 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0089] FIG. 85 is a detailed plan view of a golf club head according to the present invention.

[0090] FIG. 86 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0091] FIG. 87 is a top, rear, heel-side perspective view of the golf club head of FIG. AV, in cross-section.

[0092] FIG. 88 is a top, rear, toe-side perspective view of an insert according to the present invention.

[0093] FIG. 89 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0094] FIG. 90 is a top, rear, toe-side perspective view of the insert of FIG. BB.

[0095] FIG. 91 is a toe-side detailed, elevation view of a golf club head with an insert according to the present invention, in cross-section.

[0096] FIG. 92 is a top, rear, toe-side perspective view of the insert of FIG. AZ.

[0097] FIG. 93 is a rear perspective view of an insert according to the present invention.

[0098] FIG. 94 is a rear, heel-side perspective view of a composite faceplate embodiment.

[0099] FIG. 95 is a plan view of the golf club head composite faceplate of FIG. 74.Docket No. KMC-24-021-D-X1-PCT

[0100] FIG. 96 is a front, heel-side perspective view of an alternative embodiment of a body of a golf club head.

[0101] FIG. 97 is a rear, heel-side perspective view of an alternative embodiment of a composite faceplate.

[0102] FIG. 98 is a plan view of the composite faceplate of FIG. 77.

[0103] FIG. 99 is a front, heel-side perspective view of an alternative embodiment of a body of a golf club head.

[0104] FIG. 100 is a bottom plan view of a golf club head with casing formed lower strength material.

[0105] FIG. 101 is a bottom plan view of the golf club head of FIG. 80.

[0106] FIG. 102 is a bottom plan view of a golf club head with a composite faceplate according to the present invention.DETAILED DESCRIPTION

[0107] Wood-type golf club heads (i.e., drivers, fairway woods, or hybrids) having an impact response modulator (hereafter “IRM”) monolithically formed with a strike face, are described herein that improve performance and durability. The IRM is positioned in the sole proximate the strike face to strategically weaken the sole, increasing strike face deflection, and 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 may be provided in a composite faceplate that has one or more buffer zones that facilitate the assembly process. As used herein, the phrase “composite faceplate” does not suggest a particular material used to form the faceplate, as further defined below.Docket No. KMC-24-021-D-X1-PCT

[0108] The composite faceplate is formed of a high-strength material that improves performance and durability. More specifically, the composite faceplate has a strike face intended to impact a ball. The high-strength material allows the strike face and IRM to have a reduced thickness, improving performance while maintaining sufficient durability. The composite faceplate is a monolithic component that forms at least a portion of the strike face and comprises a sole return that forms both the casing and a forward portion of the sole. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Stress in the casing walls is reduced by forming the casing with a high-strength faceplate material. Accordingly, the casing walls can have a reduced thickness, be placed closer to the strike face without exceeding the yield strength of the high-strength material, or a combination thereof. The selected use of a high-strength material increases strike face deflection and durability, facilitates fabrication, and maintain discretionary weight over a clubhead without this monolithic construction.

[0109] The composite faceplate comprises a face region and a sole return, wherein the entire casing and the entire aperture reside within the sole return. A peripheral wall of the composite faceplate entirely surrounds the face and sole return regions. In some embodiments, the peripheral wall is continuously joined or attached to the body, such that there are no portions of the periphery that are unattached to the body. Accordingly, the body forms no portion of the casing. In other embodiments, the peripheral wall is partially or intermittently joined or attached to the body. The periphery of the composite faceplate is spaced away from the casing walls so that no joints or connections are proximate the casing walls. Furthermore, by having a monolithic, composite faceplate that forms the entire casing, joints or connections between the composite faceplate and the body are spaced from the slot and therefore minimally impact slot performance while reducing areas of potential failure increasing durability of the casing walls.I. Definitions

[0110] The golf club heads disclosed herein include a composite faceplate that improves durability and performance. The phrase “composite faceplate” is defined herein as a unitary, complex structure having multiple, integrally formed and interconnected portions, and does notDocket No. KMC-24-021-D-X1-PCT limit, describe, or suggest a particular material used to form the faceplate. More specifically, the composite faceplates disclosed herein include at least a face region, forming a strike surface of the golf club head, and a sole return region that can include a casing, extending rearwardly of the face region. As such, each of the composite faceplates disclosed herein forms different, distinct regions of the golf club head and is attached to the body as a unit or module.

[0111] 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.

[0112] 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.

[0113] The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golfball. The term “strike face” can be used interchangeably with the term “face.”

[0114] 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 theDocket No. KMC-24-021-D-X1-PCT 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. 3. 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).

[0115] 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.

[0116] The golf club head 100 defines a ground plane (GP) as a reference plane associated with the surface on which a golfball 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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 angleDocket No. KMC-24-021-D-X1-PCT20 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.

[0121] 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.

[0122] 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.

[0123] 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. 3 and 4.

[0124] 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.Docket No. KMC-24-021-D-X1-PCT

[0125] 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).

[0126] 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.

[0127] 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 golfball.

[0128] 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.

[0129] “Driver” 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 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 thanDocket No. KMC-24-021-D-X1-PCT 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 volume of the driver can be approximately 400cc - 600cc, 425cc - 500cc, approximately 500cc - 600cc, approximately 500cc - 650cc, approximately 550cc - 700cc, approximately 600cc - 650cc, approximately 600cc - 700cc, or approximately 600cc - 800cc.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] “Fairway wood” 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,Docket No. KMC-24-021-D-X1-PCT 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.

[0134] Further, “fairway wood” golf club heads as used herein comprises a 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 volume of the fairway wood can be approximately 150cc - 200cc, approximately 150cc - 250cc, approximately 150cc - 300cc, approximately 150cc - 350cc, approximately 150cc - 400cc, approximately 300cc - 400cc, approximately 325cc - 400cc, approximately 350cc - 400cc, approximately 250cc - 400cc, approximately 250 - 350 cc, or approximately 275-375 cc.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] “Hybrid” 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 35Docket No. KMC-24-021-D-X1-PCT 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.

[0139] Further, “hybrid” golf club heads as used herein comprise a 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 volume of the hybrid can be approximately lOOcc - 150cc, approximately 75cc - 150cc, approximately lOOcc - 125cc, or approximately 75cc - 125cc.

[0140] 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

[0141] Various embodiments of a golf club comprising a composite faceplate, having both a face region and a sole return region that integrally forms the entire casing and aperture, are illustrated in the figures. More specifically, the composite faceplate is monolithically formed from a high-strength material so that the sole return encompasses the entirety of the casing andDocket No. KMC-24-021-D-X1-PCT the aperture it defines. The composite faceplate is joined with the body to form a club head. The golf club is generally understood to comprise the club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

[0142] 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 composite faceplate coupled together to form an interior cavity. According to certain embodiments, the body 101 forms at least portions of one or more of the crown 110, the sole 112, the heel 104, the toe 106, and the strike face 102. A front of the body 101 further includes a frame for attaching to the composite faceplate. The composite faceplate is coupled to the frame and comprises a sole return region 116 that is integral with the face region and includes the entire casing and aperture. Specific configurations of the body 101 and the composite faceplate are described in further detail below. In some embodiments, the perimeter of the composite faceplate is joined to the body through a simple, permanent joining process, such as welding or brazing. In other embodiments, the composite faceplate can be joined to the body through adhesive or mechanical coupling means.

[0143] The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., Ixx, 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.

[0144] The composite faceplate comprises a high-strength material having sufficient strength to withstand repeated impacts with a golfball. In some embodiments, the composite faceplate material can be a high-strength steel alloy such as, 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), Hl 3 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M),Docket No. KMC-24-021-D-X1-PCTS7 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.

[0145] In other embodiments, the composite faceplate material can be a high-strength titanium alloy, for example, but not limited to HST 220, Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Til 85, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6A1-4V (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-9A1-2V (Ti-92), Ti-8Al-lMo-lV (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6A1- 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- ICr-lFe (Ti-55511), Ti-13V-l lCr-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).

[0146] The body 101 can comprise one or more body materials. In some embodiments, at least a portion of the body 101 comprises a metal material, such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the metal material can comprise a Ti-8Al-lMo-lV alloy, Ti-8A1-2V (Ti-8-1-1- plus), or a 17-4 stainless steel. In some embodiments, the metal material can comprise 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-6A1-4V (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-3A1-2.5V, Ti-6Al-lZr-lNb-lMo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals.

[0147] In some embodiments, at least portions of the body 101 comprises one or more lightweight materials, such as a carbon-composite material. The phrase “carbon-composite material” is defined herein as the type of material, such as a carbon reinforced fiber material or any other carbon organic based material. This is in contrast to the phrase “composite faceplate,”Docket No. KMC-24-021-D-X1-PCT which as noted above is defined as a mutli-faced component having integrally provided, interconnected structures that form distinct regions of the golf club head. In some embodiments, portions of the crown 110, the sole 112, the heel 104, the toe 106, or a combination thereof can be formed by a carbon-composite material. In some embodiments, the club head 100 can comprise one or more carbon-composite panels. In some embodiments, referring to FIG. 5, the club head 100 can comprise a crown panel 196 of a carbon-composite material. The crown panel 196 can comprise a heel wrap 197a and a toe wrap 197b that each extend over the heel 104 and toe 106, respectively, to form portions of the sole 112. Further, in some embodiments, the club head 100 can comprise a sole panel 198 of carbon-composite material that forms at least a portion of the sole 112, as illustrated in FIG 5. In other embodiments, referring to FIG. 7, 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. In other embodiments, the body 101 may be formed entirely of carbon-composite material.

[0148] In some embodiments, the carbon-composite material can comprise a polymer resin and reinforcing fiber. The polymer resin can comprise a thermoset or a thermoplastic resin. In some embodiments, the carbon-composite material can comprise a carbon fiber composite material having multiple layers of unidirectional carbon fibers formed as a single, continuous piece. In some embodiments, the carbon-composite material can comprise a bi-directional woven carbon fiber composite material having a single layer formed as a single, continuous piece. In some embodiments, the carbon-composite material can comprise a fiber reinforced thermoplastic material. The carbon-composite material can be extruded, compression molded, injection molded, blow molded or bladder molded, 3-D printed, or otherwise formed by any other appropriate forming means.

[0149] According to certain aspects of the present invention, the composite faceplate material comprises a high-yield strength. In some embodiments, the composite faceplate material comprises a yield strength greater than 130 ksi, greater than 145 ksi, greater than 155 ksi, greater than 165 ksi, 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, greater than 250 ksi, greater than 260 ksi, greater than 270 ksi, greater than 280 ksi, greater than 290 ksi,Docket No. KMC-24-021-D-X1-PCT greater than 300 ksi, greater than 310 ksi, greater than 320 ksi, greater than 330 ksi, greater than 340 ksi, or greater than 350 ksi.

[0150] When the composite faceplate is joined to a portion of the body formed of a metal material, the yield strength of the composite faceplate material is greater than the yield strength of that metal material. For example, when the frame of the body comprises a metal material, the yield strength of the frame material is less than that of the composite faceplate material. In some embodiments, the frame material has yield strength from 100 ksi to 165 ksi. In some embodiments, frame material has a yield strength of less than 165 ksi, less than 155 ksi, less than 145 ksi, less than 135 ksi, less than 125 ksi, less than 115 ksi, or less than 105 ksi. Regardless of the specific yield strength of the frame material, the yield strength of the composite faceplate will be greater.

[0151] In some embodiments, the club head 100 comprises a composite faceplate strength ratio comparing the yield strength of the composite faceplate material to the yield strength of the body material. In some embodiments, the composite 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.III. Impact Response Modulator

[0152] As previously mentioned, the golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”), having increased face deflection at impact with a golfball. The IRM 120 is provided in the composite faceplate, which is formed of a high-strength material that reinforces the IRM 120 to improve durability of the golf club head. Referring to FIG. 2, the IRM 120 is disposed in the sole 112, proximate the strike face 102 and within the composite faceplate. 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.Docket No. KMC-24-021-D-X1-PCT

[0153] The casing 130 includes walls that form and surround the aperture 140. As illustrated in FIGS. 8 and 9, the casing 130 comprises a front wall 132 spaced rearward of the strike face 102, a rear wall 142 spaced rearward from the front wall 132, a heel wall 152 extending between the front wall 132 and the rear wall 142 at a heel end of the casing 130, and a toe wall 154 extending between the front wall 132 and the rear wall 142 at a toe end of the casing 130. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 each extend upward from the sole 112 and collectively border and define the aperture 140 therebetween. The aperture 140 is a through-hole fluidly communicating between the club head exterior and the interior cavity. As described above, the entire casing 130 is formed by the sole return region 116 of the composite faceplate, and therefore is fully surrounded by the high-strength material. 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.

[0154] To improve durability, the front wall 132 is separated from the strike face 102 by a sole transition region 166 formed from the high-strength material. The sole transition region 166 forms an integral part of the composite faceplate. The sole transition region 166 separates the front wall 132 from the strike face 102 by an offset distance OD, which is described in further detail below. As such, the casing 130 comprises a front wall 132 that partially forms the aperture 140 and is distinct from the strike face 102. Spacing the front wall of the casing away from the strike face increases durability while maintaining performance. The sole transition region dissipates stress and evenly transfers the flow of stress from the face to the front wall of the casing.

[0155] Further, as best illustrated in FIG. 10, the strike face 102, the sole transition region 166, and the front wall 132 combine to collectively define a U-shaped trough 175. The U-shaped trough 175 can open toward and fluidly communicate with the interior cavity 107 and can be in fluid communication therewith. The U-shaped trough 175 can run along the length of the casingDocket No. KMC-24-021-D-X1-PCT130, between the front wall 132 and the strike face 102. The strike face 102, the forward sole region 166, and the front wall 132 monolithically form the high-strength U-shaped trough 175.

[0156] The sole transition region 166 balances durability and strike face deflection by spacing the casing 130 and the aperture 140 rearward of the strike face 102. If not for the sole transition region 166, the casing 130 and / or the 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 lend to lead to failure, and 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 and the aperture 140 rearward of the strike face 102 by the sole transition region 166 allows the strike face 102 and casing walls to be thinned, therefore increasing strike face deflection.

[0157] The casing 130 can comprise a front wall height FWH, as best illustrated in FIG. 10, measured as the distance between the front wall base 133 and the front wall top surface 138, along the front wall rear surface 136. The front wall height FWH can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the front wall height FWH increases strike face deflection but potentially decreases durability by reducing the amount of material and cross-sectional area of the front wall. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall height FWH to be reduced while maintaining durability. The front wall height FWH 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. In many embodiments, the front wall height FWH can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall height FWH can be between 0.050 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, between 0.40 and 0.50 inch. In some embodiments, the front wall height FWH can be less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. Forming the entire casing 130 out of high-strength faceplate material allows the front wall height FWH to be reduced, which, as discussed in Example 2 below, improves ball speed and spin rate.Docket No. KMC-24-021-D-X1-PCT

[0158] As mentioned above, the casing 130 also comprises an offset distance OD, as best illustrated in FIG. 10, measured as the distance from the leading edge 103 to the front wall base 133, in a strike face-to-rear direction. The casing offset distance OD can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the offset distance OD increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the offset distance OD to be reduced while maintaining durability. In many embodiments, the offset distance OD can be measured at or near a center of the aperture, within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the offset distance OD can be between 0.075 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, 0.40 and 0.50 inch, 0.50 and 0.60 inch, 0.60 and 0.70 inch, 0.70 and 0.80 inch, 0.80 and 0.90 inch, or between 0.90 and 1.00 inch. In some embodiments, the offset distance can be less than 1.0 inch, less than 0.90 inch, less than 0.80 inch, less than 0.70 inch, less than 0.60 inch less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. In some embodiments, the casing offset distance OD 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 some embodiments, the offset distance OD can be greater than 0.075 inch, greater than 0.080 inch, greater than 0.085 inch, greater than 0.090 inch, greater than 0.095 inch, greater than 0.10 inch, greater than 0.15 inch, greater than 0.20 inch, 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, greater than 0.70 inch, greater than 0.75 inch, greater than 0.80 inch, greater than 0.85 inch, greater than 0.90 inch, greater than 0.95 inch, or greater than 1.0 inch. Forming the entire casing 130 out of high-strength faceplate material allows the offset distance OD to be reduced, which, as discussed in Example 2 below, improves ball speed and spin rate.

[0159] The front wall 132 comprises a front wall thickness FWT, as best illustrated in FIG. 9, measured as the distance between front wall front surface 134 and the front wall rear surface 136. As mentioned above, the front wall thickness FWT can be selected to increase strike faceDocket No. KMC-24-021-D-X1-PCT deflection without compromising durability. Specifically, the front wall thickness FWT can be increased to lower strike face deflection but improve durability. Decreasing the front wall thickness FWT increases strike face deflection but potentially lowers or negatively affects durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall thickness FWT to be reduced while maintaining durability. In many embodiments, the front wall thickness FWT can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall thickness FWT can be between 0.010 and 0.025 inch, 0.025 and 0.050 inch, 0.050 and 0.075 inch, 0.075 and 0.100 inch, 0.100 and 0.125 inch, 0.125 and 0.150 inch, or between 0.150 and 0.175 inch. In some embodiments, the front wall thickness FWT can be less than 0.175 inch, less than 0.150 inch, less than 0.125 inch, less than 0.100 inch, less than 0.075 inch, less than 0.050 inch, less than 0.025 inch, or less than 0.010 inch.

[0160] In some embodiments, the casing can comprise reliefs having relief angles, defined below. 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.

[0161] In some embodiments, the casing can comprise a heel relief, a toe relief, or both. In some embodiments, the heel relief angle can be the same as the toe relief angle. In other embodiments, the heel relief angle can be different than the toe relief angle. For example, in some embodiments, the club head can comprise only a toe relief angle when used in conjunction with a lower hosel socket. In other embodiments, the casing can include both a heel relief angle and toe relief angle. The heel relief angle and toe relief angle relieve stress buildup at the heel end and toe end, respectively, thereby improving durability of the casing.Docket No. KMC-24-021-D-X1-PCT

[0162] The casing comprises a heel relief angle measured as the angle between a line that extends between the intersection of the heel plane and the front wall bottom rear edge to the absolute heel point and the leading edge plane. The heel relief angle can range between 2 and 75 degrees. The heel relief angle 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 is 53 degrees.

[0163] The casing comprises a toe relief angle measured as the angle between a line that extends between the intersection of the toe plane and the front wall bottom rear edge to the absolute toe point and the leading edge plane. The toe relief angle 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.

[0164] The above IRM geometries, as well as additional geometries are described in U.S. Patent Appl. No. 19 / 212,636, filed on May 19, 2025, of which the contents of which are fully incorporated herein.

[0165] In some embodiments, the IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170, as best illustrated in FIG. 11, closes off the aperture 140 to prevent debris from migrating into the interior chamber. The insert 170 also can impact the performance of the IRM and durability of the club head. The insert 170 is configured to engage the casing walls. In some embodiments, the insert 170 is sized to frictionally engage the casing 130, thereby securing the insert 170 within the casing 130. The material composition, overall construction, inclusion of multiple or combinations of 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 theDocket No. KMC-24-021-D-X1-PCT insert 170 within the casing 130, even after repeated, significant impacts. In some embodiments, the insert 170 has a solid construction that entirely fills the aperture 140 with 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, as illustrated in FIG. 11. Details of other suitable inserts to be used with the IRM are described in Patent Appl. No. 19 / 090,340, filed on March 25, 2025, the contents of which are fully incorporated herein.

[0166] In some embodiments, the insert 170 can be retained within the casing walls 132, 142, 152, 154 by at least one tab 145, as illustrated in FIGS. 12 and 13. The at least one tab 145 can extend into the aperture 140 defined by the walls of the casing. The at least one tab 145 provides a physical barrier or stop for the insert 170 to prevent the insert 170 from being forced into the interior cavity of the club head at impact.IV. Impact Response Modulator with High-Strength Material Reinforcement

[0167] As described above, the composite faceplate forms the entire casing and aperture, as well as a part of the strike face. The composite faceplate is formed of a high-strength material that reinforces the casing to increase strike face deflection without compromising durability. The composite faceplate also positions joints and connections away from the aperture / casing walls to facilitate fabrication and assembly while reducing the number of failure points on the walls of the casing that experience high stress.

[0168] Various embodiments of composite faceplates formed of a high-strength material forming the entire casing are described in further detail below. Specifically, embodiments of fairway wood-type club heads and driver-type club heads are shown with different hosel configurations and other features. The different hosel configurations affect the total length of the casing, and therefore performance. For example, in some embodiments, the club head comprises a bottom-adjustable hosel having a lower hosel socket in the sole. In these embodiments, the casing and aperture are relatively shorter to provide space on the sole to accommodate the lower hosel socket. In other embodiments, the lower hosel socket is omitted, thereby increasing available space on the sole to accommodate a longer casing and aperture.Docket No. KMC-24-021-D-X1-PCT

[0169] In one embodiment, a fairway wood-type club head comprises a bottom-adjustable hosel and a composite faceplate formed a high-strength material. In another embodiment, a fairway wood type club head comprises a fixed or top-adjustable hosel configuration and an composite faceplate formed of a high-strength material. In another embodiment, a driver-type club head comprises a bottom-adjustable hosel and a composite faceplate formed of a high- strength material. In another embodiment, a driver-type club head comprises a fixed or top- adjustable hosel configuration and a composite faceplate formed of a high-strength material. Aspects of the present invention may be utilized in other club head types such as irons or hybridtype club heads.

[0170] A bottom-adjustable hosel, as described above, is an adjustable hosel configuration comprising a bottom opening, or a lower hosel socket, located on the sole of the club head that receives a fastener to secure the shaft to the club head. Bottom-adjustable hosels allow the club head to be fixed at an angle relative to the shaft, thereby setting the club head to a particular loft and / or lie angle. The lower hosel socket limit available space for, and / or otherwise, may interfere with, the IRM and the composite faceplate. In some embodiments, the lower hosel socket is formed in the body and does not form part of the composite faceplate. In other embodiments, the lower hosel socket is incorporated into the composite faceplate.

[0171] A top-adjustable hosel or fixed hosel configuration, as described above, is a hosel configuration that lacks a bottom opening to increase the length of the slot thereby increasing performance. The lack of a lower hosel socket further improves manufacturability of joining the composite faceplate to the body by simplifying the weld line. In these embodiments, the hosel configuration may be top-adjustable or fixed. A top-adjustable hosel refers to a hosel configuration in which does not have a bottom opening but can still be adjusted into different loft / lie configurations in the top hosel portion. Alternatively, the hosel configuration may be fixed in which the shaft in permanently and non-adjustably secured to the hosel, removing the need for a lower hosel socket on the sole. Both the top-adjustable configuration and fixed configuration removes the need for a bottom opening, thereby allowing the length of the casing to increase, thereby increasing flexure and performance. Details of composite faceplateDocket No. KMC-24-021-D-X1-PCT embodiments which utilize top-adjustable or fixed hosel configurations are described in further detail below.

[0172] A fairway wood-type club head 1000 comprises a composite faceplate 1050 having a face region and a sole return region that forms the entire casing to increase performance while maintaining durability, as illustrated in FIGS. 14-16. In some embodiments, the composite faceplate 1050 has a periphery that is continuously coupled or attached to the body of the club head so that there are no unattached portions of the perimeter of the composite faceplate, which increases durability. Specifically, a continuously coupled periphery results in no joints or connections in the walls of the casing that experience deflection during impact with a golfball.

[0173] The interface at which the composite faceplate is joined to the body may be located to facilitate fabrication and assembly. For example, a heel section of the peripheral wall may be spaced from both the casing and the lower hosel socket to permit welding without impacting those structures. In this embodiment, the body has a sole opening to harbor and secure a bottom- adjustable hosel. The sole opening is formed within the body material and not the composite faceplate, as illustrated in FIG. 16. The shape of this region of the hosel and bottom opening can be easily casted with the body of the club head if loft / lie adjustability is desired. As such, the golf club head 1000 comprising a a high-strength composite faceplate entirely surrounding the casing increases performances, maintains durability, and provides loft / lie adjustability to the end user.

[0174] The body 1001 of the golf club head 1000 may be formed of one or more materials having a yield strength less than that of the composite faceplate 1050. More specifically, the body 1001 may have a crown 1010, a sole 1012, a toe end 1006, and heel end 1004, a rear end 1011, a front 1008, a hosel 1005, and a frame 1013 forming a front 1008 of the body 1001. The frame 1013 may be formed of the same material as some or all of the rest of the body 1001, or may be formed of a different material. In either event, the frame 1013 may be formed of a frame material having a first yield strength, as illustrated in FIG. 15. The frame 1013 further comprises a frame crown 1014 forming a forward portion of the crown 1010, a frame sole 1015 forming a forward portion of the sole 1012, a frame toe end 1017 forming a forward portion of the toe end 1006, a frame heel end 1016 forming a forward portion of the heel end 1004, and a lower hoselDocket No. KMC-24-021-D-X1-PCT socket 1018 adjacent the frame sole 1015 and the frame heel end 1016, defining a socket perimeter 1022 having a socket perimeter inboard section 1023 and a socket perimeter outboard section 1024. The frame is configured to receive the composite faceplate 1050.

[0175] The composite faceplate 1050 is coupled to the body 1001 to form an interior cavity 1007 of the golf club head 1000. The composite faceplate 1050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate having a yield strength that is greater than the frame yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golfball.

[0176] The composite faceplate 1050 comprises a face region 1051 which forms a portion of the strike face 1002 at the front 1008 of the body 1001. The face region 1051 comprises a strike surface 1052 configured to impact a golfball, a face region toe side 1053 located toe-ward of the strike surface 1052 and bordering the frame toe end 1017, a face region heel side 1054 located heel-ward of the strike surface 1052 and bordering the frame heel end 1016, a face region crown side 1055 located crown- ward of the strike surface 1052 and bordering the frame crown 1014, and a face region sole side 1056 located sole-ward of the strike surface 1052 and defining a sole leading edge 1057.

[0177] The composite faceplate further comprises a sole return region 1058, formed integral with the face region 1051 having a casing 1030 with an aperture 1040 within a sole return sole wall 1059 to improve ball speed and spin characteristics. The high-strength material of the composite faceplate 1050 and thus the casing, improves performance and durability. The casing 1030 includes a front wall 1032, a rear wall 1038, a toe wall 1036, and a heel wall 1034, wherein the front wall 1032, the rear wall 1038, the toe wall 1036, and the heel wall 1034 define an aperture 1040. Advantageously, the body 1001 does not form any portion of the aperture 1040.

[0178] The composite faceplate further comprises a sole transition region 1060, formed integral with the face region 1051 and the sole return region 1058 that spaces the aperture from the leading edge to improve bending and durability. More specifically, the sole transition region extends from the sole leading edge 1057 of the face region 1051 to the casing front wall 1032.Docket No. KMC-24-021-D-X1-PCTThe sole transition region 1060 can further define aperture offset distance (OD) as defined above, and measured between the sole leading edge 1057 and the casing front wall 1032. The sole transition region 1060 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 1052 and face region 1051.

[0179] A peripheral wall 1061 of the composite faceplate 1050 is joined to the body 1001, to form the golf club head. More specifically, the peripheral wall 1061 extends around entireties of the face region 1051, the sole return region 1058, and the sole transition region 1060, and is joined to the frame 1013 of the body 1001, such as by welding. The peripheral wall comprises a peripheral wall heel section 1062, disposed between the casing heel wall 1034 and the lower hosel socket of the frame, that is spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance. The peripheral wall 1061 further comprises a peripheral wall sole section 1063, disposed between the casing rear wall 1038 and the frame sole 1015, that is spaced from the casing rear wall 1038 by a sole buffer distance. Both the heel buffer distance and sole buffer distance are between 0.05 and 0.25 inch to sufficient space the joint of the frame and composite faceplate away from the walls of the casing to improve durability. In some embodiments, the peripheral wall 1061 is continuously joined to the frame 1013. In other embodiments, the peripheral wall is partially or intermittently joined to the frame 1013.

[0180] A golf club head 1100, as illustrated in FIGS. 20 and 21, comprises a composite faceplate 1150 that is similar to the composite faceplate 1050 described above, but further comprises a crown return region 1165. The crown return region 1165 further reinforces a forward portion of the crown 1110 that may otherwise experience high stress during impact. Specifically, the composite faceplate 1150 comprises a crown return region 1165, formed integral with the face region 1151, the sole return region 1158 and casing 1130, and the sole transition region 1160. The crown return region 1165 includes a crown return crown wall 1166 extending rearwardly of the face region 1151. The crown return region 1165 is formed by the same high-strength material to further increase durability and performance of the crown region.

[0181] The composite faceplate 1150 further comprises a crown transition region 1167, formed integral with the face region 1151, the sole return region 1158, the sole transition regionDocket No. KMC-24-021-D-X1-PCT1160, and the crown return region 1165. The crown transition region 1167 extends from a crown leading edge 1168 of the face region 1151 to the crown return crown wall 1166 of the crown return region 1165.

[0182] In this embodiment, the peripheral wall 1161 extends entirely around the face region 1151, the sole return region 1158, the sole transition region 1160, the crown return region 1165, and the crown transition region 1167, and is joined to the frame 1113 of the body 1101. The crown transition region 1167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.

[0183] In some embodiments, the high-strength crown return region 1165 further comprises an indent 1141, as shown in FIG. 21. The indent 1141 is recessed into an interior surface of the crown return region 1165. The indent 1141 is a region of reduced thickness relative to the remainder of the crown return region 1165. In the illustrated embodiment, the indent 1141 is isolated within the crown return region 1165, such that the indent perimeter is located entirely within the bounds of the crown return region 1165. The indent 1141 increases strike face deflection without compromising faceplate durability. The indent 1141 can increase ball speed by upwards of 0.5 mph (without compromising durability) over a club head comprising a crown return without an indent. Specifically, the indent 1141 can weaken the forward portion of the crown 1110, thereby increasing the amount the crown 1110 deflects upward at impact. This increased upward crown deflection in turn increases the amount of strike face deflection. The isolation of the indent 1141 within the crown return region 1165 yields additional deflection without exceeding the yield strength of the faceplate material.

[0184] The crown return region 1165 extends rearwardly away from the crown leading edge 1168 by at least a distance of 0.10 inch to provide sufficient coverage of high-strength material in the forward portion of the crown. In some embodiments, the crown return region 1165 extends between 0.10 and 1.25 inches rearwardly from the crown leading edge. For example, the crown return region 1165 can extend between 0.10 and 0.25, 0.25 and 0.50 inch, 0.50 and 0.75 inch, 0.75 and 1.00 inch, or between 1.00 and 1.25 inches.Docket No. KMC-24-021-D-X1-PCT

[0185] The indent 1141 comprises an indent thickness TI that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indent 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 indent thickness TI can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return region 1165 can comprise an indent thickness ratio TI / TCR defined as the indent thickness TI divided by the crown return thickness TCR. In some embodiments, the indent 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.

[0186] In the illustrated embodiment, the indent 1141 is located approximately in the center of the crown return region 1165 and extends in a generally heel-to-toe direction. In other embodiments, the indent 1141 can be offset towards to the toe 1106 or towards the heel 1104. In the illustrated embodiment, the indent 1141 has an approximately rectangular shape. In other embodiments, the indent 1141 can have other shapes such as an elongated oval or an arcuate shape. Altering the position and shape of the indent can target specific portions of the strike face and change flexure response, as desired. The indent # can be applied to club heads (# of crown returns) described below.

[0187] The club head 1100 having a composite faceplate 1150 formed of a high-strength material, and comprising a crown return region 1165 and a sole return region 1158, further increases durability and performance of the club head by reinforcing areas of high-stress with a high yield strength material. In other embodiments, the composite faceplate 1150 can further form other areas of the club head body 1001 with high-strength materials, such as the hosel.

[0188] A golf club head 1200, as illustrated in FIG. 22, comprises a composite faceplate 1250 that is similar to composite faceplate 1050 described above, but further incorporates a lower hosel region 1269. In this embodiment, a peripheral wall 1261 of the composite faceplate 1250 extends around and fully encompasses a lower hosel socket 1218 and corresponding structure. The peripheral wall 1261 of the composite faceplate 1250 comprises a relatively small thickness and is offset from the lower hosel socket 1218 to facilitate welding composite faceplate 1250 to the frame 1213, if needed. In this embodiment, the composite faceplate 1250 comprisingDocket No. KMC-24-021-D-X1-PCT the lower hosel region 1269 increases the overall durability of club head 1200 while maintaining adjustability of loft and / or lie angles.

[0189] Specifically, the composite faceplate 1250 comprises a lower hosel region 1269, formed integrally with the face region 1251, the sole return region 1258, and the sole transition region 1260, and extends between the face region heel side 1254 and the sole return sole wall 1259 of the sole return region 1258. The lower hosel region 1269 includes a lower hosel socket 1218 defining a socket perimeter 1222 having a socket perimeter outboard section 1224 and a socket perimeter inboard section 1223. The lower hosel socket 1218 is monolithically and entirely formed with the composite faceplate 1250 to increase the amount of high-strength material coverage in the club head, particularly in areas that experience high-stress.

[0190] The peripheral wall heel section 1262 of the composite faceplate 1250 is disposed between the frame heel end 1216 and the lower hosel socket 1218 of the lower hosel region 1269 and is spaced from the socket perimeter outboard section 1224 by a heel buffer distance. The heel buffer distance is least 0.05 inch to allow for sufficient clearance for welding the peripheral wall 1261 to the frame 1213. In other embodiments, the heel buffer distance can be less than 0.049 inches if improved welding or other techniques are used.

[0191] Furthermore, by forming the lower hosel socket 1218 integrally with the composite faceplate 1250, the casing 1230 can be positioned closer to lower hosel socket 1218, thereby extending the effective length of the casing 1230 to increase bending and deflection. Because the peripheral wall heel section 1262 does not lie between the socket perimeter inboard section 1223 and the casing heel wall 1234, additional buffer spacing is not required between the hosel and the casing. As such, the length of the casing, and therefore the aperture, can be increased to improve performance.

[0192] A golf club head 1300 and a body 1301, as shown in FIG. 24, comprises a composite faceplate 1350 that combines elements of the features of composite faceplates 1150, 1250 described above. Specifically, this composite faceplate 1350 forms both the lower hosel socket 1318 and a crown return region 1365 to further increase the overall durability of the club head.Docket No. KMC-24-021-D-X1-PCTThe composite faceplate 1350 further comprises partial heel and toe wraps to increase the coverage of high-strength material proximate the casing and striking surface.

[0193] Specifically, the composite faceplate 1350 comprises a toe wrap region 1370 that is formed integrally with the face region 1351, the sole return region 1358, the sole transition region 1360, and the lower hosel region 1369. The toe wrap region 1370 extends rearward of the face region toe side 1353. The toe wrap region 1370 extends rearward of the face region toe side 1353 such that the peripheral wall 1361 extends entirely around the toe wrap region 1370. The toe wrap region 1370 includes a toe lateral wall 1371. In some embodiments, the toe lateral wall 1371 can be approximately horizontal with the ground plane. In other embodiments, the toe lateral wall 1371 can formed at an angle relative to the ground plane.

[0194] The composite faceplate 1350 further comprises a heel wrap region 1372 formed integrally with the face region 1351, the sole return region 1358, the sole transition region 1360, and the lower hosel region 1369. The heel wrap region 1372 extends rearward of the face region heel side 1354 such that the peripheral wall 1361 extends entirely around the heel wrap region 1372. The heel wrap region 1372 includes a heel lateral wall 1373. In some embodiments, the heel lateral wall 1373 can be approximately horizontal with the ground plane. In other embodiments, the heel lateral wall 1373 can formed at an angle relative to the ground plane.

[0195] In some embodiments, the composite faceplate 1450 is coupled to a mass pad 1479 of the body 1401 having an increased thickness than a surrounding wall thickness of the sole 1412, as illustrated in FIG. 26. The mass pad 1479 alters the center of gravity of the club head as desired. For example, the mass pad 1479 may be located in a forward sole 1412 position to lower the center of gravity to increase the launch angle. In another example, the mass pad 1479 may be located in a forward toe position or a forward heel position to shift the center of gravity toeward or heelward to impart a draw or fade bias, as desired. By positioning the mass pad 1479 to border the sole weldline 1481, which is the interface between the sole return region of the composite faceplate and the frame, the CG is shifted further forward when it is spaced rearward of the interface. The thicknesses of the body 1401 and composite faceplate 1450, in this embodiment, can be greater than 0.050 inches.Docket No. KMC-24-021-D-X1-PCT

[0196] In some embodiments, a club head 1500 comprising a body and a composite faceplate can further comprise a sole trough located at the joint or junction between the body and the composite faceplate for ease of manufacture and weldability, as illustrated in FIG. 27. The trough is an area of relatively thin walls to permit the weld or other type of joint to sufficiently penetrate though the walls and fully join the body to the composite faceplate. The trough comprises a composite faceplate side and a body side. The body comprises a mass pad that extends up to the trough to shift the CG faceward and soleward to improve launch and spin characteristics. In the trough embodiments, the thickness of the components at the interface between the body and the composite faceplate are less than 0.050 inch.

[0197] By incorporating a sole trough 1578 between the composite faceplate 1550 and the club head body 1501, the golf club head 1500 may comprise a variety of sole mass pads 1579 for shifting the CG faceward and soleward. When combined with the composite faceplate 1550, these features synergistically improve launch efficiency, spin rates, and carry distance, while maintaining durability in the golf club head 1500. Each of the sole mass pad 1579 embodiments can be integrally formed or co-casted with an interior surface 1580 of the sole 1512. More specifically, the sole mass pad 1579 can be configured as increased sole thickness at the interior surface 1580 of the sole 1512 and define a front wall 1582, a rear wall 1583, a heel wall 1584, and a toe wall 1585. In preferred embodiments, the sole mass pad 1579 is positioned centrally on the sole 1512 to control spin and increase ball speed. However, the sole mass pad 1579 may also be shifted closer to the heel end 1504 or the toe end 1506, and / or extend only partially along the width of the sole 1512 for influencing the club head MOI properties, forgiveness, and shot shape tendencies.

[0198] The composite faceplate 1550 may be coupled to club head bodies 1501 comprising differently shaped sole mass pads 1579 for reducing spin rates, improving vertical launch performance, and increasing distance. As described above, each of the various sole mass pad 1579 embodiments distribute mass forward and soleward in the club head 1500 without interfering with the increased strike face deflection and durability characteristics of the composite faceplate 1550. In some embodiments, for example, the sole mass pad 1579 may comprise a substantially rectangular shape when viewing the golf club head 1500 from a crossDocket No. KMC-24-021-D-X1-PCT sectional toe- or heel-side view. As shown in FIGS. 22-24, the front 1582, rear 1583, heel 1584, and toe 1585 walls extend crownward substantially perpendicular to the ground plane 10 and define a planar upper surface 1586 therebetween that extends substantially parallel to the ground plane 10. As such, the sole mass pad 1579 defines a substantially constant thickness 1587, measured perpendicular to the ground plane 10 from the exterior surface 1509 of the sole 1512 to the upper surface 1586. By comprising a uniform thickness 1587, the sole mass pad 1579 produces predictable moment characteristics in the golf club head 1500 to maintain the increased strike face deflection and durability characteristics of the composite faceplate 1550.

[0199] In additional embodiments, the composite faceplate 1550 may be coupled to a body 1501 comprising a substantially triangular sole mass pad 1579 when viewing the golf club head1500 from a cross-sectional toe- or heel -side view. As shown in FIGS. 29 and 30, the heel 1584 and toe 1585 walls extend crownward substantially perpendicular to the ground plane 10. Alternatively, the front 1582 and rear 1583 walls extend crownward at acute angles relative to the ground plane 10. The front 1582 and rear 1583 walls converge to form an apex 1588, defining a maximum thickness 1587 of the sole mass pad 1579. As similarly described above, the thickness 1587 is measured perpendicular to the ground plane 10 from the exterior surface 1509 of the sole 1512 to the apex 1588. In preferred embodiments, the slopes of the front 1582 and rear 1583 walls vary to shift the apex 1588 forward and bias mass toward the face region 1551 of the golf club head 1500. In doing so, the sole mass pad 1579 concentrates club head mass forward and soleward without interfering with the casing 1530. Therefore, the triangular sole mass pad 1579 delivers improved spin rates and launch conditions without compromising the dynamic behavior and durability of the composite faceplate 1550.

[0200] In even further embodiments, the composite faceplate 1550 may be coupled to a body1501 comprising a sole mass pad 1579 that forms a mass pad extension 1590. As shown in FIGS. 31-34, the front 1582, rear 1583, heel 1584, and toe 1585 walls of the sole mass pad 1579 extend crownward substantially perpendicular to the ground plane 10, and the mass pad extension 1590 protrudes faceward from the front wall 1582 such that at least a portion of the mass pad extension 1590 overhangs the trough 1578 and the sole weld line 1581. The mass pad extension 1590 comprises an upper surface 1591, a lower surface 1592, and a forward surface 1593Docket No. KMC-24-021-D-X1-PCT therebetween that defines the forward most extent of the mass pad extension 1590. In particular, the upper surface 1591 and lower surface 1592 define planar surfaces that extend substantially parallel relative to the ground plane 10 and the forward surface 1593 extends substantially perpendicular relative to the ground plane 10. The lower surface 1592 can be vertically spaced an offset distance 1594 from the sole return region 1558 such that the mass pad extension 1590 does not interfere with the trough 1578 or the sole weld line 1581 between the composite faceplate 1550 and the body 1501. Therefore, the mass pad extension 1590 shifts the CG as forward and soleward as possible without compromising the structural and functional integrity of the composite faceplate 1550.

[0201] In some embodiments, the casing 330 can comprise one or more end reinforcements 326 that dissipate stress within the casing 330. The end reinforcements 326 can be regions of the sole 312 having increased thickness that surround one or more of the casing walls. The end reinforcements 326 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. In addition to integrally forming the casing walls, the faceplate 314 can also form the end reinforcement(s) 326, as illustrated in FIG. 13. The high- strength faceplate material combines with the end reinforcement(s) to reduce stress near the casing heel wall 352 or the casing toe wall 354. Further, in some embodiments, the high-strength faceplate material allows the thickness of the end reinforcements to be reduced without exceeding the faceplate material’s yield strength, thereby increasing strike face deflection and creating discretionary mass. In the illustrated embodiment, the sole return 316 forms a toe end reinforcement 326 located near the casing toe wall 354. In other embodiments, the sole return 316 can form a heel end reinforcement located near the casing heel wall 352 instead of, or in addition to, the toe end reinforcement 326. Although the end reinforcement(s) 326 are concentrations of club head mass located on the casing walls, their location towards the heel wall 352 and or / the toe wall 354 does not hinder strike face deflection. In the illustrated embodiment, the end reinforcement(s) 326 can be generally circular in shape. In other embodiments, the end reinforcement(s) can be any suitable shape for reducing stress near the heel wall 352 or the toe wall 354.Docket No. KMC-24-021-D-X1-PCT

[0202] The end reinforcement(s) can each comprise a thickness (i.e., a heel end reinforcement thickness or a toe end reinforcement thickness) measured from the aperture 340 to the opposing surface of the end reinforcement. As discussed above, the end reinforcement(s) can have substantially larger thicknesses than the remainder of the casing walls. Specifically, in some embodiments, the heel end reinforcement thickness and / or the toe end reinforcement thickness can be at least 50% greater, 75% greater, 100% greater, 150% greater, 200% greater, or 300% greater than the front wall thickness FWT.

[0203] In another embodiment, a fairway wood golf club head 2000 comprises a composite faceplate and a top-adjustable or fixed hosel configuration so that the casing / aperture can be longer to increase bending and performance of the casing. As described above, the top-adjustable and fixed hosel configurations remove the need for a lower hosel socket, thereby allowing the lengths of the casing and aperture to increase. A longer aperture increases bending and deflection of the casing experiences, thereby returning more energy back to the strike face to increase ball speed. The golf club head 2000 may comprise either a fixed hosel or a top-adjustable hosel, as desired.

[0204] The golf club head 2000 comprises a body 2001 having a crown 2010, a sole 2012, a toe end 2006, a heel end 2004, a rear end 2011, a front 2008, a hosel 2005 defining a hosel axis 2009, and a frame 2013 forming a front 2008 of the body 2001 and formed of a frame material having a first yield strength, as illustrated in FIGS. 36 and 37. The frame 2013 further comprises a frame crown 2014 forming a forward portion of the crown 2010, a frame sole 2015 forming a forward portion of the sole 2012, a frame toe end 2017 forming a forward portion of the toe end 2006, and a frame heel end 2016 forming a forward portion of the heel end 2004. The frame 2013 is configured to receive the composite faceplate 2050. The body 2001 lacks a lower hosel socket, and instead includes a top hosel 2005 formed on the heel end 2004 of the crown 2010.

[0205] The composite faceplate 2050 is coupled to the body 2001 to form an interior cavity 2007 of the golf club head 2000. The composite faceplate 2050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate 2050 having a yield strength that is greater than the body 2001Docket No. KMC-24-021-D-X1-PCT and frame 2013 yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.

[0206] The composite faceplate 2050 comprises a face region 2051 which forms a portion of the strike face 2002 of the front 2008 of the body 2001. The face region 2051 comprises a strike surface 2052 configured to impact a golfball, a face region toe side 2053 located toe-ward of the strike surface 2052 and bordering the frame toe end 2017, a face region heel side 2054 located heel -ward of the strike surface 2052 and bordering the frame heel end 2016, a face region crown side 2055 located crown-ward of the strike surface 2052 and bordering the frame crown 2014, and a face region sole side 2056 located sole-ward of the strike surface 2052 and defining a sole leading edge 2057.

[0207] The composite faceplate further comprises a sole return region 2058, formed integral with the face region 2051. The sole return region has a casing 2030 to improve ball speed and spin characteristics. Forming the casing within the sole wall 2059 of the sole return region 2058 and thereby of the high-strength material of the composite faceplate, the casing performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 2030 includes a front wall 2032, a rear wall 2039, a toe wall 2036, and a heel wall 2034, wherein the front wall 2032, the rear wall 2039, the toe wall 2036, and the heel wall 2034 define an aperture 2040. The body 2001 does not form any portion of the aperture 2040. Furthermore, the casing heel wall 2034 is heelward of the hosel axis 2009 to increase the effective length of the casing 2030 and aperture 2040.

[0208] In this embodiment, the casing comprises a Total Length (TL), measured from the absolute toe point to the absolute heel point, parallel to the x-axis 40, that can be between 2.60 to 4.0 inches. For example, the total length TL can range from 2.60 to 3.0 inches, 3.0 to 3.5 inches, or 3.5 to 4.0 inches. In one embodiment, the total length TL is 2.681 inches.

[0209] The composite faceplate further comprises a sole transition region 2065, formed integral with the face region 2051 and the sole return region 2058, extending from the sole leading edge 2057 of the face region 2051 to the casing front wall 2032. The sole transitionDocket No. KMC-24-021-D-X1-PCT region 2065 can further define an aperture offset distance (OD) as defined above, and measured between the sole leading edge 2057 and the casing front wall 2032. The sole transition region 2065 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 2052 and face region 2051.

[0210] The composite faceplate 2050 further comprises a peripheral wall 2061, extending around the entirety of the face region 2051, the sole return region 2058, and the sole transition region 2060, and is joined to the frame 2013 of the body 2001. The peripheral wall 2061 comprises a peripheral wall heel section 2062 disposed heelward of casing heel wall 2034 and heelward of the hosel axis 2009. The peripheral wall 2061 further comprises a peripheral wall sole section 2063 disposed between the casing rear wall 2038 and the frame sole 2015, spaced from the casing rear wall 2038 by a sole buffer distance. The sole buffer distance is between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability.

[0211] In another embodiment, a golf club head 2100 comprises a composite faceplate 2150 that is similar to the composite faceplate 2050 described above, but further comprises a crown return region 2165, as shown in FIGS. 38 and 39. The crown return region 2165 further reinforces a forward portion of the crown 2110 that experience high stress during impact. Specifically, the composite faceplate 2150 comprises a crown return region 2165, formed integral with the face region 2151, the sole return region 2158, and the sole transition region 2160, and includes a crown return crown wall 2166 extending rearwardly of the face region 2151. The crown return region 2165 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region. In this embodiment, the golf club head 2100 lacks a lower hosel socket so that the casing can be longer to increase the flexure and performance of the casing.

[0212] The composite faceplate 2150 further comprises a crown transition region 2167, formed integral with the face region 2151, the sole return region 2158, the sole transition region 2160, and the crown return region 2165, extending from a crown leading edge 2168 of the faceDocket No. KMC-24-021-D-X1-PCT region 2151 to the crown return crown wall 2166 of the crown return region 2165. As such, the peripheral wall 2161 extends entirely around the face region 2151, the sole return region 2158, the sole transition region 2160, the crown return region 2165, and the crown transition region 2167, and is joined to the frame 2113 of the body 2101. The crown transition region 2167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.

[0213] In another embodiment, a golf club head comprises a crown return and a long casing formed in a high-strength composite faceplate to increase performance and durability of the golf club head. The golf club head 2200 is similar to club head 2100 described above but further comprises partial heel and toe wraps, similar to club head 1300 described above.

[0214] In all embodiments of golf club heads 1000, 1100, 1200, 1300, 1400, 1500, 2000, 2100 described above, the front wall of the casing is offset from the leading by a distance of at least 0.075 inch to further increase durability while maintaining performance of the casing. Offsetting the casing front wall away from the strike face allows stress to flow around the leading edge and onto the sole. Furthermore, the stress flows throw high-strength material of the composite faceplate.

[0215] In another embodiment, and according to aspects of the present invention, a driver type club head 3000 comprises a composite faceplate 3050 that comprises a sole return that forms the entire casing to increase performance while maintaining durability, as illustrated in FIGS. 40-46. The composite faceplate 3050 has a periphery that is coupled or attached to the body of the club head, also referred to as the frame. In some embodiments the periphery is continuously joined to the frame, such that there are no unattached portions of the composite faceplate 3050. A continuously coupled periphery results in no joints or connections in the walls of the casing that experience deflection during impact with a golf ball. Durability is increased by spacing the joints and connections away from the walls of the casing. In this embodiment, the body has a sole opening to harbor and secure a bottom-adjustable hosel. The sole opening is formed within the body material and not the composite faceplate, as illustrated in FIG. 41 . The shape of this region of the hosel and bottom opening can be easily casted with the body of theDocket No. KMC-24-021-D-X1-PCT club head if loft / lie adjustability is desired. As such, the golf club head 3000 comprising a a high-strength composite faceplate entirely surrounding the casing increases performances, maintains durability, and provides loft / lie adjustability to the end user.

[0216] The golf club head 3000 comprises a body 3001 having a crown 3010, a sole 3012, a toe end 3006, and heel end 3004, a rear end 3011, a front 3008, a hosel 3005, and a frame 3013 forming a front 3008 of the body 3001 and formed of a frame material having a first yield strength, as illustrated in FIG. 40. The frame 3013 further comprises a frame crown 3014 forming a forward portion of the crown 3010, a frame sole 3015 forming a forward portion of the sole 3012, a frame toe end 3017 forming a forward portion of the toe end 3006, a frame heel end 3016 forming a forward portion of the heel end 3004, and a lower hosel socket 3018 adjacent the frame sole 3015 and the frame heel end 3016, defining a socket perimeter 3022 having a socket perimeter inboard section 3023 and a socket perimeter outboard section 3024. The frame 3013 is configured to receive the composite faceplate 3050.

[0217] The composite faceplate 3050 is coupled to the body 3001 to form an interior cavity 3007 of the golf club head 3000. The composite faceplate 3050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate having a yield strength that is greater than the body and frame yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golfball.

[0218] The composite faceplate 3050 comprises a face region 3051 which forms a portion of the strike face 3002 and the front 3008 of the body 3001. The face region 3051 comprises a strike surface 3051 configured to impact a golfball, a face region toe side 3053 located toe-ward of the strike surface 3051 and bordering the frame toe end 3017, a face region heel side 3054 located heel-ward of the strike surface 3051 and bordering the frame heel end 3016, a face region crown side 3055 located crown-ward of the strike surface 3051 and bordering the frame crown 3014, and a face region sole side 3056 located sole-ward of the strike surface 3051 and defining a sole leading edge 3057.Docket No. KMC-24-021-D-X1-PCT

[0219] The composite faceplate 3050 further comprises a sole return region 3058, formed integral with the face region 3051. The sole return region has a casing 3030 to improve ball speed and spin characteristics. Forming the casing 3030 within the sole wall 3059 of the sole return region 3058 and thereby of the high-strength material of the composite faceplate 3050, the casing 2020 performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 3030 includes a front wall 3032, a rear wall 3039, a toe wall 3036, and a heel wall 3034, wherein the front wall 3032, the rear wall 3039, the toe wall 3036, and the heel wall 3034 define an aperture 3040. The body 3001 does not form any portion of the aperture 3040.

[0220] The composite faceplate further comprises a sole transition region 3060, formed integral with the face region 3051 and the sole return region 3058, extending from the sole leading edge 3057 of the face region 3051 to the casing front wall 3032. The sole transition region 3060 can further define aperture offset distance (OD) as defined above, and measured between the sole leading edge 3057 and the casing front wall 3032. The sole transition region 3060 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 3052 and face region 3051.

[0221] The composite faceplate 3050 further comprises a peripheral wall 3061, extending around the entirety of the face region 3051, the sole return region 3058, and the sole transition region 3060, joined to the frame 3013 of the body 3001. The peripheral wall comprises a peripheral wall heel section 3062 disposed between the casing heel wall 3034 and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance. The peripheral wall 3061 further comprises a peripheral wall sole section 3063 disposed between the casing rear wall 3038 and the frame sole 3015, spaced from the casing rear wall 3038 by a sole buffer distance. Both the heel buffer distance and sole buffer distance are between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability. In some embodiments, the peripheral wall 3061 is continuously joined to the frame 3013.Docket No. KMC-24-021-D-X1-PCT

[0222] In another embodiment, a driver type golf club head 3100 comprises a composite faceplate 3150 that is similar to the composite faceplate 3050 described above, but further comprising a crown return region 3165, as shown in FIG. 47. The crown return region further reinforces a forward portion of the crown 3110 that experience high stress during impact. Specifically, the composite faceplate 3150 comprises a crown return region 3165, formed integral with the face region 3151, the sole return region 3158, and the sole transition region 3160, and includes a crown return crown wall 3166 extending rearwardly of the face region 3151. The crown return region 3165 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.

[0223] The composite faceplate 3150 further comprises a crown transition region 3167, formed integral with the face region 3151, the sole return region 3158, the sole transition region 3160, and the crown return region 3165, extending from a crown leading edge 3168 of the face region 3151 to the crown return crown wall 3166 of the crown return region 3165. As such, the peripheral wall 3161 extends entirely around the face region 3151, the sole return region 3158, the sole transition region 3160, the crown return region 3165, and the crown transition region 3167, and is joined to the frame 3113 of the body 3101. The crown transition region 3167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.

[0224] The crown return region 3165 extends rearwardly away from the crown leading edge 3168 by at least a distance of 0.075 inch to provide sufficient coverage of high-strength material in the forward portion of the crown. In some embodiments, the crown return region 3165 extends a distance by at least 0.5 inches rearwardly of the crown leading edge 3168.

[0225] In another embodiment, a golf club head 3200 further comprises a composite faceplate 3250 that is similar to composite faceplate 3050 described above, but further comprises a lower hosel region 3269, as illustrated in FIGS.48-50. In this embodiment, a peripheral wall 3261 of the composite faceplate 3250 extends around and fully encompasses a lower hosel socket 3218 and corresponding structure. The peripheral wall 3261 of the composite faceplateDocket No. KMC-24-021-D-X1-PCT3250 comprises a relatively small thickness and is offset from the lower hosel socket 3218 for ease of weldability of the composite faceplate 3250 to the frame 3213. In this embodiment, the composite faceplate 3250 comprising the lower hosel 3214 increases the overall durability of club head 3200 while maintaining adjustability.

[0226] Specifically, the composite faceplate 3250 comprises a lower hosel region 3269, formed integrally with the face region 3251, the sole return region 3258, and the sole transition region 3260, and extends between the face region heel side 3254 and the sole return sole wall 3259 of the sole return region 3258. The lower hosel region 3269 includes a lower hosel socket 3218 defining a socket perimeter having a socket perimeter outboard section 3224 and a socket perimeter inboard section 3223. The lower hosel socket 3218 is monolithically and entirely formed with the composite faceplate 3250 to increase the amount of high-strength material coverage in the club head, particularly in areas that experience high-stress.

[0227] The peripheral wall heel section 3262 of the composite faceplate 3250 is disposed between the frame heel end 3216 and the lower hosel socket 3218 of the lower hosel region 3269 and is spaced from the socket perimeter outboard section 3224 by a heel buffer distance. In some embodiments, the heel buffer distance is least 0.025 inch to facilitate certain methods of joining the composite faceplate to the body, such as welding. In other embodiments, the heel buffer distance can be less than 0.025 inches.

[0228] Furthermore, by forming the lower hosel socket 3218 integrally with the composite faceplate 3250, the casing 3230 can positioned closer to lower hosel socket 3218, thereby extending the effective length of the casing 3230 to increase bending and deflection. Because the peripheral wall heel section 3262 does not lie between the socket perimeter inboard section 3223 and the casing heel wall 3234, the buffer distance does not exist within the region between the hosel and the casing. As such, the length of the casing can be longer to increase the performance of the casing.

[0229] In another embodiment, a driver type golf club head 4000 comprises a composite faceplate 4050 and a top-adjustable or fixed hosel configuration so that the casing / aperture can be longer to increase bending and performance of the casing. As described above, the topDocket No. KMC-24-021-D-X1-PCT adjustable and fixed hosel configurations remove the need for a lower hosel socket, thereby allowing the lengths of the casing and aperture to be increased. A longer aperture increases bending and deflection of the casing, thereby returning more energy back to the strike face to increase ball speed. The golf club head 4000 may comprise either a fixed hosel or a top- adjustable hosel, as desired.

[0230] The golf club head 4000 comprises a body 4001 having a crown 4010, a sole 4012, a toe end 4006, a heel end 4004, a rear end 4011, a front 4008, a hosel 4005 defining a hosel axis 4009, and a frame 4013 forming a front 4008 of the body 4001 and formed of a frame material having a first yield strength, as illustrated in FIG. 52. The frame 4013 further comprises a frame crown 4014 forming a forward portion of the crown 4010, a frame sole forming a forward portion of the sole 4012, a frame toe end 4017 forming a forward portion of the toe end 4006, and a frame heel end 4016 forming a forward portion of the heel end 4004. The frame 4013 is configured to receive the composite faceplate 4050. The body 4001 lacks a lower hosel socket and instead includes a top hosel formed on the heel end of the crown 4010.

[0231] The composite faceplate 4050 is coupled to the body 4001 to form an interior cavity 4007 of the golf club head 4000. The composite faceplate 4050 is formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material. The composite faceplate 4050 having a yield strength that is greater than the body 4001 and frame 4013 yield strength increases the durability and performance of the casing, the strike face, and surrounding transition regions that experience high-stress during impact with a golf ball.

[0232] The composite faceplate 4050 comprises a face region 4051 which forms a portion of the strike face 4002 at the front 4008 of the body 4001. The face region 4051 comprises a strike surface 4052 configured to impact a golfball, a face region toe side 4053 located toe-ward of the strike surface 4052 and bordering the frame toe end 4017, a face region heel side 4054 located heel -ward of the strike surface 4052 and bordering the frame heel end 4016, a face region crown side 4055 located crown-ward of the strike surface 4052 and bordering the frame crown 4014,Docket No. KMC-24-021-D-X1-PCT and a face region sole side 4056 located sole-ward of the strike surface 4052 and defining a sole leading edge 4057.

[0233] The composite faceplate further comprises a sole return region 4058, formed integral with the face region 4051. The sole return region has a casing 4030 to improve ball speed and spin characteristics. Forming the casing within the sole wall 4059 or the sole return region 4058 and thereby of the high-strength material of the composite faceplate, the casing performance and durability can be further improved over a casing formed within a body and of lower yield strength. The casing 4030 includes a front wall 4032, a rear wall 4039, a toe wall 4036, and a heel wall 4034, wherein the front wall 4032, the rear wall 4039, the toe wall 4036, and the heel wall 4034 define an aperture 4040. The body 4001 does not form any portion of the aperture 4040. Furthermore, the casing heel wall 4034 is heelward of the hosel axis 4009 to increase the effective length of the casing 4030 and aperture 4040.

[0234] The composite faceplate further comprises a sole transition region 4065, formed integral with the face region 4051 and the sole return region 4058, extending from the sole leading edge 4057 of the face region 4051 to the casing front wall 4032. The sole transition region 4065 can further define an aperture offset distance (OD) as defined above, and measured between the sole leading edge 4057 and the casing front wall 4032. The sole transition region 4065 can improve bending and durability of the composite faceplate and casing by spacing the casing away from the strike surface 4052 and face region 4051.

[0235] The composite faceplate 4050 further comprises a peripheral wall 4061, extending around the entirety of the face region 4051, the sole return region 4058, and the sole transition region 4060, and is joined to the frame 4013 of the body 4001. The peripheral wall 4061 comprises a peripheral wall heel section 4062 disposed heelward of casing heel wall 4034 and heelward of the hosel axis 4009. The peripheral wall 4061 further comprises a peripheral wall sole section 4063 disposed between the casing rear wall 4038 and the frame sole 4015, spaced from the casing rear wall 4038 by a sole buffer distance. The sole buffer distance is between 0.05 and 0.25 inch to space the joint of the frame and composite faceplate away from the walls of the casing to improve durability.Docket No. KMC-24-021-D-X1-PCT

[0236] In this embodiment, the casing comprises a Total Length (TL), measured from the absolute toe point to the absolute heel point, parallel to the x-axis 40, that can be between 2.60 to 4.0 inches. For example, the total length TL can range from 2.60 to 3.0 inches, 3.0 to 3.5 inches, or 3.5 to 4.0 inches. In one embodiment, the total length TL is 2.65 inches.

[0237] In another embodiment, a golf club head 4100 comprises a composite faceplate 4150 that is similar to the composite faceplate 4050 described above, but further comprises a crown return region 4165, as shown in FIG. 54. The crown return region 4165 further reinforces a forward portion of the crown 4110 that experience high stress during impact. Specifically, the composite faceplate 4150 comprises a crown return region 4165, formed integral with the face region 4151, the sole return region 4158, and the sole transition region 4160, and includes a crown return crown wall 4166 extending rearwardly of the face region 4151. The crown return region 4165 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region. In this embodiment, the golf club head 4100 lacks a lower hosel socket so that the casing can be longer to increase the flexure and performance of the casing.

[0238] The composite faceplate 4150 further comprises a crown transition region 4167, formed integral with the face region 4151, the sole return region 4158, the sole transition region 4160, and the crown return region 4165, extending from a crown leading edge 4168 of the face region 4151 to the crown return crown wall 4166 of the crown return region 4165. As such, the peripheral wall 4161 extends entirely around the face region 4151, the sole return region 4158, the sole transition region 4160, the crown return region 4165, and the crown transition region 4167, and is joined to the frame 4113 of the body 4101. The crown transition region 4167 is formed by the same high-strength material as the composite faceplate that has a higher yield strength than the frame to further increase durability and performance of the crown region.

[0239] In some embodiments, the crown return region 4165 may comprise turbulators 4172 to decrease the drag of the driver-type golf club head. The turbulators 4172 are formed integral with the composite faceplate 4150 and therefore are formed in a forward portion of the crown. In some embodiments, there can be additional turbulators formed on the body. In someDocket No. KMC-24-021-D-X1-PCT embodiments, the crown return region 4165 of the composite faceplate 4150 comprises at least 2 turbulators 4172.V. Method of forming Impact Response Modulator with High-Strength Material

[0240] Any of the above embodiments of the composite faceplate can be formed through one or more methods, such as forming. In other embodiments, the composite faceplate may be forged into a rough shape and then bent to a final geometry. Still further, the composite faceplate may be casted or formed through additive manufacturing.

[0241] In some embodiments, the faceplate that integrally forms the casing can be manufactured via a multi-stage forging process. FIG. 56 illustrates a process flow diagram of said multi-stage forging process 5000 suitable for forming a monolithic faceplate with an integral casing. Referring to block 5100, a solid block billet of faceplate material is rough forged. The solid block billet can comprise any suitable faceplate material described herein, including C300 steel and T9s+ titanium.

[0242] Referring to block 5200, the solid block billet is initially forged into an intermediate composite faceplate 519. The solid block billet can be heated to a desired forging temperature, and a forging pressure can be applied to shape the malleable billet into the intermediate composite faceplate 519. In some embodiments, the forging temperature can be between 700°C and 1100°C. In some embodiments, the forging pressure can be between 500 tons and 800 tons. The intermediate composite faceplate 519, illustrated in FIG. 57, comprises a strike surface 552, a sole return region 558, and a sole transition region 560 therebetween. The strike surface 552 can be substantially flat such that the bottom surfaces of the strike surface 552, the sole return region 558, and the sole transition region 560 are all substantially coplanar. The desired casing wall geometries for both the front wall 532 and the rear wall 542 can be formed into the sole return region 558 during this initial forging step. As illustrated in FIG. 57, the initial forging step does not form an aperture entirely through the sole return region 558. After the initial forging step, the space between the intermediate composite faceplate slit walls can be occupied by billet material.Docket No. KMC-24-021-D-X1-PCT

[0243] Next, referring to block 5300, the billet material between the front wall 532 and the rear wall 542 is machined away to form an aperture 540. In some embodiments, a one-step process can be used to form by fully machining the aperture 540 through the sole return region 558. In other embodiments, the aperture 540 can be formed through a two-step process comprising an aperture machining step followed by an aperture precision forging step. In such embodiments, the aperture machining step creates a pilot recess that extends only partially through the sole return region 558. The aperture precision forging step can thereafter press through the pilot recess, forming the final, desired aperture geometry by pressing all the way through the sole return region 558.

[0244] Referring to block 5400, the desired strike face geometry can be formed. In some embodiments, as illustrated in FIG. 58, a Variable Face Thickness (VFT) geometry 590 (described in further detail below) can be formed into the strike surface 552. In some embodiments, the VFT geometry 590 can be machined into the strike surface 552. In other embodiments, the VFT geometry 590 can be precision forged into the strike surface 552. In some embodiments, the VFT geometry 502 can be formed into the strike surface 552 via a combination of machining and precision forging. In such cases, a VFT machining step can initially form the general shape of the VFT geometry 502, and subsequently, a VFT precision forging step can clean up any imperfections or machining marks, thereby creating a more precise VFT geometry.

[0245] Similarly, the geometry of the transition component can be formed by machining, precision forging, or a combination thereof. The sole transition region 560 can be formed to a specific desired thickness to balance strike face deflection with durability. In some embodiments, the transition component thickness can be substantially uniform. In other embodiments, the transition component thickness can vary such that a central portion of the sole transition region 560 comprises a greater thickness than the transition component thickness proximate the heel and toe. In such embodiments, the increased thickness near the center of the transition portion 503 can reinforce the casing front wall 532 and improve durability without sacrificing strike face deflection.Docket No. KMC-24-021-D-X1-PCT

[0246] Referring to block 5500, the intermediate composite faceplate 519 is forged into its ultimate configuration via a bending precision forging step. In some embodiments, prior to the bending precision forging step, a die 547 can be placed into the aperture 540 to prevent the aperture 540 from collapsing during bending, as illustrated in FIG. 59. The bending precision forging step can occur at a similar or different forging temperature and forming pressure within the ranges described in relation to block 5200. During the bending precision forging step, the intermediate composite faceplate is bent about the sole transition region 560. The strike surface 552 can be bent upwards relative to the sole return region 558 to match the desired loft angle for the finished faceplate. This bending precision forging step creates a monolithic composite faceplate 550 that integrally forms the casing 530, as illustrated in FIG. 60.

[0247] The multi-stage forging process described above can be especially useful in manufacturing faceplates with integral sole returns forming the casing, but without additional returns such as a crown return, a toe return, or a heel return. This configuration simplifies manufacturing, as only a single bending precision forging step is required to bend the strike surface 552 relative to the sole return region 558. In other embodiments, the multi-stage forging process can be used to manufacture a faceplate integrally forming the entire casing and also including a crown return, sole return, toe return, or any combination thereof. In such embodiments, the multi-stage forging process can include multiple bending precision forging steps to bend the various returns relative to the strike face component.

[0248] In alternative embodiments, the composite faceplate and casing can be manufactured via a multi-stage forming process 6000, as illustrated in the process flow diagram of FIG. 61. The multi-stage forming process differs from the previously described multi-stage forging process in that the process begins with rough forging a sheet material instead of a solid block billet. The forming process facilitated the creation of complex geometries and thin-walled structures. Similar to the solid block billet described above, the sheet material can comprise a suitable faceplate material, including C300 steel and T9s+ titanium.

[0249] As referenced in block 6100, the sheet material is rough forged to redistribute material and selectively increase thickness in designated regions of the sheet. In particular, theDocket No. KMC-24-021-D-X1-PCT sheet material can be heated to a desired rough forging temperature to allow the sheet material to become sufficiently malleable. In some embodiments, the rough forging temperature can be between 700°C and 1100°C. Upon heating, a rough forging pressure can be applied to the sheet material to locally thicken or thin designated regions of the sheet to meet specific structural or functional requirements. In some embodiments, the rough forging pressure can be between 800 tons and 1200 tons.

[0250] Following rough forging, a detailed forging step, as shown in block 6200, is carried out to refine the geometry and surface features of the metal sheet. Similar to the rough forging step, the sheet material can be heated to a desired detailed forging temperature, and a detailed forging pressure can be applied to shape the malleable sheet material. In some embodiments, the rough forging temperature can be between 700°C and 1100°C and the rough forging pressure can be between 800 and 1200 tons. By refining the geometry and surface features, the detailed forging step ensures precise dimensional tolerances and localized thickness variations necessary to optimize the sheet for the subsequent forming process, described in greater detail below.

[0251] Once detail forging is complete, the sheet material is formed into a substantially flat intermediate composite faceplate 619 comprising specific strike face and sole geometries, as referenced in block 6300. For example, the sheet material can undergo any suitable forming process to define a strike surface 652 and a sole return region 658, as illustrated in FIG. 62. More specifically, the forming process configures the sole return region 658 to include the casing comprising a defined front wall 632 and rear wall 642. The forming process additionally defines a sole transition region 660 positioned between the strike surface 652 and the casing front wall 632, thereby separating the strike surface 652 and the casing. Further, the sole transition region 660 functions as a designated bending surface in a subsequent forming process, described in greater detail below. In exemplary embodiments, the forming step does not form an aperture entirely through the sole return region 658. Upon completion of the forming step, the space between the front wall 632 and rear wall 642 of the casing can be occupied by sheet material.

[0252] Similar to the previous forging steps, a forming pressure can be applied to shape the components of the intermediate composite faceplate 619. In some embodiments, the formingDocket No. KMC-24-021-D-X1-PCT pressure can be between 100 and 500 tons. In some embodiments, the forming pressure can be applied by stamping, embossing, or otherwise forming the intermediate composite faceplate 619. In even further embodiments, the components are machined into the intermediate composite faceplate 619.

[0253] Thereafter, the intermediate composite faceplate 619 undergoes a controlled bending process along the sole transition region 660, as shown in block 6400, establishing the intended strike surface 652 and sole return region 658 configurations for final assembly. In particular, the strike surface 652 can be bent upwards relative to the sole return region 658 to match the desired loft angle for the finished faceplate. This controlled bending process creates a monolithic composite faceplate 650 that integrally forms the casing 630, as illustrated in FIG. 63.

[0254] In the final step of the multi-step forming process, an aperture 640 is machined into the casing 630 of the sole return region 658. In some embodiments, the aperture 640 can be fully machined through the sole return region 658. In other embodiments, the aperture 640 can be formed through a two-step process comprising an aperture machining step followed by an aperture precision forging step. In some embodiments, the aperture machining step creates a pilot recess that extends only partially through the sole return component. The aperture precision forging step can thereafter press through the pilot recess and form the remainder of the aperture 640 all the way through the sole return region 658.

[0255] The composite faceplate created with any of the above methods of manufacturing can be attached, fused, or joined to the club head body through various means. In one example, the composite faceplate can be welded to the body. The body has a frame with complementary geometry to the composite faceplate so that the periphery of the composite faceplate is continuously or intermittently welded to the body. Accordingly, the casing remains completely surrounded by high-strength material without any joints / connections located near the walls of the casing. In other embodiments, the composite faceplate can be adhesively, mechanically, removably, or co-casted to club head body. Still further, multiple different joining methods may be used on different sections of the peripheral wall.Docket No. KMC-24-021-D-X1-PCTVI. Laser Peening

[0256] In some embodiments, the surfaces of the composite faceplate are partly or entirely treated with laser peening to improve durability. Laser peening, also referred to as laser shock peening (LSP), is a surface treatment that uses high-intensity laser pulses to induce plastic deformation and compressive residual stress within the crystal structure of a metal material. The residual compressive stress layer experiences lower tensile stress, and thereby enhances the resistance to cracking of the laser peened treated material. Accordingly, the interior and exterior surfaces of the composite faceplate can be laser peened to improve durability. To reduce processing time, the laser peening can be targeted to areas that are more prone to failure. In general, cracks propagate more readily under tensile stress, and therefore in some embodiments the laser peening can be focused to only those areas. For example, this process can be applied to various surfaces of the composite faceplate that experience high tensile stress (stress that is equal to or greater than the yield strength of the material) during impact, thereby increasing their durability. These various composite faceplate surfaces include, but are not limited to, the casing wall surfaces, the exterior surface of the sole transition region, the interior surface of strike face, and the exterior surface of the crown and crown transition region. Laser peening can treat some or all of the surfaces of the composite faceplate that do not experience high tensile stress at impact, such as the exterior surface of the strike face, the interior surface of the sole transition region, and the interior surface of the crown, also can be treated by laser peening. Laser peening can additionally be applied to various interior and exterior surfaces of heel and toe wrap regions. For example, various interior (i.e., surfaces of the lower hosel socket exposed to the interior cavity of the club head, spanning between the socket perimeter, outboard section, and inboard section) and exterior surfaces of a lower hosel socket within the heel wrap region can be treated with laser peening. The various surfaces of the composite faceplate that are treated via laser peening will have crystal structures that have plastic deformation and compressive residual stresses. Laser peening some or all of the surfaces of the composite faceplate not only improves durability but also enables improvements to the location and geometry of the impact responseDocket No. KMC-24-021-D-X1-PCT modulator (IRM), which in turn improves performance (i.e., ball speed, spin rate, launch angle, etc.).

[0257] The laser peening method can comprise the steps of surface preparation, opaque overlay application, transparent overlay application, and laser pulse delivery. The laser peening process begins with prepping the target surface. An opaque overlay, such as a tape or paint, is applied to the surface to help absorb the laser energy during the lasering process. Next, a transparent water overlay is placed over the opaque overlay in order to confine the plasma and dissipate heat that is generated during the laser process. This step helps amplify the shock wave intensity within the area of the laser impact. The high-intensity laser then pulses beams onto the prepared surface. Each pulse vaporizes the opaque overlay, creating plasma that produces a shock wave. The shock wave propagates into the treated material, causing localized plastic deformation, inducing compressive residual stress; and reducing tensile stress. The laser beam is indexed across the surface in a controlled pattern to ensure uniform coverage across the target surface.

[0258] Operational parameters that can affect the final surface treatment imparted by laser peening include maximum power density, maximum laser energy, wavelength, pulse width, frequency, and laser spot size. In laser shock peening, power density refers to the amount of laser energy delivered per unit area during the pulse generating the shock wave. This parameter impacts the generated plasma and the resulting pressure applied to a material’s surface. In some embodiments, the maximum power density can be between 1 GW / cm2and 16 GW / cm2. In other embodiments the maximum power density can be between 1 GW / cm2and 4 GW / cm2, 4 GW / cm2and 7 GW / cm2, 7 GW / cm2and 10 GW / cm2, 10 GW / cm2and 13 GW / cm2, or 13 GW / cm2and 16 GW / cm2. The laser energy directly influences the depth of compressive residual stress in laser peening because it determines the peak pressure of the plasma shock wave. In some embodiments, the maximum laser energy can be between 100 mj and 10 J. In other embodiments, the maximum laser energy can be between 100 mj and 1 J, 1 J and 2 J, 2 J and 3 J, 3 J and 4 J, 4 J and 5 J, 5 J and 6 J, 6 J and 7 J, 7 J and 8 J, 8 J and 9 J, or 9 J and 10 J.Docket No. KMC-24-021-D-X1-PCT

[0259] The laser wavelength determines how well the opaque overlay and the transparent overlay absorb energy from the laser. Efficient absorption ensures rapid plasma generation, which can create the desired pressure shock wave. If the wavelength matches the opaque overlay’s absorption peak, more energy converts into plasma pressure rather than to heat. In some embodiments, the maximum laser wavelength can be between 500 nm and 2000 nm. The maximum laser wavelength can be between 500 nm to 600 nm, 600 nm to 700 nm, 700 nm to 800 nm, 800 nm to 900 nm, 900 nm to 1000 nm, 1000 nm to 1100 nm, 1100 nm to 1200 nm, 1200 nm to 1300 nm, 1300 nm to 1400 nm, 1400 nm to 1500 nm, 1500 nm to 1600 nm, 1600 nm to 1700 nm, 1700 nm to 1800 nm, 1800 nm to 1900 nm, or 1900 nm to 2000 nm. In an exemplary embodiment, the wavelength can be 1064 nm. In another exemplary embodiment, the wavelength can be 532 nm.

[0260] The pulse width controls how long energy from the laser interacts with the material, affecting the shock wave characteristics and the resulting compressive stress layer. In some embodiments, the pulse width is between 8 ns and 20 ns. The process frequency determines how quickly pulses are delivered to the material’s surface which affects the speed and productivity of the process, thermal management, and the consistency of the induced stresses. In some embodiments, the process frequency is between 1 Hz and 500 Hz. The spot size in laser peening is the diameter of the laser beam’s footprint of a single laser pulse. In some embodiments, the spot size is between 0.2 mm and 5 mm.

[0261] The laser peening process can be applied to various surfaces of the composite faceplate to increase the crack resistance of said surface. In some embodiments, at least one of the casing front wall 132 surfaces can be treated, including, but not limited to, the front surface 134, the rear surface 136, or the top surface 138. At least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the total surface area of at least one of the front wall 132 surfaces 134, 136, 138 can be treated with laser peening. In other embodiments, at least one of the casing rear wall 142 surfaces can be treated, including, but not limited to, the front surface 144, the rear surface 146, or the top surface 148. At least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the total surface area of at least one of the rear wall 142Docket No. KMC-24-021-D-X1-PCT surfaces 144, 146, 148 can be treated with laser peening. Various surfaces of the casing heel and toe walls 152, 154 can be treated by laser peening. In some embodiments, at least one of an interior surface of the sole transition region 166 (i.e. the surface of the sole transition region 166 that is exposed to the interior of the club head) and an exterior surface of the sole transition region 166 (i.e. the surface of the sole transition region 166 that is exposed to the exterior of the club head and creates a surface of the sole 112) can be treated by laser peening. At least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the total surface area of the interior and / or exterior surface of the sole transition region 166 can be treated with laser peening. A rear surface, exterior surface, or both surfaces of the strike face 102 can be treated with laser peening. At least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the total surface area of the rear and / or exterior surface of the strike face 102 can be treated with laser peening. In some embodiments, a combination of the above-described surfaces can be laser peened. For example, the interior surface of the sole transition region 166, the casing front wall front surface 134, and the rear surface of the strike face 102 can all be treated by laser peening. Other combinations of surfaces, not explicitly described within, can be treated with laser peening. Laser peening various surfaces of the composite faceplate can be applied to the other composite faceplate embodiments described above, not just to that of embodiment 100.

[0262] In some embodiments, such as that of club head 1100, the composite faceplate 1150 includes a crown return region 1165 with surfaces suitable for laser peening. At least one of an interior surface of the crown return region 1165 (i.e. the surface of the crown return region 1165 that is exposed to the interior of the club head) and an exterior surface of the crown return region 1165 (i.e. the surface of the crown return region 1165 that is exposed to the exterior of the club head and creates a surface of the sole 112) can be treated by laser peening. At least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the total surface area of the interior and / or exterior surface of the crown return region 1165 can be treated with laser peening.Docket No. KMC-24-021-D-X1-PCTInserts

[0263] An insert can be disposed within the aperture which can affect how the IRM responds to impact with a ball. In some embodiments, the insert is formed of a flexible, polymeric material. The insert closes off the aperture to prevent migration of debris into the interior chamber, and can tune performance of the IRM and durability of the club head. The insert is configured to engage surrounding structure of the club head such as the casing walls, thereby securing the insert within the aperture. Overall performance (bending, retraction rate, reactivity to force) of the IRM is affected by the material composition, overall construction (including hybrid materials), and geometry of the insert. The insert and the casing can comprise complementary geometries that provide durability and mechanically interlock or otherwise secure the insert within the casing, even after repeated, significant impacts. FIGS. 74-93 illustrate various embodiments of inserts and casings comprising corresponding geometries.A. L-Shaped, Z-Shaped, and U-Shaped Inserts

[0264] An insert having an L-shaped cross-section is illustrated in FIG. 74. The L-shaped insert 6070 blocks access to the interior cavity, preventing water and debris from entering, while allowing the IRM to deflect as desired. The L-shaped insert further uses complementary geometry to secure itself and provide durability to the IRM. The insert of FIG. 74 can comprise a base 6072 and an insert front wall 6074. The base 6072 can extend along the sole of the club head from the casing front wall 6032 to the casing rear wall 6042 to cover an exterior opening 6096 of the aperture 6040 and seal the interior cavity from the club head exterior. In general, the base 6072 extends approximately from the casing front wall rear surface 6036 to the rear wall front surface 6044. In some embodiments, the base 6072 can be substantially flush with the surrounding sole surface, creating a continuous sole appearance. The L-shaped insert 6070 further comprises a rear extension 6078 extending rearward of the base 6072 (i.e., away from the strike face). The rear extension 6078 can extend rearward of the casing rear wall 6042, engaging a casing recess 6082, and terminating at a rising surface 6083. The casing recess 6082 creates a lap joint thereby providing a bonding surface for the rear extension 6078. The rear extension 6078 is coupled to the casing recess 6082 at the lap joint and flush against the rising surface 6083 and a setting surface 6084. Further, the casing recess 6082 acts as a mechanical stop preventingDocket No. KMC-24-021-D-X1-PCT the insert 6070 from exiting the casing and being pushed into the interior cavity. The casing recess 6082 provides a force against the rear extension that opposes any forces acting against the insert 6070 from the club head exterior. The rear extension and casing recess 6082 thereby secure the insert 6070 within the casing.

[0265] The insert front wall 6074 extends upward from a front end 6086 of the base, towards the interior cavity. The insert front wall 6074 comprises an insert front wall bottom end 6087 integral to a front end 6086 of the base, and an insert front wall top end 6088 opposite the insert front wall bottom end 6087. The insert front wall 6074 can be configured to abut the casing front wall 6032. The insert front wall 6074 can have a shape that is complementary to the casing front wall 6032. In some embodiments, the insert front wall 6074 can be adhesively coupled to the casing front wall 6032. In other embodiments, the insert front wall 6074 can be front loaded to be pressed and expanded as an interference fit with the casing front wall 6032. In some embodiments, the insert front wall 6074 comprises a similar height to the casing front wall 6032 to increase the bonding area between the insert front wall 6074 and the casing front wall 6032. In other embodiments, the insert front wall 6074 can be taller or shorter than the casing front wall 6032. In some embodiments, the insert front wall height can vary along the casing length.

[0266] In the installed configuration illustrated in FIG. 74, the L-shaped insert 6070 only fills a portion of the aperture 6040, creating a gap 6071 between the base 6072, the insert front wall 6074, and the casing rear wall 6042. As illustrated, in some embodiments, the gap 6071 can be open to the interior cavity. The gap 6071 provides space for the insert 6070 to deflect during installation. Once installed, the insert front wall 6074 can engage the casing front wall 6032, mechanically interlocking the insert 6070 within the casing. Further, once fully installed, the gap 6071 permits the insert 6070 to flex with the casing walls, thereby increasing ball speed over a solid insert filling the entire casing.

[0267] The Z-shaped insert illustrated in FIG. 75 is similar to the L-shaped insert 6070 illustrated in FIG. 74, in that the Z-shaped insert 6170 of FIG. 75 comprises a base 6172 configured to seal the exterior opening 6196 of the aperture 6140, a rear extension 6178 configured to engage a casing recess 6182, and an insert front wall 6174 configured to abut andDocket No. KMC-24-021-D-X1-PCT couple to the casing front wall 6132. The Z-shaped insert 6170 in FIG. 75 can further comprise a front flange 6181 extending from the insert front wall top end 6188. The front flange 6181 can extend forward towards the strike face and overlap the front wall top surface 6138. In some embodiments, the front flange 6181 can be adhesively coupled to the front wall top surface 6138. The front flange 6181 acts as a mechanical stop preventing the insert 6170 from being pushed out to the club head exterior. The front wall top surface 6138 exerts a force against the front flange 6181 that opposes any forces acting against the insert 6170 from the interior cavity. The front flange 6181 and casing front wall 6132 thereby secure the insert 6170 within the casing. In some embodiments, the front flange extends along the entire length of the casing front wall. In other embodiments, the front flange 6181 can be localized along a certain portion of the casing length. For example, in some embodiments, the front flange 6181 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 6181 can secure the insert 6170 within the casing without using any unnecessary mass. The Z-shaped insert 6170 only fills a portion of the aperture 6140, creating a gap 6171 between the base 6172, the insert front wall 6174, and the casing rear wall 6142 front surface 6144. The gap 6171 provides space for the insert 6170 to deflect during installation so that the front flange 6181 can fit through both the exterior opening 6196 and the interior opening 6197 (i.e., the portion of the casing that opens to the interior cavity) of the aperture 6140. Once installed, the insert front wall 6174 can engage the casing front wall 6132 and the front flange 6181 can engage the front wall top surface 6138, mechanically interlocking the insert 6170 within the casing.

[0268] FIGS. 76 and 77 illustrate two similar embodiments of U-shaped inserts 6270, 6370 and a casing comprising corresponding geometries. The U-shaped inserts 6270, 6370 of FIG. 76 and 77 are similar to the insert 6070 illustrated in FIG. 74, in that the inserts 6270, 6370 of FIG. 76 and 77 comprise a base 6272, 6372 configured to seal the exterior opening 6296, 6396 of the aperture 6240, 6340, a rear extension 6278, 6378 configured to engage a casing recess 6282, 6382, and an insert front wall 6274, 6374 configured to abut and couple to the casing front wall 6232, 6332. Further, the U-shaped inserts 6270, 6370 in FIGS. 76 and 77 can comprise an insert rear wall 6276, 6376 extending upwards from a rear end 6289, 6389 of the base 6272, 6372,Docket No. KMC-24-021-D-X1-PCT towards the interior cavity. The insert rear wall 6276, 6376 comprises an insert rear wall bottom end 6292, 6392 coupled to a base rear end 6289, 6389, and an insert rear wall top end 6292, 6392 opposite the insert rear wall bottom end 6291, 6391. The insert rear wall 6276, 6376 can be configured to abut the casing rear wall 6242, 6342. The insert rear wall 6276, 6376 can have a shape that is complementary to the casing rear wall 6242, 6342. In some embodiments, the insert rear wall 6276, 6376 can be adhesively coupled to the casing rear wall 6242, 6342. In some embodiments, the insert rear wall 6376 comprises a similar height to the casing rear wall 6342 to increase the bonding area between the insert rear wall 6376 and the casing rear wall 6342, as illustrated in FIG. 77. In other embodiments, the insert rear wall 6276 can be taller or shorter than the casing rear wall 6242, as illustrated in FIG. 76. 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.

[0269] The U-shaped inserts 6270, 6370 include an insert interior cavity 6250, 6350 that forms a gap between the base 6272, 6372, the insert front wall 6274, 6374, and the insert rear wall 6276, 6376. In some embodiments, the insert interior cavity can further be created and bound by heel and toe walls. As illustrated, in some embodiments, the insert interior cavity 6250, 6350 can be open to the interior cavity. The gap provides space for the insert 6270, 6370 to deflect during installation. Once installed, the insert front wall 6274, 6374 can engage the casing front wall 6232, 6332, mechanically interlocking the insert 6270, 6370 within the casing.Further, once fully installed, the insert interior cavity 6250, 6350 permits the insert 6270, 6370 to flex with the casing walls, thereby increasing ball speed over a solid insert fdling the entire casing.

[0270] The casing recess 6282, 6382 provides a bonding surface to which the rear extension 6278, 6378 can be coupled, thereby forming a lap joint. Further, the casing recess 6282, 6382 acts as a mechanical stop preventing the insert from exiting the casing and being pushed into the interior cavity. The casing recess 6282, 6382 provides a force against the rear extension 6278, 6378 that opposes any forces acting against the insert 6270, 6370 from the club head exterior. The rear extension 6278, 6378, and casing recess 6282, 6382 thereby secure the insert 6270,Docket No. KMC-24-021-D-X1-PCT6370 within the casing. The insert 6270 of FIG. 76 has a base surface recessed at a relatively greater distance from the sole, a relatively thinner rear extension 6278, and thicker insert front and rear walls 6274, 6276 when compared to the insert 6370 of FIG. 77. The insert of FIG. 77 illustrates an insert 6370 having a relatively thicker rear extension 6378 and thicker insert front and rear walls 6374, 6376 when compared to the insert 6270 of FIG. 76.

[0271] Another example of a sole having a casing with a U-shaped insert 6470 is shown in FIG. 78. The insert 6470 is similar to the inserts 6270, 6370 illustrated in FIGS. 76 and 77, in that the insert 6470 comprises a base 6472, an insert front wall 6474 configured to couple to the casing front wall 6432, an insert rear wall 6476 configured to couple to the casing rear wall 6442, and a rear extension 6478 configured to engage a casing recess 6482. The insert 6470 of FIG. 78 can further comprise a front extension 6479 configured to engage the casing recess 6482. The front extension 6479 can extend forward of the casing front wall 6432 rear surface and engage a forward region of the casing recess 6482. The casing recess 6482 provides a bonding surface to enable the front extension 6479 to be coupled to in order to create a lap joint between the sole and insert 6470. Further, the casing recess 6482 mechanically fixes the insert 6470 to prevent ingress into the interior cavity. The casing recess 6482 opposes any forces from the club head exterior that would otherwise push the insert 6470 further into the casing. The rear extension 6478, front extension 6479, and casing recess 6482 thereby secure the insert 6470 within the casing.

[0272] The insert 6470 can further comprise a rear flange 6480 extending from the insert rear wall top end 6492. The rear flange 6480 can extend rearward and away from the face and overlap the casing rear wall top surface 6448. In some embodiments, the rear flange 6480 can be adhesively coupled to the casing rear wall top surface 6448. The rear flange 6480 acts as a mechanical stop preventing the insert 6470 from exiting the casing and being pushed out to the club head exterior. The casing rear wall top surface 6448 exerts a force against the rear flange 6480 that opposes any forces acting against the insert 6470 from the interior cavity. The rear flange 6480 and casing rear wall 6442 thereby secure the insert 6470 within the casing. In some embodiments, the rear flange extends along the entire length of the casing rear wall. In other embodiments, the rear flange 6480 can be localized along a certain portion of the casing length.Docket No. KMC-24-021-D-X1-PCTFor example, in some embodiments, the rear flange 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 rear flange can secure the insert within the casing without using any unnecessary mass.

[0273] The insert 6470 includes an insert interior cavity 6450 that forms a gap between the base 6472, the insert front wall 6474, and the insert rear wall 6476. The gap provides space for the insert 6470 to deflect during installation so that the rear flange 6480 can fit through both the exterior opening 6496 and the interior opening 6497 of the aperture 6440. The insert 6470 is mechanically interlocked within the casing when the insert walls 6474, 6476 engage the casing walls 6432, 6442, and the rear flange 6480 engages the casing rear wall top surface 6448. The gap 6471 formed upon this interlocking permits the insert 6470 to flex with the casing walls 6432, 6442, thereby increasing ball speed over a solid insert filling the entire casing.

[0274] Other geometries can be associated with the insert 6570 and the casing, as in FIG. 79. The insert 6570 of FIG. 79 is similar to the insert 6470 illustrated in FIG. 78, regarding having a base 6572 configured to seal an exterior opening 6596 of an aperture 6540; a rear extension 6578 configured to engage a casing recess 6582; an insert front wall 6574 configured to abut and couple to a casing front wall 6532; an insert rear wall 6576 configured to abut and couple to a casing rear wall 6542; and a rear flange 6580 configured to overlap a casing rear wall top surface 6548. As illustrated, the insert 6570 of FIG. 79 is devoid of a front extension. The insert front wall 6574 and the insert rear wall 6576 can be configured to abut the casing front wall 6532 and the casing rear wall 6542, respectively. The insert front and rear walls 6574, 6576 can be shaped complementarily to the casing front and rear walls 6532, 6542, respectively. In some embodiments, the insert front and rear walls 6574, 6576 can be adhesively coupled to the casing front and rear walls 6532, 6542. The insert’s rear flange 6580 can extend rearward and away from the face and overlap the casing rear wall top surface 6548. In some embodiments, the rear flange 6580 can be adhesively coupled to the casing rear wall top surface 6548. The rear flange 6580 acts as a mechanical stop preventing the insert 6570 from exiting the casing and being pushed out to the club head exterior. The casing rear wall top surface 6548 exerts a force against the rear flange 6580 that opposes any forces acting against the insert 6570 from the interiorDocket No. KMC-24-021-D-X1-PCT cavity. The rear flange 6580 and casing rear wall 6542 thereby secure the insert 6570 within the casing. In some embodiments, the rear flange 6580 extends along the entire length of the casing rear wall. In other embodiments, the rear flange can be localized along a certain portion of the casing length.

[0275] As illustrated in FIG. 79, the insert 6570 only fills a portion of the aperture 6540, and a gap 6571 is formed between the base 6572, the insert front wall 6574, and the insert rear wall 6576. In some embodiments, the gap 6571 can be open to the interior cavity. The gap 6571 provides space for the insert 6570 to deflect during installation so that the rear flange 6580 can fit through both the exterior opening 6596 and the interior opening of the aperture 6540. Once installed, the insert walls 6574, 6576 can engage the casing walls 6532, 6542 and the rear flange 6580 can engage the casing rear wall top surface 6548, mechanically interlocking the insert 6570 within the casing. Further, once fully installed, the gap 6571 permits the insert 6570 to flex with the casing walls 6532, 6542, thereby increasing ball speed over a solid insert filling the entire casing.

[0276] FIG. 80 illustrates an embodiment of an insert 6670 further configured to engage the casing walls 6632, 6642. The insert 6670 is substantially similar to the insert 6570 illustrated in FIG. 79, in that the insert comprises a base 6672; an insert front wall 6674 configured to couple to a casing front wall 6632; an insert rear wall 6676 configured to couple to a casing rear wall 6642; a rear extension 6678 configured to engage a casing recess 6582; and a rear flange 6680 configured to overlap a casing rear wall top surface 6648. As illustrated, the insert further comprises a lip 6693 extending soleward from the end of the rear flange 6680. The lip 6693 can engage a casing rear wall rear surface 6646. In some embodiments, the lip 6693 can be adhesively coupled to the casing rear wall rear surface 6646. The lip 6693 acts as a mechanical stop preventing the insert 6670 moving in a front-to-rear direction during use. The casing rear wall rear surface 6646 exerts a force against the lip 6693 that opposes forces acting on the insert 6670 from the rear. This prevents the insert rear wall 6676 from deforming into the casing and disengaging the insert 6670 from the casing.Docket No. KMC-24-021-D-X1-PCT

[0277] Similar to the insert 6570 illustrated in FIGS. 79, a gap 6671 is formed between the base 6672, the insert front wall 6674, and the insert rear wall 6676. The gap 6671 can be sufficiently large to allow the rear flange 6680 and the lip 6693 to fit through both the exterior opening and the interior opening of the aperture. The insert 6670 can mechanically interlock the casing by the front wall 6674 engaging the casing front wall 6632; the insert rear wall 6676 engaging the casing rear wall 6642; the rear flange 6680 engaging casing rear wall top surface 6648; and the lip 6693 engaging the casing rear wall rear surface 6646. Further, once fully installed, the gap 6671 permits the insert 6670 to flex with the casing walls 6632, 6642, thereby increasing ball speed over a solid insert filling the entire casing. Although FIG. 80 illustrates a flange 6680 and lip 6693 extending from the insert rear wall 6676, 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.

[0278] In some embodiments, as illustrated in FIG. 81, the insert 6770 comprises both a front flange 6781 and a rear flange 6780. The front flange 6781 overlaps the casing front wall top surface 6738 and the rear flange 6780 overlaps the casing rear wall top surface 6748. Similar to the insert 6770 illustrated in FIG. 79, a gap 6771 is formed between the base 6772, the insert front wall 6774, and the insert rear wall 6776. The gap 6771 can be sufficiently large to allow both the front flange 6781 and the rear flange 6780 to fit through both the exterior opening and the interior opening of the aperture. The insert 6770 can mechanically interlock the casing by the front wall 6774 engaging the casing front wall 6732; the insert rear wall 6776 engaging the casing rear wall 6742; the rear flange 6780 engaging the casing rear wall top surface 6748; and the front flange 6781 engaging the casing front wall top surface 6738. Further, once fully installed, the gap 6771 permits the insert 6770 to flex with the casing walls 6732, 6742, thereby increasing ball speed over a solid insert filling the entire casing.

[0279] Insert 6870, 6970 having an insert exterior notch 6894, 6994 are illustrated in FIGS.82, 83, and 84. FIGS. The inserts 6870, 6970 are similar to the insert 6470 illustrated in FIG. 78, in that the inserts comprises a base 6872, 6972; an insert front wall 6874, 6974 configured toDocket No. KMC-24-021-D-X1-PCT couple to a casing front wall 6832, 6932; an insert rear wall 6876, 6976 configured to couple to a casing rear wall 6842, 6942; and rear and front extensions 6878, 6879, 6978, 6979 configured to engage a casing recess 6882, 6982. The insert 6870 of FIG. 82 and 83 additionally has a rear flange 6880 configured to overlap a casing rear wall top surface 6848, similar to that of FIG. 78. The insert 6970 of FIG. 84 lacks a rear flange. Although not illustrated in an exemplary embodiment, an insert having an insert exterior notch can additionally have a front flange, similar to that of FIG. 81, and / or a lip, similar to that of FIG. 80. As illustrated, the inserts further comprises an insert notch 6894, 6994 in the base 6872, 6972 of the insert. The insert exterior notch 6894, 6994 increases compressibility of the insert 6870, 6970 in a front-to back direction, which increases sole flexibility while maintaining durability. The geometry of the insert exterior notch 6894, 6994 can be selected to achieve desired launch characteristics. In particular, a width (INw) can be increased to increase ball speed and decrease launch angle. Alternatively, insert notch width (INw) can be decreased to increase launch angle and decreased ball speed. An insert notch height (INH) similarly can also be sized to achieve desired launch characteristics.

[0280] Forward and rearward transitions of the insert exterior notch 6894, 6994 along the base 6872, 6972 of the insert 6870, 6970 define an insert notch width (INw), as shown in FIG. 83. The forward transition is the point along the base 6872, 6972 where the front extension 6879, 6979 ends and the insert notch 6894, 6994 begins. The rearward transition is the point along the base 6872, 6972 where the rear extension 6878, 6978 ends and the insert notch 6894, 6994 begins. The forward and rearward transitions can be linear or arcuate. For arcuate transitions, the insert notch width (INw) is measured from points where the base 6872, 6972 surface diverges from the front and rear extensions 6879, 6979, 6878, 6978. The insert notch height (INH) is measured vertically from a plane coincident with the front and rear extensions 6879, 6979, 6878, 6978 to an apex 6895, 6995 of the insert notch 6894, 6994. In some embodiments, the surface of the insert notch 6894, 6994 may be curved at the apex 6895, 6995, in which case the insert notch height (CNH) is measured to the highest point of the curved apex.

[0281] In an exemplary embodiment, the insert notch width (INw) is 0.100 inches. Alternatively, the insert notch width (INw) is between 0.050 and 0.070 inches, 0.070 and 0.090 inches, 0.090 and 0.110 inches, 0.110 and 0.130 inches, 0.130 and 0.150 inches, 0.150 and 0.170Docket No. KMC-24-021-D-X1-PCT inches, 0.170 and 0.190 inches, 0.190 and 0.210 inches, 0.210 and 0.230 inches, or between 0.230 and 0.250 inches. In an exemplary embodiment, the insert notch height (INH) is 0.075 inches. Alternatively, the insert notch height (INH) is between 0.010 and 0.030 inches, 0.030 and 0.050 inches, 0.050 and 0.070 inches, 0.070 and 0.090 inches, 0.090 and 0.110 inches, 0.110 and 0.130 inches, 0.130 and 0.150 inches, 0.150 and 0.170 inches, 0.170 and 0.190 inches, 0.190 and 0.210 inches, 0.210 and 0.230 inches, or between 0.230 and 0.250 inches.B. Reinforcing Components

[0282] The insert can be constructed with and / or include auxiliary components that strengthen or reinforce the insert. For example, an insert having a varying front wall thickness (IFWT) is illustrated in FIG. 85. FIG. 85 depicts a top-down view of the front wall 7174 of the insert. The insert front wall thickness (IFWT) measures from the insert front wall front surface 7175 to the insert front wall rear surface 7160. The insert front wall thickness (IFWT) can vary across the length of the insert 7170. The illustrated embodiment in FIG. 85 shows a greater front wall thickness (IFWT) in a heelward portion of the insert 7170 when compared to the front wall thickness (IFWT) in a toeward portion of the insert 7170. The front wall thickness (IFWT) can be greater a central portion of the insert 7170 when compared to the front wall thickness (IFWT) of the insert in a heelward and / or toeward portion of the insert 7170. The front wall thickness (IFWT) in a toward portion of the insert 7170 can be greater than the front wall thickness (IFWT) in a heelward portion of the insert 7170. The varying front wall thickness (IFWT) can reinforce specific regions of the IRM along the length of the insert 7170. A front wall with a varying thickness can be applied to any of the inserts described above.

[0283] An insert 7270 having a solid center region 7298 is illustrated in FIGS. 86 and 87. Similar to the inserts 6070, 6170 illustrated in FIGS. 74 and 75, the insert 7270 of FIGS. 86 and 87 comprises a base 7272 configured to seal the exterior opening of the aperture; a rear extension 7278 configured to engage a casing recess 7282; and an insert front wall 7274 configured to abut and couple to a casing front wall 7232. As illustrated, the insert 7270 of FIGS. 86 and 87 can further comprise at least one thickened zone 7267. The thickened zone 7267 can comprise a solid region 7298 spanning the width of the base 7272, from the casing front wall 7232 to the casing rear wall 7242. The thickened zone 7267 can additionally comprise a rear flange 7280Docket No. KMC-24-021-D-X1-PCT extending from the solid region top surface 7299 and rearwardly away from the face to overlap the casing rear wall top surface 7248. Although FIGS. 86 and 87 show a specific embodiment of the insert (L-shaped insert), the thickened zone can be incorporated into any of the insert embodiments described above.

[0284] An insert having reinforcing components, such as ribs 7373, is illustrated in FIG. 88. Similar to the insert 7270 illustrated in FIGS. 86 and 87, the insert 7370 of FIG. 88 comprises a base 7372 configured to seal the exterior opening of the aperture, a rear extension 7378 configured to engage a casing recess, an insert front wall 7374 configured to abut and couple to the casing front wall, and at least one rib 7373. As illustrated, the ribs 7373 may extend only across the base 7372 and do not continue onto the rear extension 7378 of the insert 7370. The ribs 7373 can comprise a region of solid material spanning the width of the base 7372 from the casing front wall to the casing rear wall. Although FIG. 88 shows a specific embodiment of the insert (L-shaped insert), the ribs can be incorporated into any of the insert embodiments described above.C. Solid Insert

[0285] The complimentary geometries of the insert relative to the casing not only prevent debris from entering the interior cavity, but also provide support to the casing walls during impact. Additional support can be added by including a solid construction insert over an insert with a gap. In some embodiments, the insert 7470 has a solid region 7498 in which the insert material continuously fills between the front and rear walls for the casing 7432, 7442. An insert 7470 having a continuous construction is illustrated in FIGS. 89 and 90. The insert 7470 of FIGS. 89 and 90 does not comprise individual walls nor a gap. The insert still comprises a base 7472 configured to seal the exterior opening 7496 of the aperture 7440 and a rear extension 7478 configured to engage a casing recess 7482, however, instead of having an insert front wall and an insert rear wall to form a gap, similar to that of FIGS. 76 and 77, the insert 7470 comprises a solid region 7498 spanning the width of the base 7472, from the casing front wall 7432 to the casing rear wall 7442, similar to that of the thickened zone 7298 illustrated in FIGS. 86 and 87. While the insert 7270 of FIGS. 86 and 87 has a solid construction within a specificDocket No. KMC-24-021-D-X1-PCT region of the insert 7270, the insert 7470 of FIGS. 89 and 90 spans the entire length of the insert 7470.D. Heel and Toe Wraps

[0286] The insert 7770 illustrated in FIGS. 91 and 92 comprise a heel end wall 7763 and a toe end wall (not shown in cross-section). The heel end 7763 and toe end walls can have complementary geometry to the casing toe end (not shown in cross-section) and casing heel end 7752, respectively. Inserts described above and below can comprise at least one of the heel end wall and the toe end wall, even if not shown in cross-section views. Although FIG. 91 and 92, shows a specific embodiment of the insert (L-shaped insert), the heel end and tow end walls can be incorporated into any of the insert embodiments described above.E. Insert Protrusions

[0287] Protrusions on the insert or receiving geometry, relative to the casing walls, can create extra surface area for an adhesive to retain the insert in the casing walls. In some embodiments, the insert front wall 7574 can form one or more protrusions configured to create excess surface area and space for adhering the insert into the casing. In other embodiments, an insert rear wall can form one of more protrusions configured to create excess space and surface area for adhering the insert into the casing. In other embodiments, an insert heel side wall 7563 can form one of more protrusions 7566 configured to create excess space and surface area for adhering the insert into the casing. In other embodiments, an insert toe side wall 7564 can form one of more protrusions 7566 configured to create excess space and surface area for adhering the insert into the casing. In other embodiments, any combination of insert front, rear, heel side, and toe side walls can form one of more protrusions. In an exemplary embodiment, shown in FIG. 92, the heel side wall 7563 and toe side wall 7564 each have a protrusion 7566.

[0288] In an exemplary embodiment, the one or more insert protrusions have a width of 0.050 inches. Alternatively, the one or more insert protrusions have a width between 0.020 and 0.030 inches, 0.030 and 0.040 inches, 0.040 and 0.050 inches, 0.050 and 0.060 inches, 0.060 and 0.070 inches, 0.070 and 0.080 inches, 0.080 and 0.090 inches, or 0.090 and 0.100 inches. In an exemplary embodiment, the one or more insert protrusions have a height (defined generally in aDocket No. KMC-24-021-D-X1-PCT direction from the insert base to the top surfaces of the insert walls) of 0.100 inches. Alternatively, the one or more insert protrusions have a height between 0.050 and 0.060 inches, 0.060 and 0.070 inches, 0.070 and 0.080 inches, 0.080 and 0.090 inches, 0.090 and 0.100 inches, 0.100 and 0.110 inches, 0.110 and 0.120 inches, 0.120 and 0.130 inches, 0.130 and 0.140 inches, or 0.140 and 0.150 inches. In an exemplary embodiment, the one or more insert protrusions have a depth (defined generally in a direction from an insert wall front surface to an exterior surface of a protrusion) of 0.010 inches. Alternatively, the one or more insert protrusions have a depth between 0.0025 and 0.0050 inches, 0.0050 and 0.0075 inches, 0.0075 and 0.0100 inches, 0.0100 and 0.0125 inches, 0.0125 and 0.0150 inches, 0.0150 and 0.0175 inches, 0.0175 and 0.0200 inches, 0.0200 and 0.0225 inches, or 0.0225 and 0.0250 inches.

[0289] In some embodiments, the casing walls can form one or more protrusions configured to secure the insert within the casing. One or more protrusions can extend from the casing rear wall into the aperture. In other embodiments, one or more protrusions can extend from the casing front wall into the aperture. In some embodiments, the one or more protrusions can be integrally cast with the casing walls. In other embodiments, the one or more protrusions can be separately formed and attached to the casing walls. The protrusions can be configured to engage a corresponding recess 7666 formed into the insert 7670. For example, the one or more protrusions formed in the casing front wall can engage one or more recesses formed in the insert front wall front surface 7675, as shown in FIG. 93.

[0290] In an exemplary embodiment, the one or more casing protrusions have a width of 0.050 inches. Alternatively, the one or more casing protrusions have a width between 0.020 and 0.030 inches, 0.030 and 0.040 inches, 0.040 and 0.050 inches, 0.050 and 0.060 inches, 0.060 and 0.070 inches, 0.070 and 0.080 inches, 0.080 and 0.090 inches, or 0.090 and 0.100 inches. In an exemplary embodiment, the one or more casing protrusions have a height (defined generally in a direction from the sole to the top surfaces of the casing walls) of 0.100 inches. Alternatively, the one or more insert protrusions have a height between 0.050 and 0.060 inches, 0.060 and 0.070 inches, 0.070 and 0.080 inches, 0.080 and 0.090 inches, 0.090 and 0.100 inches, 0.100 and 0.110 inches, 0.110 and 0.120 inches, 0.120 and 0.130 inches, 0.130 and 0.140 inches, or 0.140 and 0.150 inches. In an exemplary embodiment, the one or more casing protrusions have a depthDocket No. KMC-24-021-D-X1-PCT(defined generally in a direction from a casing wall surface to an exterior surface of a protrusion) of 0.010 inches. Alternatively, the one or more insert protrusions have a depth between 0.0025 and 0.0050 inches, 0.0050 and 0.0075 inches, 0.0075 and 0.0100 inches, 0.0100 and 0.0125 inches, 0.0125 and 0.0150 inches, 0.0150 and 0.0175 inches, 0.0175 and 0.0200 inches, 0.0200 and 0.0225 inches, or 0.0225 and 0.0250 inches.

[0291] In some embodiments, one or more grooves, recesses, or channels can be formed into one or more of the casing walls and configured to secure the insert within the casing. In such embodiments, one or more of the insert walls can form a corresponding protrusion, extension, or other suitable geometry configured to engage the casing wall groove, recess, or channel.F. Materials

[0292] 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, ethyl ene-vinyl acetate foam, polymer-based foam, any combination of a suitable resin and a suitable reinforcing fiber, or any combination of the above materials.

[0293] 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.

[0294] 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.Docket No. KMC-24-021-D-X1-PCT

[0295] 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.CLAUSES

[0296] Clause 1. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; a lower hosel socket, adjacent the frame sole and the frame heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club head, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including 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 sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; and a peripheral wall, extending around entireties of the faceDocket No. KMC-24-021-D-X1-PCT region, the sole return region, and the sole transition region, continuously j oined to the frame of the body.

[0297] Clause 2. The golf club head of clause 1, wherein the first yield strength of the frame is less than 150 ksi.

[0298] Clause 3. The golf club head of clause 1, wherein the second yield strength of the composite faceplate is greater than 195 ksi.

[0299] Clause 4. The golf club head of clause 1, wherein the frame material is formed from 17-4 stainless steel.

[0300] Clause 5. The golf club head of clause 1 wherein the composite faceplate material is formed from c300 maraging steel.

[0301] Clause 6. The golf club head of clause 1 wherein a ratio of the second yield strength to the first yield strength is at least 1.5.

[0302] Clause 7. The golf club head of clause 1 wherein the peripheral wall further comprises a peripheral wall sole section, disposed between the rear wall of the casing and the frame sole, spaced from the rear wall of the casing by a sole buffer distance of at least 0. 10 inch.

[0303] Clause 8. The golf club head of clause 1, wherein an insert is disposed within the aperture.

[0304] Clause 9. The golf club head of clause 1, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

[0305] Clause 10. The golf club head of clause 1, wherein the peripheral wall further comprises a peripheral heel section, disposed between the lower hosel socket and the heel wall of the casing.

[0306] Clause 11. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of theDocket No. KMC-24-021-D-X1-PCT body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a front wall, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall, the rear wall including 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 sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having an socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region and is continuously joined to the frame of the body.

[0307] Clause 12. The golf club head of clause 11, wherein the peripheral wall further comprises a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance of at least 0.075 inch.Docket No. KMC-24-021-D-X1-PCT

[0308] Clause 13. The golf club head of clause 11, wherein the first yield strength of the frame is less than 150 ksi.

[0309] Clause 14. The golf club head of clause 11, wherein the second yield strength of the composite faceplate is greater than 195 ksi.

[0310] Clause 15. The golf club head of clause 11, wherein the frame material is formed from 17-4 stainless steel.

[0311] Clause 16. The golf club head of clause 11, wherein the composite faceplate material is formed from c300 maraging steel.

[0312] Clause 17. The golf club head of clause 11, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.

[0313] Clause 18. The golf club head of clause 11, wherein an insert is disposed within the aperture.

[0314] Clause 19. The golf club head of clause 11, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

[0315] Clause 20. The golf club head of clause 11, wherein the composite faceplate further comprises: a toe wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region toe side; and a heel wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region heel side.

[0316] Clause 21. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; and a lower hosel socket, adjacent the frame sole and the frameDocket No. KMC-24-021-D-X1-PCT heel end, defining a socket perimeter having a socket perimeter inboard section; and a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe- ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; and a peripheral wall,Docket No. KMC-24-021-D-X1-PCT extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the sole return heel wall and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance; and a peripheral wall sole section disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.

[0317] Clause 22. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; a frame heel end forming a forward portion of the heel end; and a lower hosel socket, adjacent the frame sole and the frame heel end, defining a socket perimeter having a socket perimeter inboard section; and a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe- ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and defining a crown leading edge; and a face region sole side located sole- ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the frontDocket No. KMC-24-021-D-X1-PCT wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; a crown return region, formed integral with the face region, the sole return region, and the sole transition region, including a crown return crown wall extending rearwardly of the face region; a crown transition region, formed integral with the face region, the sole region, the sole transition region, and the crown return region, extending from the crown leading edge of the face region to the crown return crown wall of the crown return region; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, the crown return region, and the crown transition region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the sole return heel wall and the lower hosel socket of the frame, spaced from both the sole return heel wall and the socket perimeter inboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.

[0318] Clause 23. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of theDocket No. KMC-24-021-D-X1-PCT sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the sole return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and aDocket No. KMC-24-021-D-X1-PCT ground surface; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having a socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.

[0319] Clause 24. A golf club head, comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a sole return sole wall extending rearward of the face region; a sole return toe wall, extending upward from the sole return sole wall at a toe side of the sole return region; a sole return heel wall opposite the sole return toe wall and extending upward from the sole return sole wall at a heel side of the sole return region; a sole return front wall extending upward from the sole return sole wall, spaced rearward of the face region, and connecting between the sole return toe wall and the sole return heel wall, the soleDocket No. KMC-24-021-D-X1-PCT return front wall comprising: a front wall forward surface; a front wall rearward surface spaced rearward of the front wall forward surface; a front wall base; and a front wall top surface spaced above the front wall base; wherein the front wall rearward surface defines a rearward surface midpoint, equidistant from the sole return toe wall and the sole return heel wall; a sole return rear wall extending upward from the sole return sole wall, spaced rearward of the sole return front wall, and connecting between the sole return toe wall and the sole return rear wall, the sole return rear wall comprising: a rear wall forward surface spaced from and facing the front wall rearward surface; a rear wall rear surface spaced rearward of the rear wall forward surface; a rear wall base; and a rear wall top surface spaced above the rear wall base; wherein the sole return toe wall, the sole return heel wall, the sole return front wall, and the sole return rear wall border an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region, the sole transition region defining an aperture distance between the sole leading edge of the face region and the rearward surface midpoint, measured in an imaginary vertical plane passing through the rearward surface midpoint and perpendicular to both the strike surface and a ground surface; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, disposed between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having a socket perimeter outboard section; a toe wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region toe side; a heel wrap region, formed integral with the face region, the sole region, the sole transition region, the lower hosel region, and the toe wrap region, extending rearward of the face region heel side; a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, the lower hosel region, the toe wrap region, and the heel wrap region, continuously joined to the frame of the body, the peripheral wall comprising: a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance; and a peripheral wall sole section, disposed between the sole return rear wall and the frame sole, spaced from the sole return rear wall by a sole buffer distance.Docket No. KMC-24-021-D-X1-PCT

[0320] Clause 25: A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength; a composite faceplate coupled to the body to form an interior cavity of the golf club head, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region; a sole return region, formed integral with the face region, comprising: a casing including: a casing front wall; a casing rear wall; a casing toe wall; and a casing heel wall, wherein the casing front wall, the casing rear wall, the casing toe wall, and the casing heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of the sole region; and a peripheral wall, extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body; and an insert including: an insert front wall that engages with the casing front wall; a base that covers an exterior opening of the aperture; and a rear extension that engages with a casing recess.

[0321] Clause 26: The golf club head of clause 25, wherein the frame comprises a frame crown forming a forward portion of the crown, a frame sole forming a forward portion of the sole, a frame toe end forming a forward portion of the toe end, a frame heel end forming a forward portion of the heel end, and a lower hosel socket, adjacent the frame sole and the frame heel end; and a face region comprises a strike surface, a face region toe side located toe-ward of the strike surface and bordering the frame toe end, a face region heel side located heel-ward of the strike surface and bordering the frame heel end, a face region crown side located crown-ward of the strike surface and bordering the frame crown, and a face region sole side located sole-ward of the strike surface and defining a sole leading edge.

[0322] Clause 27: The golf club head of clause 25, wherein the casing front wall includes a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface.

[0323] Clause 28: The golf club head of clause 25, wherein the casing rear wall includes a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface.Docket No. KMC-24-021-D-X1-PCT

[0324] Clause 29: The golf club head of clause 25, wherein the first yield strength of the frame is less than 150 ksi.

[0325] Clause 30: The golf club head of clause 25, wherein the second yield strength of the composite faceplate is greater than 195 ksi.

[0326] Clause 31 : The golf club head of clause 26, wherein the peripheral wall further comprises a peripheral wall sole section, disposed between the rear wall of the casing and the frame sole, spaced from the rear wall of the casing by a sole buffer distance of at least 0.10 inch.

[0327] Clause 32: The golf club head of clause 25, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

[0328] Clause 33: The golf club head of clause 26, wherein at least one of an interior surface of the face region, an exterior surface of the sole transition region, or the casing front wall rear surface comprise plastic deformation or compressive residual stress.

[0329] Clause 34: A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole; a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising:a casing including: a casing front wall; a casing rear wall; a casing toe wall; and a casing heel wall, wherein the casingDocket No. KMC-24-021-D-X1-PCT front wall, the casing rear wall, the casing toe wall, and the casing heel wall define an aperture; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having an socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the sole return region, the sole transition region, and the lower hosel region and is continuously joined to the frame of the body; and an insert including: an insert front wall that engages with the casing front wall; a base that covers an exterior opening of the aperture; and a rear extension that engages with a casing recess.

[0330] Clause 35: The golf club head of clause 34, wherein a sole transition region is formed integral with the face region and the sole return region, and extends from the sole leading edge of the face region to the sole return front wall of the sole region;

[0331] Clause 36: The golf club head of clause 34, wherein the casing front wall includes a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface.

[0332] Clause 37: The golf club head of clause 34, wherein the casing rear wall includes a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface.

[0333] Clause 38: The golf club head of clause 34, wherein the peripheral wall further comprises a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance of at least 0.075 inch.

[0334] Clause 39: The golf club head of clause 34, wherein the first yield strength of the frame is less than 150 ksi.

[0335] Clause 40: The golf club head of clause 34, wherein the second yield strength of the composite faceplate is greater than 195 ksi.Docket No. KMC-24-021-D-X1-PCT

[0336] Clause 41 : The golf club head of clause 34, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.

[0337] Clause 42: The golf club head of clause 34, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

[0338] Clause 43: The golf club head of clause 34, wherein the composite faceplate further comprise a heel wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region heel side.

[0339] Clause 44: The golf club head of clause 35, wherein at least one of an interior surface of the face region, an exterior surface of the sole transition region, the lower hosel socket, or the casing front wall rear surface comprise plastic deformation or compressive residual stress.EXAMPLESA. Example 1 - Ball Flight Performance of Golf Club Head with IRM

[0340] 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 control club head was substantially similar to the exemplary club head but was devoid of an Impact Response Modulator entirely.

[0341] The exemplary and control club heads were used by golfers and shots were studied for various ball flight characteristics, including ball speed, launch angle, and spin rate. 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 1 : Player Test Ball Flight CharacteristicsDocket No. KMC-24-021-D-X1-PCT

[0342] 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.

[0343] 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 by hitting golf balls 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 2: Robotic Testing Ball Flight CharacteristicsDocket No. KMC-24-021-D-X1-PCT

[0344] 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 over the control club head. It was further observed that the ball impacts of the exemplary club head over the control club head created a more piercing ball flight that cut through the air and traveled 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 comparative tests illustrate the general efficacy of the IRM in comparison to a club head without an IRM. In particular, the IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. As such, the exemplary club head exhibited improved ball speed, spin rate, and distance in comparison to the control club head devoid of the IRM. As discussed above, performance can be further improved through high-strength reinforcement of the casing.B. Example 2 - Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0345] The example below explored an Impact Response Modulator with a casing reinforced by high-strength material. The ball flight performance characteristics of an exemplary fairwaywood type club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control fairway -wood type club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a high-strength faceplate and a separately formed high-strengthDocket No. KMC-24-021-D-X1-PCT component located on the sole and forming the Impact Response Modulator and 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. In particular, the high-strength faceplate and high-strength sole casing were formed of C300 steel, comprising a material yield strength of 255 ksi. 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 body, Impact Response Modulator, and casing comprised a 17-4 steel material, comprising a lower material strength of 150 ksi. 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.

[0346] The exemplary and control club heads were used by golfers and shots were studied for various ball flight characteristics, including ball speed, launch angle, and spin rate, 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 3: Ball Flight Characteristics

[0347] As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength IRM component allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. Although the casing was not integrally formed with theDocket No. KMC-24-021-D-X1-PCT faceplate, the example demonstrates that reinforcing the casing with a high-strength component results in measurable performance benefits, including an increased ball speed and reduced spin rate. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the embodiments described herein, which include forged and formed faceplates having sole returns that integrally form the entire casing. Similar ball speed and spin rate improvements are expected for the exemplary club head.C. Example 3 - Durability Performance of Golf Club Head Comprising IRM Spaced Rearwardly from Strike Face

[0348] The durability performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator spaced rearwardly from the strike face were compared to those of a control fairway-wood type club head comprising an Impact Response Modulator positioned directly adjacent to the strike face of the club head. The exemplary club head, as shown in FIGS. 74-76, comprised a forged or formed C300 steel composite faceplate 7050, including a strike surface 7052 and a sole return region 7058 that integrally formed the entire casing 7030 and a formed slot. Specifically, the exemplary casing 7030 included a front wall 7032 positioned proximate the strike surface 7052 and sole transition region 7060 yet separated an offset distance OD therefrom. In turn, the combination of the strike surface 7052, sole transition region 7060, and front wall 7032 comprised a U-shaped sole return region 7058 when viewed in cross-section. The offset distance OD defined between the front wall 7032 and the sole transition region 7060 is 0.090 in. The control club head, as shown in FIGS. 77-79, also included a forged or formed C300 steel composite faceplate 8050 comprising a sole transition region 8060 that integrally formed the entire casing 8030. However, the casing 8030 was devoid of sole return region and a front wall. Instead, the aperture 8040 was positioned directly adjacent to the rear of the strike surface 8052 and sole transition region 8060, thereby defining an offset distance OD of 0.001 in.

[0349] Durability characteristics in the strike surface and club head body, including maximum structural stress values, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The material stress yield limits and results are displayed in Table 4 below.Docket No. KMC-24-021-D-X1-PCTTABLE 4: Durability Characteristics

[0350] As displayed in Table 4 above, both the exemplary and control club heads exhibited equivalent faceplate peak stress values approaching and surpassing the C300 stress yield limit of 255 ksi. However, as shown in FIGS. 74 and 75, the maximum stress region 7090 of the exemplary club head is only present in the casing heel wall 7034. In particular, a maximum stress region defines any region that exhibits stress levels at or above the material stress yield limit. Because the maximum stress region 7090 is only present in the casing heel wall 7034, only a small area of the casing 7030 is subject to high stresses at impact. Further, the specific heel wall maximum stress region 7090 of the exemplary golf club head is subject to stress under compression. Due to the structure and characteristics of C300 steel, the material can withstand repeated high levels of stress under compression without risks of crack propagation and / or buckling over time. On the other hand, the control club head exhibited multiple maximum stress regions 8090 dispersed over large areas of the strike face 8002, casing heel 8034, and toe walls 8036, as shown in FIGS. 77 and 78. Such areas of the integrated component 8050 and casing 8030 are subject to stress under tension at impact. While strong under compressive stresses, C300 steel is weaker and will fracture over time when exposed to repeated high levels of stress under tension over multiple, larger areas of the club head.

[0351] Additionally, Table 4 displays that the exemplary club head exhibited a decrease in club head body peak stress of 27 ksi compared to the control club head. Because the club head body peak stress is less than the body material stress yield, the exemplary club head does not comprise maximum stress regions within the club head body, as shown in FIG. 76. On the other hand, the control club head exhibits multiple maximum stress regions 8090 dispersed over largeDocket No. KMC-24-021-D-X1-PCT areas of the crown 8010 and sole 8012, as shown in FIG. 79. As described above, such areas of the control club head body are subject to stress under tension upon impacting a golf ball and thus, will fracture over time when exposed to repeated high levels of stress under tension. Therefore, this data demonstrates that spacing the casing matters for stress management. An offset distance OD of 0.090 in. from the sole transition region via the sole return region 7058 (as demonstrated by the exemplary club head) results in measurable durability benefits in the composite faceplate and club head body in comparison to a casing with an offset distance OD of only 0.001 in. from the sole transition region.D. Example 4 - Durability Performance of IRM with High-Strength Material Reinforcement

[0352] The durability performance characteristics of an exemplary fairway -wood type 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 that was a lesser strength than the casing of the exemplary fairway-wood type club head. Both the exemplary and control club heads comprised casings with equivalent lengths and depths. The two club heads differed, however, because the exemplary club head comprised a forged C300 steel casing, having a tensile yield strength of 255 ksi, and the control club head comprised a casing formed by the casted 17-4 steel body material, having a tensile yield strength of 150 ksi. Because the exemplary club head casing was formed of the higher strength C300 steel material, the exemplary club head casing additionally incorporated a reduced casing front wall height (FWH) and a decreased offset distance (OD) between the casing front wall and the strike face. In particular, the control club head had a front wall height FWH of 0.300 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.211 inch due to the high-strength material reinforcement. Further, the offset distance OD from the casing front wall to the strike face in the control club head was 0.150 inch, whereas the exemplary club head had a reduced offset distance OD of 0.090 inch. A reduction in front wall and sole return region surface area limits the amount of material that can disperse impact stresses. As such, the reduced front wall height FWH and offset distance OD each allow for increased strike face deflection but also contribute to decreased Impact Response Modulator and golf club head durability.Docket No. KMC-24-021-D-X1-PCT

[0353] Impact Response Modulator and club head body durability were determined via an air cannon test. For this test, golf balls repeatedly impacted the strike face until the golf club head exhibited signs of damage, such as cracks in the strike face, cracks in the sole, or other club head deformities. An increased impact speed was imparted onto the exemplary vs. control clubs. More specifically, the golf ball impacted the strike face at 115 miles per hour for the first 2000 shots, 125 miles per hour for shots 2001-2500, 135 miles per hour for shots 2501-3000, and 145 miles per hour for shots 3001-3500. Despite having a reduced front wall height (FWH) and offset distance (OD), the high-strength C300 steel casing (255 ksi) of the exemplary club head exhibited greater durability performance in comparison to the 17-4 steel body material casing (150 ksi) of the control club head. In particular, the control club head exhibited sole cracks after 2798 impacts. The exemplary club head, however, showed no sign of club head body damage until the 3377th impact. Because of the graduated increased of ball speed mph over a larger number of hits, the exemplary club strike face was impacted with 10 mph of greater speed than the control club strike face (at failure). As proven by the durability testing results, reinforcing the Impact Response Modulator casing with a high-strength material, such as C300 steel, provided the Impact Response Modulator and golf club head with greater structural integrity capable of withstanding repeated high-speed impacts. Although the casing of the exemplary club head featured an inherently less durable design with the reduced front wall height FWH and offset distance OD, the incorporation of the high-strength material allowed for a level of durability capable of resisting degradation and exceeding the performance of the control club head.E. Example 5 - Ball Flight Performance of Composite Faceplate with High-Strength Material Reinforcement

[0354] The ball flight performance characteristics of driver type golf club heads with various casing embodiments were tested via Finite Element Analysis (FEA) simulations. All the club heads were formed of the same body material and comprised similar back weighting. Each casing embodiment, however, either comprised different casing lengths or were formed of a different casing material. The analysis simulated face center (FC) and low center (LC) strikes at 105 mph club head speed. Ball speed, launch angle, and spin rate were collected as comparative results across the various casing embodiments. The following casing designs were studied: (1) a control golf club head comprising a lower hosel socket and an Impact Response Modulator withDocket No. KMC-24-021-D-X1-PCT a casing formed by the 17-4 steel body material; (2) a golf club head comprising a lower hosel socket and a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing; and (3) a golf club head devoid of a lower hosel socket and comprising a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing. Due to the presence of the lower hosel socket, club heads (1) and (2) comprise casings extending only partially across the width of the club head. In particular, the casings of club heads (1) and (2) comprise a casing length, measured from the heel wall to the toe wall, of 2.33 in. Alternatively, club head (3), which lacks a lower hosel socket, comprises a casing extending across the entire width of the club head. In particular, the casing of club head (3) comprises a casing length, measured from the heel wall to the toe wall, of 2.84 in. The ball speed, launch angle, and spin rate results of the face center (FC) and lower center (LC) strikes are displayed in Tables 5 and 6 below, respectively.TABLE 5: Ball Flight Characteristics, Face Center LocationTABLE 6: Ball Flight Characteristics, Low Center LocationDocket No. KMC-24-021-D-X1-PCT

[0355] As illustrated by Tables 5 and 6, golf club (1) exhibited the worst ball flight performance and golf club (3) exhibited the best combined ball and spin rate improvements, on average, for face center and low center strikes. In particular, golf club (1) exhibited the lowest ball speeds and greatest spin rates in comparison to golf clubs (2) and (3) for both the face center and low center strikes. Golf club (2) performed significantly better for face center and low center strikes with an average ball speed increase of 0.245 mph and an average spin rate decrease of 110 rpm in comparison to golf club (1). Lastly, golf club (3) also performed significantly better for face center and lower center strikes with an average ball speed increase of 0.17 mph and an average spin rate decrease of 276 mph in comparison to golf club (1). Despite golf club (3) exhibiting a lower ball speed increase than golf club (2) in comparison to the control golf club (1), golf club (3) exhibited the most significant improvements in spin rate, especially with low center strikes. Low spin is especially desirable for high swing speeds (over 100 mph) that result in greater compression and friction between the golfball and strike surface. By reducing spin rates, golfers with high swing speeds can maximize distance and reduce shot curvature.

[0356] As proven by the ball flight performance testing results, incorporating the Ti-9s+ composite faceplate on a golf club head with a lower hosel socket contributed to an increased ball speed and a reduced spin rate. Further, removing the lower hosel socket and incorporating the C300 steel composite faceplate with a full-length casing collectively provided golf club (3) with greater ball speed and reduced spin rate for both face center (FC) and low center (LC) strikes. Such improvements, especially the reduced spin rate, result in golf club (3) maximizing distance, improving trajectory stability, and reducing the effects of drag during flight.F. Example 6 - Impact Behavior of Golf Club Head with Composite faceplate and Casing

[0357] The impact behavior characteristics of driver type golf club heads with various casing embodiments were tested via Finite Element Analysis (FEA) simulations. All the club heads were formed of the same body material and comprised similar back weighting. Each casing embodiment, however, either comprised different casing lengths or were reinforced with a different casing material. The analysis simulated face center strikes at 105 mph club head speed. Ball speed, launch angle, and spin rate were collected results across the various casingDocket No. KMC-24-021-D-X1-PCT embodiments. More specifically, an FEA dynamic solver computed a maximum displacement (in.) of the casing front wall over the duration of impact. A greater maximum displacement is a direct indicator of greater energy absorption and thus, greater energy transfer back to the golf ball for increased ball speed and reduced spin rate. The impact behavior comparison was made between clubs (1), (2), and (3), as described in Example 5. In particular, club (1) is a control club head comprising a lower hosel socket and Impact Response Modulator with a casing formed by the 17-4 steel body material; club (2) is a club head comprising a lower hosel socket and a Ti-9s+ composite faceplate with an Impact Response Modulator and a casing; and club (3) is a club head devoid of a lower hosel socket and comprising a Ti-9s+ composite faceplate with an Impact Response Modulator and casing. The maximum front wall displacement values for club heads (1), (2), and (3) are displayed in Table 7 below.TABLE 7: Ball Flight Characteristics, Face Center Location

[0358] As illustrated by Table 7, golf club (1) exhibited the worst impact behavior performance. Club (3) exhibited the most dynamic impact behavior. In particular, golf club (1) exhibited the lowest front wall displacement values in comparison to golf clubs (2) and (3). Golf club (2) performed significantly better with a displacement increase of 0.015 in. in comparison to golf club (1). Lastly, golf club (3) performed significantly better with a displacement increase of 0.032 in. in comparison to golf club (1).

[0359] As proven by the ball flight performance testing results and consistent with the ball flight performance results of Example 5, incorporating the Ti-9s+ composite faceplate on a golf club head with a lower hosel socket contributed to an increased casing front wall displacement.Docket No. KMC-24-021-D-X1-PCTThe combination of removing the lower hosel socket and incorporating the Ti-9s+ composite faceplate with a full-length casing collectively provided golf club (3) with a front wall displacement value capable of maximizing energy transfer into the golfball, thereby increasing ball speed, improving trajectory stability, and reducing the effects of drag during flight.G. Example 7 - Modal AnalysisThe vibrational impact response characteristics of an exemplary fairway -wood type club head comprising a composite faceplate with a high-strength Impact Response Modulator and casing were compared to those of a control fairway-wood type club head comprising an Impact Response Modulator with a casing formed by the body material. The body material comprises a lower yield strength than the exemplary club’s composite faceplate material. The exemplary club head, as shown in FIG. 80, comprised a forged C300 steel composite faceplate 9050, having a strike surface 9052 and an Impact Response Modulator with a casing 9030. More specifically, the C300 steel composite faceplate 9050 comprised a material yield strength of 255 ksi. The control club head, as shown in FIGS. 81 and 82, also included an Impact Response Modulator with a casing 10030, however the Impact Response Modulator and casing were not integrally formed with the strike surface. Instead, the Impact Response Modulator with the casing 10030 were formed of the 17-4 steel club head body material, having a lower material yield strength of 150 ksi.

[0360] The vibrational impact response characteristics of the club head were determined via Finite Element Analysis (FEA) simulations. The analysis evaluated the vibrational behavior of the club head in response to undamped, free vibrations in various directions and deformation patterns. More specifically, the analysis focused on peak excitation regions 9095, 10095 of the club head in the dominant vibrational frequency (hereafter referred to as “first mode”) observed at impact. A peak excitation region 9095, 10095 defines any region of the club head that experiences at least 70% peak vibrational excitation in the first mode at impact. The lower the club head volume of these peak excitation regions 9095, 10095, the easier it is to dampen summative modes in the club head that contribute to the increased resonance and duration of post-impact vibrations. Therefore, a smaller peak excitation region volume facilitates the abilityDocket No. KMC-24-021-D-X1-PCT to attenuate vibrations that contribute to undesired sound and impact feel. The peak excitation region volumes (in.3) for the exemplary and control club heads are displayed in Table 8 below.TABLE 7: Ball Flight Characteristics, Face Center LocationAs displayed in Table 8 above, the exemplary club head exhibited a much smaller peak excitation region volume in comparison to the control club head. In particular, the peak excitation region 9095 of the exemplary club head is only present in a small region of the sole 9012 rearward of the casing 9030, as shown in FIG. 80. There were no additional peak excitation regions in the crown, face, or skirt. Due to the localized peak excitation region 9095, the exemplary club head can more easily dampen post-impact vibrations that contribute to undesirable sound and feel. On the other hand, the control club head exhibited multiple peak excitation regions 10095 dispersed over large areas of the crown 10010 and sole 10012, as shown in FIGS. 81-82. Because the peak excitation regions 10095 comprised a much larger volume and covered more components of the club head, the control club head would not be able to attenuate the resonance and duration of post-impact vibrations as the exemplary club would. Therefore, this data demonstrates that integrally forming the strike surface, Impact Response Modulator, and casing from a high-strength material, as demonstrated by the exemplary club head, results in measurable vibrational impact response benefits that contribute to improved feel and sound.H. Example 8 - Robotic PerformanceDocket No. KMC-24-021-D-X1-PCT

[0361] A robot test was conducted to compare the performance of exemplary club head of the present invention to a control club head. The exemplary club head was similar to the golf club head 1200 above in that the exemplary club head had a composite faceplate formed of a higher strength material than the body. The composite faceplate included a sole return region having a casing forming an aperture. The composite faceplate further formed a lower hosel region including a lower hosel socket. The control club head lacked a composite faceplate, but still included a casing formed by the body that was a lower strength material over the high strength material of the composite faceplate of the exemplary club head.

[0362] The robot was programmed to deliver both clubs with the same club head speed and impact dynamics, and repeatedly striking the ball at the same location. The resulting ball speed for each club head was recorded and averaged, and displayed in Table 8 below.TABLE 8: Ball Flight Characteristics, Face Center Location

[0363] As illustrated in Table 8 above, the exemplary club head having a high-strength casing exhibited an increase of 1.1 mph ball speed and a decrease in spin of 517 rpm over the control club head having a lower strength casing. The high-strength material allows for the casing to be thinner while maintaining sufficient durability so that the casing can flex more during impact with the golfball. The increased flexure results in at least 1 mph increase in ball speed and a 517 rpm decrease in spin over a casing with lower yield strength found in the body of the club head. Low spin is especially desirable for high swing speeds (over 100 mph) that result in greater compression and friction between the golfball and strike surface. By reducing spin rates, golfers with high swing speeds can maximize distance and reduce shot curvature.Docket No. KMC-24-021-D-X1-PCTI. Example 9 - Durability Performance of Golf Club Heads with Laser Peened Surface

[0364] The durability performance characteristics of six exemplary driver-wood type club head comprising a strike face with laser peened surfaces were compared to those of a control driver-wood type club head that has no laser peened surfaces. The six exemplary club head, as summarized in the table below, comprised a strike face treated via laser peening on at least the interior or exterior surfaces of the strike face. The power at which the laser was operating at during the laser peening process and the location of peening differs for each exemplary club head. The power the laser is operating at correlates to the depth of the compressive layer, for example, the higher the power results in a deeper compressive layer compared to a lower power level. All six exemplary club heads were treated at the same laser pulse duration of 20 ns. Additionally, all six exemplary club heads received a single layer of treatment.TABLE 9: Club Head Samples

[0365] Total hits to failure to test durability in the strike surface and club head body were captured via an air cannon test. For this test, golfballs repeatedly impacted the strike face untilDocket No. KMC-24-021-D-X1-PCT the golf club head exhibited signs of damage, such as cracks in the strike face, cracks in the sole, or other club head deformities. A ball impact speed was imparted onto the exemplary vs. control clubs. The impact ball speed was 130 miles per hour. The total hits to failure for each club head was recorded and is displayed in Table 10 below. The range of characteristic time (CT) was also collected and displayed below. CT has a direct correlation to ball speed.TABLE 10: Durability Characteristics

[0366] As displayed in Table 10, all six exemplary club heads exhibited greater durability performance compared to the control club head. The control club head failed after just 1961 hits. Exemplary club head 4 as the next to fail after 3145 hits, 1184 more hits than the control club. Exemplary club head 3 exhibited the greatest resistance to failure and withstood 4000 hits, about 104% more hits than the control club head. The exemplary club heads that were laser peened on the interior surface of the strike face, exemplary club heads 1, 5, and 6, withstood 3877, 3776. And 3875 hits, respectively. Laser peening the interior surface showed similar durability advantages to that of exemplary club head 3, which was laser peened on both strike face surfaces.Docket No. KMC-24-021-D-X1-PCT

[0367] Additionally, as displayed in Table 10 above, all the exemplary club heads and the control club head exhibited similar CT values, all ranging between 244 and 253. Since the CT values of the exemplary club heads resulted in similar CT values as the control club leads to the hypothesis that ball speed would be maintained.

[0368] Although the control club head and the exemplary club heads did not comprise composite faceplates that comprise and IRM, the example demonstrates that laser peening club head surfaces, especially those under tensile stress, such as the interior surface of the strike face at impact, results in measurable durability improvements. Additional physical testing (i.e., player testing, robotic testing, and air cannon testing) will be conducted on prototypes corresponding to the embodiments described herein, which include composite faceplates having sole returns that integrally form the entire casing. Laser peening will be used to treat additional surfaces of the composite faceplate, such as the surfaces of various casing walls and various surfaces of the sole transition region. Similar durability performance is expected for the exemplary club heads.J. Example 10 - Durability Performance of Golf Club Heads with Laser Peened Surfaces

[0369] A durability test is currently being conducted to evaluate the effects of laser peening surfaces of composite faceplates, according to aspects of the present disclosure, that experience tensile stress. As shown in Example 9 above, laser peening at least one of the exterior or interior surface of the strike face significantly improved durability with minimal or no significant change to CT value. Although peening either interior or exterior surfaces improved durability, interior surfaces that were peened showed the best results. The exemplary peened faceplates of Example 9 did not comprise sole returns or IRMs and instead were strike face inserts only forming a portion of the strike face and front of the club head. However, based off the results of Example 9, it is expected that laser peening other surfaces of the composite faceplates, especially surfaces that are in tensile stress, will result in significant improvements to durability.

[0370] Accordingly, the durability test currently being conducted is evaluating three embodiments of composite faceplates having at least one peened surface. In one embodiment, the composite faceplate has a sole transition exterior surface that is laser peened. The soleDocket No. KMC-24-021-D-X1-PCT transition exterior surface experiences tensile stress during impact with a golfball, and as such, is expected to benefit from laser peening to increase the durability of the club head. The second embodiment is similar to the first embodiment except has a composite faceplate with a crown return, wherein a crown transition exterior surface is laser peened. The crown transition exterior surface experiences tensile stress during impact with a golf ball, and as such, is expected to benefit from laser peening to increase the durability of the club head. The third embodiment has an IRM with a rear surface front wall that is laser peened. The front wall experiences tensile stress during impact with a golfball, and as such, is expected to benefit from laser peening to increase the durability of the club head. These embodiments of laser peened composite faceplates are expected to exhibit significant increases in durability, as indicated by the results of Example 9, because each of these areas are dominant modes of failures in the composite faceplates. The three embodiments of composite faceplates having at least one peened surfaces are expected to withstand at least 2500 hits, compared to less than 2000 hits for an untreated clubhead. Other embodiments that could be tested in the future may have different combinations of peened surfaces to achieve desired durability. Furthermore, other embodiments can have other surfaces peened that may either be in tensile stress or compressive stress.

[0371] These three exemplary embodiments currently being tested are expected to show an improvement in durability over similar club heads without laser peening. However, these embodiments may not show as high of an improvement as the embodiments from example 9 due to the decrease in area of the laser peening. Peening the large surface of the interior surface of the strike face will increase durability more so than a smaller surface area. Nonetheless, it is still expected that the three exemplary embodiments of the present example will still show significant improvements to durability while being cheaper to manufacture due to the decrease in surface area and less time required to peen the surfaces.Docket No. KMC-24-021-D-X1-PCTK. Example 11 - L-Shaped vs Solid Inserts

[0372] A robot test was conducted to compare the performance of an exemplary club head of the present disclosure to a control club head. The exemplary club head comprises a club head body with an IRM and strike face formed of a higher strength material than the body. The IRM comprises a casing forming an aperture. An L-shaped insert, as described above, is disposed within the aperture. The control club head has the same body construction as the exemplary club head, but includes a solid insert disposed within the aperture.

[0373] The robot was programmed to deliver both clubs with the same club head speed and impact dynamics, and repeatedly striking the ball at the same location. The resulting ball speed for each club head was recorded and averaged, and displayed in Table 11 below.TABLE 1 1 : Ball Flight Characteristics, Face Center Location

[0374] As illustrated in Table 11 above, the exemplary club head having an L-shaped insert exhibited an increase of 1.7 mph ball speed and a decrease in spin of 531 rpm over the control club head having a solid insert. The L-shaped insert allows for the IRM to flex more during impact with the golfball. The increased flexure results in at least 1.7 mph increase in ball speed and a 531 rpm decrease in spin over a club head with a solid insert. Low spin is especially desirable for high swing speeds (over 100 mph) that result in greater compression and friction between the golfball and strike surface. By reducing spin rates, golfers with high swing speeds can maximize distance and reduce shot curvature.

Claims

Docket No. KMC-24-021-D-X1-PCTCLAIMS1. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength; a composite faceplate coupled to the body to form an interior cavity of the golf club head, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region; a sole return region, formed integral with the face region, comprising: a casing including: a casing front wall; a casing rear wall; a casing toe wall; and a casing heel wall, wherein the casing front wall, the casing rear wall, the casing toe wall, and the casing heel wall define an aperture; a sole transition region, formed integral with the face region and the sole return region, extending from the sole leading edge of the face region to the sole return front wall of theDocket No. KMC-24-021-D-X1-PCT sole region; and a peripheral wall, extending around entireties of the face region, the sole return region, and the sole transition region, continuously joined to the frame of the body; and an insert including: an insert front wall that engages with the casing front wall; a base that covers an exterior opening of the aperture; and a rear extension that engages with a casing recess.

2. The golf club head of claim 1, wherein the frame comprises a frame crown forming a forward portion of the crown, a frame sole forming a forward portion of the sole, a frame toe end forming a forward portion of the toe end, a frame heel end forming a forward portion of the heel end, and a lower hosel socket, adjacent the frame sole and the frame heel end; and a face region comprises a strike surface, a face region toe side located toe-ward of the strike surface and bordering the frame toe end, a face region heel side located heel-ward of the strike surface and bordering the frame heel end, a face region crown side located crown-ward of the strike surface and bordering the frame crown, and a face region sole side located sole-ward of the strike surface and defining a sole leading edge.

3. The golf club head of claim 1, wherein the casing front wall includes a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface.

4. The golf club head of claim 1, wherein the casing rear wall includes a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface.

5. The golf club head of claim 1, wherein the first yield strength of the frame is less than 150 ksi.Docket No. KMC-24-021-D-X1-PCT6. The golf club head of claim 1, wherein the second yield strength of the composite faceplate is greater than 195 ksi.

7. The golf club head of claim 2, wherein the peripheral wall further comprises a peripheral wall sole section, disposed between the rear wall of the casing and the frame sole, spaced from the rear wall of the casing by a sole buffer distance of at least 0.10 inch.

8. The golf club head of claim 1, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

9. The golf club head of claim 2, wherein at least one of an interior surface of the face region, an exterior surface of the sole transition region, or the casing front wall rear surface comprise plastic deformation or compressive residual stress.

10. A golf club head comprising: a body comprising: a crown; a sole opposite the crown; a toe end; a heel end opposite the toe end; a rear end; a frame forming a front of the body and formed of a frame material having a first yield strength, the frame comprising: a frame crown forming a forward portion of the crown; a frame sole forming a forward portion of the sole;Docket No. KMC-24-021-D-X1-PCT a frame toe end forming a forward portion of the toe end; and a frame heel end forming a forward portion of the heel end; a composite faceplate coupled to the body to form an interior cavity of the golf club, the composite faceplate formed of a composite faceplate material having a second yield strength greater than the first yield strength of the frame material, the composite faceplate comprising: a face region, comprising; a strike surface; a face region toe side located toe-ward of the strike surface and bordering the frame toe end; a face region heel side located heel-ward of the strike surface and bordering the frame heel end; a face region crown side located crown-ward of the strike surface and bordering the frame crown; and a face region sole side located sole-ward of the strike surface and defining a sole leading edge; a sole return region, formed integral with the face region, comprising: a casing including: a casing front wall; a casing rear wall; a casing toe wall; and a casing heel wall, wherein the casing front wall, the casing rear wall, the casing toe wall, and the casing heel wall define an aperture; a lower hosel region, formed integral with the face region, the sole return region, and the sole transition region, extending between the face region heel side and the sole return sole wall of the sole return region, the lower hosel region including a lower hosel socket defining a socket perimeter having an socket perimeter outboard section; and a peripheral wall, extending around entireties of the face region, the soleDocket No. KMC-24-021-D-X1-PCT return region, the sole transition region, and the lower hosel region and is continuously joined to the frame of the body; and an insert including: an insert front wall that engages with the casing front wall; a base that covers an exterior opening of the aperture; and a rear extension that engages with a casing recess.

11. The golf club head of claim 10, wherein a sole transition region is formed integral with the face region and the sole return region, and extends from the sole leading edge of the face region to the sole return front wall of the sole region;12. The golf club head of claim 10, wherein the casing front wall includes a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface.

13. The golf club head of claim 10, wherein the casing rear wall includes a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface.

14. The golf club head of claim 10, wherein the peripheral wall further comprises a peripheral wall heel section, disposed between the frame heel end and the lower hosel socket of the lower hosel region, spaced from the socket perimeter outboard section by a heel buffer distance of at least 0.075 inch.

15. The golf club head of claim 10, wherein the first yield strength of the frame is less than 150 ksi.

16. The golf club head of claim 10, wherein the second yield strength of the composite faceplate is greater than 195 ksi.Docket No. KMC-24-021-D-X1-PCT17. The golf club head of claim 10, wherein a ratio of the second yield strength to the first yield strength is at least 1.5.

18. The golf club head of claim 10, wherein the front wall of the casing is offset from the sole leading edge by a distance of at least 0.25 inch.

19. The golf club head of claim 10, wherein the composite faceplate further comprises a heel wrap region, formed integral with the face region, the sole return region, the sole transition region, and the lower hosel region, extending rearward of the face region heel side.

20. The golf club head of claim 11, wherein at least one of an interior surface of the face region, an exterior surface of the sole transition region, the lower hosel socket, or the casing front wall rear surface comprise plastic deformation or compressive residual stress.

Images