GOLF CLUB HEAD WITH UNDERCUT AND INSERT

TECHNICAL FIELD

This disclosure generally relates to an iron-type golf club head with a back cavity and a back cavity insert.

BACKGROUND

It is common to affix inserts to the rear surface of an iron-type golf club head strikeface. Typical inserts affixed to the iron golf club head strikeface rear surface have continuous hard plastic or metallic covers comprising a single piece. When the golf club strikes a golf ball, the strikeface flexure also attempts to move the insert rearward and to flex the insert affixed to the strikeface rear surface. Further, the designer may desire to thin the iron-type golf club head strikeface to both move more mass to the perimeter and also allow greater strikeface flexibility. In this iron-type golf club head design (having a thinner strikeface), a back cavity insert attached to the strikeface rear surface may have a greater effect on strikeface flexion. A single-piece hard plastic or metallic insert cover is put into tension as the insert flexes rearwards, which inhibits rearward flexure of the insert, thereby reducing the energy returned to, ball and travel distance of the golf ball. Further, iron-type golf club heads with thin faces may have undesirable vibrations in the top rail. Consequently,, there is a need in the art for a back cavity insert having improved flexibility while damping vibrations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front view of an iron-type golf club head.

FIG. 2 illustrates a top view of the golf iron-type club head of FIG. 1.

FIG. 3 illustrates a bottom view of the golf iron-type club head of FIG. 1.

FIG. 4 illustrates a rear view of the golf iron-type club head of FIG. 1 without an insert.

FIG. 5A illustrates a cross-sectional view of an insert embodiment.

FIG. 5B illustrates a cross-sectional view of an insert embodiment.

FIG. 5C illustrates a cross-sectional view of an insert embodiment.

FIG. 6 illustrates an exploded view of an insert embodiment.

FIG. 7 illustrates a rear view of an embodiment of an insert received in a back cavity of the golf iron-type club head of FIG. 1.

FIG. 8 illustrates a rear view of FIG. 7.

FIG. 9 illustrates a cross-section the golf club and insert of FIG. 7.

FIG. 10 illustrates a rear view of another embodiment of an insert received in a back cavity of an iron-type golf club head.

FIG. 11 illustrates a rear view the insert of FIG. 10.

FIG. 12 illustrates a cross-section of the golf club and FIG. 10 insert.

FIG. 13 illustrates an exploded view of the golf club and FIG. 10 insert.

FIGS. 14A-14E are charts of Example 1 comparative test results.

FIG. 15 illustrates a rear view of another embodiment of a golf club head with a back cavity insert.

FIG. 16 illustrates a perspective view of the back cavity insert of FIG. 15.

FIG. 17 illustrates a rear view of the back cavity insert of FIG. 15.

FIG. 18 illustrates a vibrational mode analysis of a golf club head.

FIG. 19 illustrates a rear view of another embodiment of a back cavity insert.

FIG. 20 illustrates a cross-sectional view of the back cavity insert of FIG. 19 attached a golf club head.

FIG. 21 illustrates a top view of the back cavity insert FIG. 19.

FIG. 22 illustrates a front view of an elastomeric layer of the back cavity insert o FIG. 19.

FIG. 23 illustrates a rear view another embodiment of a back cavity insert.

FIG. 24 illustrates a cross-sectional view of the back cavity insert of FIG. 23 attached to a golf club head.

FIG. 25 illustrates a top, rear, exploded view of the back cavity insert of FIG. 23.

FIG. 26 illustrates a top, front, exploded view of a back cavity insert of FIG. 23.

FIG. 27 illustrates a rear view of the damping member of the back cavity insert of FIG. 23.

FIG. 28 illustrates a front view of the damping member of FIG. 27.

FIG. 29 illustrates a rear view of the damping member of FIG. 27.

FIG. 30 illustrates a rear view of the back cavity insert of FIG. 23 assembled in a golf club head.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

DETAILED DESCRIPTION

Back cavity inserts for iron-type golf club heads are described herein that permit a desired amount of strikeface flexure, while damping undesirable vibrations of the club head. The iron-type golf club head rear perimeter and the strikeface rear surface cooperate to define a back cavity. The rear perimeter can comprise any edge or percentage of the back cavity perimeter. An insert may be placed into the back cavity such that the insert covers at least 60 percent to 100 percent of the strikeface rear surface area. The insert, when attached to the iron-type golf club head strikeface rear surface, interacts with strikeface as it flexes after impact with a golf ball. The back cavity insert comprises multiple layers that can be divided into discrete sections form expansion and flexing gaps. The insert reduces the amount of energy lost when striking a golf ball, thereby increasing energy returned to the golf ball and promoting desirable flight characteristics such as lower ball spin rate, higher launch angle, and higher ball speed that can increase shot distance for each golf stroke. Additionally or alternatively, the back cavity inserts disclosed herein damp rear perimeter areas that would otherwise response with higher amplitude vibrations, while also reducing the amplitude in rear perimeter vibrations associated with undesirable sound. that would otherwise respond with.

I. Definitions
A. General Terminology

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.

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.

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

B. Coordinate System

A coordinate system may be defined as an x-axis 1050 defined in a direction parallel to a ground plane 1000. The iron-type golf club head 100 defines a ground plane 1000 that is tangent to the sole 102 when the iron-type golf club head 100 is at an address position. The x-axis 1050 passes through the strikeface geometric center 140 from the heel portion 108 to the toe portion 106. A y-axis 1060 is defined as passing through the strikeface geometric center 140, perpendicular to the x-axis 1050 from the sole 102 towards the top portion 104. A z-axis 1070 is defined perpendicular to both the x-axis 1050 and the y-axis 1060, passing through the strikeface geometric center 140 from a strikeface front surface 117 rearward through the strikeface rear surface 118. The strikeface front surface 117 is planar.

II. Iron-Type Golf Club Head Structure

The iron-type golf club head body 101 comprises a top portion 104, a sole or sole portion 102, a heel portion 108, a toe portion 106, a front portion 112 further comprising a strikeface 110, and a back portion 114 opposite the front portion 112. The iron-type golf club head body 101 further comprises a rear perimeter extension 121, extending rearward of a strikeface perimeter 142. The rear perimeter extension 121 is offset rearwardly from the strikeface rear surface 118. The rear perimeter extension top portion 125 extends rearwardly from the strikeface perimeter 142 adjacent the top portion 104. The rear perimeter extension sole portion 127 extends rearwardly from the strikeface perimeter 142 adjacent to the sole portion 102. The rear perimeter extension heel portion 129 extends rearwardly from the strikeface perimeter 142 adjacent to the heel portion 108. The rear perimeter extension toe portion 131 extends rearwardly from the strikeface perimeter 142 adjacent to the toe portion 106. The rear perimeter extension 121 and strikeface rear surface 118 define back cavity 116. In many embodiments, an undercut recess 133 circumscribes the back cavity 116, thereby forming a continuous or 360-degree undercut. The undercut recess 133 is defined by the rear perimeter extension 121, the strikeface rear surface 118, and a surface connecting the strikeface rear surface 118 and the rear perimeter extension 121. Any imaginary line perpendicular to the strikeface rear surface 1148 within undercut recess 133 will intersect an rear perimeter extension inner surface 123. In other embodiments, the undercut recess 133 encompasses only a portion of the back cavity 116.

Referring to FIGS. 1-4, the iron-type golf club head 100 can comprise an iron-type golf club head body 101 with a back cavity 116 and an insert 200 received within the back cavity 116. The golf club head body 101 can comprise a front portion 112 and a back portion 114, a strikeface 110 comprising a strikeface front surface 117 located at the front portion 112, and a strikeface rear surface 118 located opposite the strikeface front surface 117 towards the back portion 114. The strikeface 110 can further comprise a strikeface geometric center 140, a strikeface perimeter 142. The golf club head body 101 comprises a rear perimeter extension 121 extending rearward from the strikeface perimeter 142. The strikeface 110 comprises a strikeface thickness 144 measured from the strikeface front surface 117 to the strikeface rear surface 118 in a direction perpendicular to the strikeface front surface 117. The golf club head body 101 back cavity 116 is defined by a rear perimeter extension inner surface 123 and the strikeface rear surface 118.

Still referring to FIGS. 1-4B, the golf club head body 101 can further comprise a top rail 105 where the top rail 105 is a rear perimeter extension 121 portion. The top rail 105 further comprises an arcuate top rail top portion 150 and a top rail rear wall 152 extending toward the sole 102 to form a top rail wall 154. The top rail 105 further can comprise a top rail outer surface 156 and a top rail inner surface 158 such that a top rail rear wall inner surface 159 is substantially parallel to and offset rearwardly from the strikeface rear surface 118. The top portion 104 further comprises a top portion rear wall perimeter 160 connecting the top portion inner surface 162 to the rear extension top portion outer surface 164. The iron-type golf club head body 101 can comprise a bottom portion 107 having a sole 102 and a back portion 114 that is integrally formed with the sole 102. The back portion 114 can extend upward toward the top portion 104. The sole 102 can comprise a sole inner surface 113 and a sole outer surface 115. The back portion 114 can comprise a back portion outer surface 120 and a back portion inner surface 126. The back portion 114 further comprises a back portion perimeter 124 connecting the back portion inner surface 126 to the back portion outer surface 120. The back portion inner surface 122 can be offset rearwardly from the strikeface rear surface 118.

The iron-type golf club head 100 comprises a face height 122 a top rail front edge 146 and a sole leading edge 148. The top rail front edge 146 is the transition from the planar strikeface front surface 117 to the arcuate top rail portion 150. The sole leading edge 148 is the sole 102 forwardmost portion, and is the transition from the planar strikeface front surface 117 to the sole 102. The face height 122 is measured parallel to the loft plane 1010 tangent to the strikeface 110 at the strikeface geometric center 140, between the top rail front edge 146 and the sole leading edge 148. The face height 122 can range from 1.4 inches to 2.2 inches. In other embodiments, the face height 122 can range from 1.4 inches to 1.8 inches or 1.8 inches to 2.2 inches. In other embodiments still, the face height 122 can range from 1.4 inches to 1.9 inches, 1.5 inches to 2.0 inches, 1.6 inches to 2.1 inches, or 1.7 inches to 2.2 inches. For example, the face height 122 can be 1.4 inches, 1.5 inches, 1.6 inches, 1.7 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, or 2.2 inch inches.

The strikeface 110 comprises a strikeface thickness 144 measured from the strikeface front surface 117 to the strikeface rear surface 118 in a direction perpendicular to the loft plane 1010 or the strikeface front surface 117. The multi-component insert 200 allows the strikeface 110 to be thinner compared to an iron-type golf club head without it. The insert 200 further reinforces the strikeface 110 and allows the strikeface thickness 119 to be reduced. In many embodiments, the strikeface 110 comprises a variable face thickness with a maximum thickness positioned near the strikeface geometric center 140 and a minimum thickness positioned near the strikeface perimeter 142. The strikeface thickness 119 can range from 0.065 to 0.14 inch. In other embodiments, the strikeface thickness 119 can range from 0.065 to 0.12 inch, 0.07 to 0.13 inch, or 0.075 to 0.14 inch. For example, the strikeface thickness 119 can be 0.065, 0.07, 0.075, 0.08, 0.085, 0.09, 0.10, 0.11, 0.12, 0.13, or 0.14 inch. For example, the strikeface thickness 119 near the geometric strikeface center 140 can range from 0.10 to 0.13 inch, and the strikeface thickness 119 near the strikeface perimeter 142 can range from 0.065 to 0.095 inch. An iron-type club head 100 without the multi-component insert can require a strikeface thickness above 0.14 inch and a strikeface perimeter thickness above 0.10 inch to posses sufficient durability and proper flexural response. When the strikeface thickness is in the lower portions of this range, the strikeface will flex more under impact. A back cavity insert adhered to the strikeface rear surface (as discussed herein below) will affect the strikeface flexure for any strikeface thickness, but more so as the strikeface thickness decreases.

The iron-type golf club 100 aspects described herein may be applied to one or more golf clubs within a set of irons. In some embodiments, the set of irons comprises irons having varying clubhead size, shaft length, lie angle, loft angle, head weight, and/or other parameters. Each clubhead in the set of irons can be numbered according to the convention, with numbers ranging from 1 to 10. Most commonly, a set is numbered from 2 to 9, wedge, and utility clubs. Furthermore, the set of irons can comprise one or more wedges, which have a loft angle higher than the numbered irons.

A loft angle 1020 is defined as the angle between the ground plane 1000 and the loft plane 1010. In many embodiments, the iron-type golf club head 100 comprises a loft angle 1020 less than approximately 64 degrees, less than approximately 63 degrees less than approximately, less than approximately 62 degrees, less than approximately 61 degrees, less than approximately 60 degrees, less than approximately 59 degrees, less than approximately 58 degrees, less than approximately 57 degrees, less than approximately 57 degrees, less than approximately 56 degrees, less than approximately 55 degrees, less than approximately 54 degrees, less than approximately 53 degrees, less than approximately 52 degrees, less than approximately 51 degrees, less than approximately 50 degrees, less than approximately 49 degrees, less than approximately 48 degrees, less than approximately 47 degrees, less than approximately 46 degrees, less than approximately 45 degrees, less than approximately 44 degrees, less than approximately 43 degrees, less than approximately 42 degrees, less than approximately 41 degrees, less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, less than approximately 30 degrees, less than approximately 29 degrees, less than approximately 28 degrees, less than approximately 27 degrees, less than approximately 26 degrees, less than approximately 25 degrees, less than approximately 24 degrees, less than approximately 23 degrees, less than approximately 22 degrees, less than approximately 21 degrees, less than approximately 20 degrees, less than approximately 19 degrees or less than approximately 18 degrees.

The iron-type golf club head 100 volume described herein comprises a volume ranging between 1.9 cubic inches and 2.7 cubic inches. In some embodiments, the iron-type golf club head total volume can be between 1.9 cubic inches and 2.4 cubic inches, 2.0 cubic inches and 2.5 cubic inches, 2.1 cubic inches and 2.6 cubic inches, 2.2 cubic inches and 2.7 cubic inches, 2.3 cubic inches, and 2.7 cubic inches, or 2.4 cubic inches and 2.7 cubic inches. In other embodiments, the iron-type golf club head 100 total volume can be 1.9 cubic inches, 2.0 cubic inches, 2.1 cubic inches, 2.2 cubic inches, 2.3 cubic inches, 2.4 cubic inches, 2.5 cubic inches, 2.6 cubic inches, or 2.7 cubic inches.

The iron-type golf club head 100 mass described herein comprises a total mass ranging between 200 grams and 300 grams inclusive. In some embodiments, the iron-type golf club head 100 can comprise a total mass of between 200 grams and 210 grams, 210 grams and 220 grams, 220 grams and 230 grams, 230 grams and 240 grams, 240 grams and 250 grams, 250 grams, and 260 grams, 255 grams and 260 grams, 260 grams to 270 grams, 265 grams to 275 grams, 270 grams and 280 grams, 275 grams, and 280 grams, or 250 grams and 270 grams. In other embodiments, the total mass can be 200 grams, 205 grams, 210 grams, 220 grams, 225 grams, 230 grams, 235 grams, 240 grams, 245 grams, 250 grams, 255 grams, 260 grams, 265 grams, 270 grams, 275 grams, 280 grams, 285 grams, 290 grams, 295 grams, or 300 grams.

Referring to FIGS. 1-4, the iron-type club head 100 includes a strikeface 110 for contacting a golf ball. The iron-type golf club head body 101 further includes a hosel 130 for receiving a shaft (not shown). The multi-material iron-type golf club head body 101 described herein can be constructed from any material used to construct a conventional iron-type golf club head. For example, the golf club head body 101 can be constructed from any one or combination of the following: 8620 alloy steel, S25C steel, carbon steel, maraging steel, 17-4 stainless steel, 1380 stainless steel, 303 stainless steel, stainless steel alloys, tungsten, aluminum, aluminum alloys, ADC-12, titanium, titanium alloys, or any metal for creating an iron-type golf club head.

III. Back Cavity Insert
1. General Insert Structure

The iron-type golf club head 100 can further comprise a back cavity insert 200 adhesively attached to a strikeface rear surface. In one embodiment, a multi-material back cavity insert 200 can be formed from an elastomeric material, plastic, and/or aluminum. In other embodiments, the back cavity insert 200 can be formed solely of an elastomeric material or other flexible polymeric materials. In still other embodiments, the back cavity insert 200 can be formed from an adhesive layer and a stiffening cap. The back cavity insert 200 structure may comprise two or more layers comprising different materials permanently affixed one to another.

The back cavity insert 200 may cover 100 percent of the strikeface rear surface 118. The back cavity insert 200 may cover less than 100 percent of the strikeface rear surface 118. The back cavity insert 200 may cover between 60 percent and 100 percent of the strikeface rear surface 118. The back cavity insert 200 may cover 60 percent, 65 percent, 70 percent, 75 percent, 80 percent, 85 percent, 90 percent, 95 percent, or 100 percent of the strikeface rear surface.

Referring to FIGS. 5A-C and 6, the insert 200 can comprise up to three layers wherein up to two layers are separated into portions forming multiple insert sections 224. The three layers are the adhesive layer 204, the elastomeric layer 210, and the cap 220. In one embodiment, the adhesive layer 204 is a single, continuous piece that is unitary and without divisions. In all insert 200 embodiments disclosed herein, the adhesive layer 204 is not separated into portions or sections. As explained here and below, the separation of one or more other insert 200 layers into multiple insert sections 224 enables better insert flexural response when the strikeface 110 deforms under impact with a golf ball. Insert 200 embodiments comprising a plurality of insert sections 224 may comprise between 3 and 12 sections. The insert 200 may comprise 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 insert sections 224.

In one embodiment, the elastomeric layer 210 and the cap 220 are configured to form a plurality of discontinuous insert sections 224. The elastomeric layer 210 is discontinuous, comprising a plurality of elastomeric layer portions 212. The cap 220 is discontinuous, comprising a plurality of cap portions 222. Each elastomeric layer portion 212 is bonded with a single cap portion 222 to form a plurality of insert sections 224. Each elastomeric layer portion 212 is shaped congruently to the matching cap portion 222. Each insert section 224 comprising an elastomeric portion 212 and a cap portion 222 is affixed to the adhesive layer 204 such that each elastomeric portion 212 is entirely affixed to the adhesive layer 204. The plurality of insert sections 224 are not continuous. The insert sections 224 are positioned on the adhesive layer 204 such that the outer edges of any one insert section 224 do not directly abut the outer edges of any adjacent insert sections 224. The adhesive layer 204 is not completely covered by the insert sections 224; instead, the insert sections 224 are separated by gaps 240 between the spaced-apart, insert sections 224 outside edges defined by the adhesive layer 204 uncovered areas. As explained further below, the gaps 240 provide increased insert flexibility and, in turn, allows more energy to be returned to the golf ball when struck by the golf club.

Referring to FIG. 5C, in a different embodiment, the insert comprises multiple insert sections 224 as described above, but the plurality of insert sections 224 each consists of only a single cap portion 222, having no elastomeric portions 212 between the adhesive layer 204 and the cap portions 222. The adhesive layer 204 is, again, a single continuous piece. However, in this embodiment, the insert sections 224 are constructed from cap portions 222 attached directly to the adhesive layer 204. Again, the adhesive layer 204 is not completely covered by the insert sections 224 (cap portions 222); instead, the insert sections 224 (cap portions 222) are separated by gaps 240 between the spaced-apart, insert section 224 outside edges defined by the adhesive layer 204 uncovered areas.

Referring to FIG. 5B, in still another embodiment, the adhesive layer 204 is a single continuous piece, and the elastomeric layer 210 is also a single continuous piece congruent to and entirely covering the adhesive layer 204. In this embodiment, the elastomeric layer 210 is not divided into portions. In this embodiment, the insert 200 comprises multiple insert sections 224 as described above, but each individual insert section 224 consists of only a single cap portion 222. In this embodiment, the adhesive layer is not exposed in the gaps 240 between the insert sections 224, as it is covered by the elastomeric layer 210. Instead, the continuous elastomeric layer 210 is exposed between the gaps 240, spacing the insert sections 224 from one another.

The adhesive layer 204 is applied to and adheres to the strikeface rear surface 118. When present, the elastomeric layer 210 abuts directly against and is attached to the adhesive layer 204. When present, the elastomeric layer 210, is located between the adhesive layer 204 and the cap 220. The insert cap 220 comprises an insert outer surface 225. The cap 220 comprises the insert 200 outermost, rearward layer, with an inner side adhering to the elastomeric layer 210. The cap 220 may function as a stiffener layer. The insert 200 further comprises an insert interior surface 226, wherein the insert interior surface 226 comprises the exposed portion of adhesive layer 204 prior to the insert 200 installation into the back cavity 116.

The insert thickness 230 comprises the sum of the thicknesses for each of the one or more layers. The insert thickness is measured perpendicularly from an interior surface to an insert exterior surface. The thickness may be constant for each of the one or more layers. The thickness may vary for each of the one or more layers. Referring to FIGS. 5A-6, the insert thickness 230 comprises the sum of the thicknesses of the adhesive layer 204, the elastomeric layer 210, and cap 220 together. The insert thickness 230 of any one of the plurality of insert sections 224 may be constant. The insert thickness 230 of any one of the plurality of insert sections 224 may vary. The insert thickness 230 may be the same for any two sections 224. The insert thickness 230 may differ between any two sections 224.

Referring to FIG. 5A, a total insert thickness 230 is measured between an innermost adhesive layer surface and the outermost layer exposed surface. The total insert thickness 230 can range between 0.033 inch and 0.620 inch. For example, in many embodiments, the total insert thickness 230 can be approximately 0.033 inch, 0.035 inch, 0.037 inch, 0.040 inch, 0.050 inch, 0.060 inch, 0.070 inch, 0.080 inch, 0.090 inch, 0.100 inch, 0.110 inch, 0.120 inch, 0.130 inch, 0.140 inch, 0.150 inch, 0.160 inch, 0.170 inch, 0.180 inch, 0.190 inch, 0.200 inch, 0.210 inch, 0.220 inch, 0.230 inch, 0.240 inch, 0.250 inch, 0.260 inch, 0.270 inch, 0.280 inch, 0.290 inch, 0.300 inch, 0.310 inch, 0.320 inch, 0.330 inch, 0.340 inch, 0.350 inch, 0.360 inch, 0.370 inch, 0.380 inch, 0.390 inch, 0.400 inch, 0.410 inch, 0.420 inch, 0.430 inch, 0.440 inch, 0.450 inch, 0.460 inch, 0.470 inch, 0.480 inch, 0.490 inch, 0.500 inch, 0.510 inch, 0.520 inch, 0.530 inch, 0.540 inch, 0.550 inch, 0.560 inch, 0.570 inch, 0.580 inch, 0.590 inch, 0.600 inch, 0.610 inch, or 0.620 inch. The total insert thickness 230 can be constant. The total insert thickness 230 can vary.

The adhesive layer 204 may have an adhesive layer thickness 203 in a range of 0.003 inch to 0.120 inch. The adhesive layer thickness 203 may be 0.003 inch, 0.005 inch, 0.010 inch, 0.020 inch, 0.030 inch, 0.040 inch, 0.050 inch, 0.060 inch, 0.070 inch, 0.080 inch, 0.090 inch, 0.100 inch, 0.110 inch, or 0.120 inch. The elastomeric layer 210 may have an elastomeric layer thickness 211 in a range of 0.020 inch to 0.400 inch. The elastomeric layer thickness 211 may be 0.020 inch, 0.030 inch, 0.040 inch, 0.050 inch, 0.060 inch, 0.070 inch, 0.080 inch, 0.090 inch, 0.100 inch, 0.110 inch, 0.120 inch, 0.130 inch, 0.140 inch, 0.150 inch, 0.160 inch, 0.170 inch, 0.180 inch, 0.190 inch, 0.200 inch, 0.210 inch, 0.220 inch, 0.230 inch, 0.240 inch, 0.250 inch, 0.260 inch, 0.270 inch, 0.280 inch, 0.290 inch, 0.300 inch, 0.310 inch, 0.320 inch, 0.330 inch, 0.340 inch, 0.350 inch, 0.360 inch, 0.370 inch, 0.380 inch, 0.390 inch, or 0.400 inch. The cap 220 may have a cap thickness 221 in a range of 0.010 inch to 0.100 inch. The cap thickness 221 may be 0.010 inch, 0.020 inch, 0.030 inch, 0.040 inch, 0.050 inch, 0.060 inch, 0.070 inch, 0.080 inch, 0.090 inch, or 0.100 inch.

The insert 200 comprises an insert top end 213, insert bottom end 214, insert toe end 215, and an insert heel end 216. The insert 200 comprises a maximum insert length 252 measured from the insert toe end most toeward point to the insert heel end most heelward point. The insert 200 comprises a maximum insert width 254 measured from the insert top end most topward portion to the insert bottom end most bottomward portion. The maximum insert length 252 may vary in a range of 2.5 inches to 3.2 inches. The maximum insert length may be 2.5 inches, 2.6 inches, 2.7 inches, 2.8 inches, 2.9 inches, 3.0 inches, 3.1 inches, or 3.2 inches. The maximum insert width 254 may vary in a range of 1.0 inch to 1.4 inches. The maximum insert width 254 may be 1.0 inch, 1.1 inches, 1.2 inches, 1.3 inches, or 1.4 inches.

2. General Insert Function

A typical insert having a single, continuous, unbroken outer layer, usually metallic, lacks the ability to fully conform to the changing shape of a strikeface flexing at impact. Instead, the insert outer layer is put into tension as it is pushed rearwards, resisting the strikeface rearward bowing to some degree. Some disclosed insert embodiments reduce the insert 200 flexural resistance. Referring to FIGS. 5A-5C, the insert 200 comprising multiple sections 224 is assembled with the iron-type golf club head by affixing the insert 200 to the strikeface rear surface 118. The strikeface 110 flexes rearward when the iron-type golf club head 100 strikes a golf ball. As the strikeface 110 flexes rearward, the adhesive layer 204 also flexes rearward, curving to match the strikeface rearward flexing. As the adhesive layer 204 flexes rearward at impact, the gaps 240 between individual insert sections 224 allow the insert sections 224 to spread apart (instead of being put into tension), increasing the gap width 242 between the individual insert sections 224. This, in turn, preserves the energy available to return to the golf ball upon the strikeface rebound. The insert 200 does not resist the strikeface flexing to the same extent as an insert comprising a single piece cap or outer layer due to the gaps 240 between insert sections 224. As the strikeface 110 rebounds, the adhesive layer 204 returns to its flatter shape, and the individual compound panels or sections are returned to their original configuration, having lesser gaps between them.

Referring to FIGS. 5A-5C, the gaps 240 between the individual sections 224 prior to impact with a golf ball have a minimum or resting gap width 242 that ranges from 0.005 inch to 0.010 inch. The minimum gap width 242 may be 0.005 inch, 0.006 inch, 0.007 inch, 0.008 inch, 0.009 inch, 0.010 inch, 0.011 inch, 0.012 inch, 0.013 inch, 0.014 inch, 0.015 inch, 0.016 inch, 0.017 inch, 0.018 inch, 0.019 inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch, 0.024 inch, 0.025 inch, 0.026 inch, 0.027 inch, 0.028 inch, 0.029 inch, 0.030 inch, 0.031 inch, 0.032 inch, 0.033 inch, 0.034 inch, 0.035 inch, 0.036 inch, 0.037 inch, 0.038 inch, 0.039 inch, or 0.040 inch. The minimum gap width 242 is not less than 0.005 inch to prevent interference from outer edges of the individual sections 224. During the strikeface impact flexing, the flexed or maximum gap width 244 between the individual sections 224 may increase up to an additional 0.010 inch more than the resting, minimum gap width 242, depending on the individual gap location on the insert 200. The maximum gap width 244 may be 0.015 inch, 0.016 inch, 0.017 inch, 0.018 inch, 0.019 inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch, 0.024 inch, 0.025 inch, 0.026 inch, 0.027 inch, 0.028 inch, 0.029 inch, 0.030 inch, 0.031 inch, 0.032 inch, 0.033 inch, 0.034 inch, 0.035 inch, 0.036 inch, 0.037 inch, 0.038 inch, 0.039 inch, 0.040 inch, 0.041 inch, 0.042 inch, 0.043 inch, 0.044 inch, 0.045 inch, 0.046 inch, 0.047 inch, 0.048 inch, 0.049 inch, or 0.050 inch. The maximum gap width 242 further controls the particles size of dust, dirt, sand, or other material that might be entrapped in the gaps by sticking to the adhesive layer 204 surface. The larger the maximum gap width 244, the larger the size an entrapped particle could be. It is therefore preferred to control the maximum gap width 244 to the above ranges to prevent larger particle entrapment. Gaps 240 between individual insert sections 224 closer to the strikeface rear surface 118 center will increase in width to a larger extent than those further from the strikeface center 140 because the strikeface 110 flexes to a greater degree near the strikeface center 140 when striking a golf ball. Again, the gaps expansion reduces the insert 200 flexural resistance and allows more energy to be returned to the golf ball.

Referring to FIGS. 5A-5C, the flexing of an insert 200 facilitated by the gaps 240 between the individual insert sections 224 restrains the flexing of the strikeface 110 at impact to a lesser degree than an insert comprising a single, continuous, unbroken outer surface layer. This allows more energy to be returned to the golf ball. More specifically, the lowered flexural resistance of insert 200 provides for a golf ball launch speed of 1 to 2 mph greater (assuming an 85 mph swing speed) with the multiple insert sections 224 in comparison to the same iron-type golf club head with an insert comprising a single outer surface layer. In turn, the added golf ball launch speed will allow the golf ball to fly further—as much as 1-3 yards further. The benefit to the golfer is that an iron with a higher loft may be used, further allowing a higher arcing flight trajectory for the golf shot.

The iron-type golf club head strikeface 110 typically flexes the most near the strikeface geometric center 140. It is, therefore, advantageous for insert sections 224 to be arranged such that the gaps 240 between insert sections 224 are on or very near the region of strikeface 110 directly surrounding the strikeface geometric center 140. It is advantageous for a portion of the insert sections 224 outer edges to be in a range of 0.1 inch to 0.5 inch of the strikeface geometric center. The portion of insert section 224 outer edges can be 0.1 inch, 0.2 inch, 0.3 inch, 0.4 inch, or 0.5 inch from the strikeface geometric center 140 for a more advantageous flexing effect. The insert sections 224 may be arranged in a variety of configurations. In some embodiments, polygonal insert sections can be arranged around the strikeface geometric center such that a vertex of each polygonal insert is on or near the strikeface geometric center 140. In other embodiments, longer edges of two or more insert sections of any shape may be positioned on or near the geometric center 140. Providing gapping at or near the strikeface geometric center 140 allows the insert 200 to expand at the area of greatest strikeface deformation under impact. The gaps 240 have a minimum gap width 242 and a gap depth 246 that is same as the thickness of the insert sections 224 surrounding each of the gaps 240. Because the flexure of the strikeface 110 at impact is in three dimensions, the flexure of the back cavity insert attached to the strikeface rear surface 118 is also three dimensional. As a result, the rearward flexion of the insert 200 extends the gap width 242 more at the back cavity insert outer surface 225 than it does at the surface of the adhesive layer 204. The gaps 240 must, therefore, spread apart in the same manner the jaws of a set of pliers would spread apart; the bottom portion will spread apart less than the top portion as the jaws are opened.

The insert 200 with insert sections 224 is designed to flex with the strikeface 110 when a ball is struck and to minimize the dissipation of the energy imparted by the impact with the golf ball. However, some impact energy is still lost in the insert 200. Therefore, the insert 200 also serves to reinforce the strikeface 110 to some extent. The strikeface 110 comprises a strikeface thickness 119 measured between the strikeface front surface 117 and the strikeface rear surface 118. The strikeface thickness 119 contributes to the durability of the strikeface 110 under impact. The impact energy that is absorbed by the insert 200 allows the strikeface thickness 119 to be smaller than it could be while remaining sufficiently durable without the insert 200 attached to the strikeface rear surface 118.

A first and second embodiment of the back cavity insert disclosed within are presented below. However, the claimed back cavity insert is not limited to the first and second embodiments disclosed. Other back cavity insert configurations are disclosed in the discussion of general insert structure and general insert function. These may include, but are not limited to, back cavity inserts having a different number of insert sections, different insert section shapes, and any combination of the attribute ranges disclosed herein.

C) First Back Cavity Insert Embodiment

Referring to FIGS. 7-9, the back cavity insert 300 may comprise adhesive layer 304, the elastomeric layer 310, and the cap 320. The adhesive layer 304 may comprise a VHB tape wherein an elastomeric layer 310 comprises a plurality of flexible polymeric or rubber portions that are affixed to the VHB tape. The cap 320 is comprised of a plurality of metallic outer portions affixed to each of the plurality of elastomeric layer portions 312. In this first embodiment, the plurality of elastomeric layer portions 312 paired with the cap portions 322 form a plurality of individual insert sections 324. The individual insert sections 324 are arranged on the adhesive layer 304 such that they have gaps 340 between each of the individual insert sections and such that the adhesive layer 304 is visible through the gaps 340 (as explained in more detail above).

Referring to FIGS. 7-9, this insert embodiment comprises seven distinct individual insert sections 324. The seven elastomeric layer portions 312 are each adhesively affixed to both the adhesive layer 304 and to separate cap portions 322.

Referring to FIGS. 7-9, the seven distinct individual sections 324 each comprise a multi-sided shape, such that the sides of each section adjacent to another individual section are straight and parallel to the sides of the adjacent piece or section. The insert 300 further comprises two heel-side insert sections (one upper heel-side section 351 and one lower heel-side section 352), two toe-side compound sections (one upper toe-side section 353 and one lower toe-side section 354), and three central compound sections (an upper central section 355, a lower, heel-side central section 356, and a lower, toe-side central section 357).

The upper heel-side section 351 is adjacent to the top rail 105, the lower heel-side section 352, the upper central section 355, and the lower, heel-side central section 356. The lower heel-side section 352 is adjacent to the upper heel-side section 351, and the lower, heel-side central section 356. The upper toe-side section 353 is adjacent to the top rail 105, the lower toe-side section 354, the upper central section 355, and the lower, toe-side central section 357. The lower toe-side section 354 is adjacent to the upper toe-side section 353, and the lower, toe-side central section 357. The upper central section 355, lower, heel-side central section 356, and lower, toe-side central section 357 are all adjacent to each other such that each central section has a side parallel to each of the other two central sections. Further, the upper central section 355, lower, heel-side central section 356, and lower, toe-side central section 357 form an intersection wherein one corner or vertex of each of the central sections are all adjacent at an insert center 358. The insert 300 is oriented in the back cavity 116 such that the insert center 358 is located on the strikeface rear surface 118 approximately opposite a strikeface geometric center 140. The three central sections completely surround the insert center 358, such that the three central sections' shared corners each define an approximately 120-degree angle with the two other intersecting central section walls at that corner.

Referring to FIGS. 7-9, the upper heel-side section 351, upper toe-side section 353, upper central section 355, lower toe-side section 354, and lower heel-side section 352 each have one or more sides adjacent to the rearward projection inner perimeter. The one or more sides of each section adjacent to the rear perimeter extension 121 may be straight or may be curved to follow the rear perimeter extension 121 shape.

D) Second Back Cavity Insert Embodiment

Described below is another embodiment of a multi-component insert. Referring to FIGS. 10-13, the iron-type golf club head 100 comprises a multi-component insert 400 to help increase ball speed and launch angle. The multi-component insert 400 allows for gaps 440 between the insert sections 424 to minimize the insert's influence on strikeface flexing.

Referring to FIGS. 10-13, the back cavity insert 400 can be formed from an adhesive layer 404 comprising a foam-based very high bond tape (i.e., VHB), an elastomeric layer 410 comprising a plurality of flexible polymeric portions 412 (e.g., ABS plastic with Shore D hardness ranging from 70 to 100), and a cap 420 comprising a plurality of metallic outer portions 422 (e.g., aluminum). The elastomeric layer 410 plurality of flexible polymeric portions 412 are affixed to the adhesive layer 404 VHB tape, and the cap portions 422 are affixed to elastomeric portions 412. The combination of elastomeric portions 412 and the cap portions 422 form a plurality of insert sections 424. The insert sections 424 are arranged on the VHB tape such that they have gaps 440 between each of the insert sections 424 as described above. The gaps 440 comprise a minimum gap width 442 when the golf club head is not impacting a golf ball. The gaps 440 comprise a maximum gap width 444 during the largest strikeface displacement during the golf ball impact. Gap width is measured in a direction perpendicular to the insert section edges. The adhesive layer 404 can be visible through the gaps 440. The insert 400 is affixed to the strikeface rear surface 118.

Referring to FIGS. 10-13, the insert 400 can comprise four insert sections 424. The four insert sections 424 comprise a multi-sided shape, such that the sides or edges between adjacent insert sections are curvilinear, curved, arcuate, or rounded. The insert sections 424 edges converge, merge, or connect at or near the strikeface geometric center 140. The insert section 424 edges converge to a center gap 441 that is adjacent or located near the strikeface geometric center 140. As described in more detail below, the center gap 441 can improve the strikeface flexing during a golf ball impact.

Referring to FIGS. 10-13, the insert 400 comprises a heel side section 451, a toe side section 452, a top section 453, and a bottom section 454. The heel side section 451 is adjacent to the heel portion 108, the toe side section 452 is adjacent to the toe portion 106, the top section 453 is adjacent to the top portion 104, and the bottom section 454 is adjacent to the bottom portion 107. The heel side section 451 can be adjacent to the heel portion 108, the top section 453, and the bottom section 454. The toe side section 452 can be adjacent to the toe portion 106, the top section 453, and the bottom section 454. The top section 453 can be adjacent to the top portion 104, the heel side section 451, and the toe side section 452. The bottom section 454 can be adjacent to the bottom portion 107, the heel side section 451, and the toe side section 452. The insert sections 424 each comprise at least one curvilinear edge, wherein an adjacent section edge has a complimentary curve.

Further, the heel side section 451, the toe side section 452, the top section 453, and the bottom section 454 form an intersection wherein one corner, vertex, or edge of each of the sections can be adjacent to the strikeface geometric center 140. The heel side section 451, the toe side section 452, the top section 453, and the bottom section 454 form a center gap 441 adjacent to the strikeface geometric center 140. Wherein a corner, vertex, or edge of each of the sections 424 forms a gap perimeter. FIGS. 10-13 illustrate the sections 424 forming the center gap 441 and the gap perimeter. In particular, a top section 453 curved edge, a bottom section 454 curved edge, a heel side section 451 vertex, and a toe side section 452 vertex form the center gap 441 and the gap perimeter.

Referring to FIGS. 10-13, the insert 400 comprising multiple sections 424 is assembled with the iron-type golf club head 100 by affixing the insert 400 to the strikeface rear surface 118. The strikeface 110 flexes rearward when the iron-type golf club head strikes a golf ball. As the strikeface 110 flexes rearward, the adhesive layer 404 also flexes rearward, curving to match the strikeface rearward flexing. As the adhesive layer 404 flexes rearward at impact, the gaps 440 between insert sections 424 allows the sections to spread apart (instead of being put into tension), increasing the gap width up to 0.010 inch between the insert sections 424 to achieve the maximum gap width 444. In this second embodiment, the insert 400 does not resist the strikeface flexing. As the strikeface 110 rebounds, the adhesive layer 404 returns to its flatter, original shape, and the insert sections 424 are returned to their original configuration having a minimum gap width 442 as discussed below.

Still referring to FIGS. 10-13, the minimum gap width 442 prior to a golf ball impact can be smaller or less than the maximum gap width 444 during the golf ball impact. The gap width increases due to the strikeface 110 flexing under the golf ball impact force, wherein the strikeface 110 bends and the insert 400 bends. The gaps 440 between the sections prior to impact with a golf ball comprise a minimum gap width 442 that ranges from 0.005 inch to 0.040 inch. For example, the minimum gap width 442 prior to impact can be 0.005 inch, 0.006 inch, 0.007 inch, 0.008 inch, 0.009 inch, 0.010 inch, 0.011 inch, 0.012 inch, 0.013 inch, 0.014 inch, 0.015 inch, 0.016 inch, 0.017 inch, 0.018 inch, 0.019 inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch, 0.024 inch, 0.025 inch, 0.026 inch, 0.027 inch, 0.028 inch, 0.029 inch, 0.030 inch, 0.031 inch, 0.032 inch, 0.033 inch, 0.034 inch, 0.035 inch, 0.036 inch, 0.037 inch, 0.038 inch, 0.039 inch, or 0.040 inch. During the strikeface impact flexing, the width of the gaps between the sections can increase up to 0.010 inch, and ranges from 0.015 to 0.050 inch, depending on the gap location. For example, the maximum gap width 444 during the golf ball impact can be 0.015 inch, 0.016 inch, 0.017 inch, 0.018 inch, 0.019 inch, 0.020 inch, 0.021 inch, 0.022 inch, 0.023 inch, 0.024 inch, 0.025 inch, 0.026 inch, 0.027 inch, 0.028 inch, 0.029 inch, 0.030 inch, 0.031 inch, 0.032 inch, 0.033 inch, 0.034 inch, 0.035 inch, 0.036 inch, 0.037 inch, 0.038 inch, 0.039 inch, 0.040 inch, 0.041 inch, 0.042 inch, 0.043 inch, 0.044 inch, 0.045 inch, 0.046 inch, 0.047 inch, 0.048 inch, 0.049 inch, or 0.050 inch. Gaps 440 between insert sections 424 closer to the strikeface geometric center 140 will increase in width to a larger extent than gaps 440 further from the strikeface geometric center 140.

E) Third Back Cavity Insert Embodiment

Referring to FIGS. 15-17, the back cavity insert 500 is a multi-material insert. The insert 500 comprises an adhesive layer 504, and elastomeric layer 510, a carbon fiber insert 515, a metallic cap 520, a damping member 530, and gaps 540 between the damping member 530 and adjacent insert components. An insert perimeter 550 is defined by the area of the adhesive layer 504. Any portion of the back cavity insert 500 extending beyond the adhesive layer area extends beyond the insert perimeter 550. The metallic cap 520 may comprise one, two, three, four, or more pieces. The carbon fiber insert 515 may comprise one, two, three, four, or more pieces. The damping member 530 comprises a damping member base portion 532, at least one damping member extension 534 that extends from the damping member base portion 532 toward the insert perimeter 550 proximate the top rail 105, and wherein the damping member extensions 534 each further comprises a damping member extension tip 536 distal from the damping member base portion 532. In some embodiments, the damping member extension tip 536 extends beyond the insert perimeter 550, and in some embodiments the damping member extension tip 536 does not extend beyond the insert perimeter 550. Similar to previously discussed inserts, the multi-material insert 500 further comprises gaps 540 between the damping member 530 and the elastomeric layer 510, allowing the insert 500 to flex when the golf club head strikes a golf ball. The gaps 540 have similar characteristics as the gaps 440 discussed above.

The damping member 530 comprises a flexible, compressible material. The damping member material may be a natural or synthetic rubber, a thermoplastic, a resin, a felt, or cork. The damping member material has a Shore A hardness in a range between 10 and 60. The damping member material Shore A hardness may be 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, or 60. The damping member 530 reduces the vibrational amplitude of the club head when struck at the point of contact between the damping member and the golf club head.

The insert 500 has a layered construction. The adhesive layer 504 is proximate the strikeface rear surface 118. The insert exterior surface 525 may comprise an insert most rearward surface. The metallic cap 520 and the carbon fiber insert 515 together constitute a third layer proximate and rearward of the elastomeric layer 510. The damping member 530 generally constitutes a fourth layer proximate to and rearward of the metallic cap 520 and the carbon fiber insert 515. In some embodiments the damping member 530 may be proximate and rearward of the elastomeric layer 510, separating metallic cap portions 522 and the carbon fiber insert portions 517.

The metallic cap 520 comprises a metallic cap upper portion 523, a metallic cap toeward portion 524, and a metallic cap soleward portion 525. The metallic cap upper portion 523, the metallic cap toeward portion 524, and the metallic cap soleward portion 525 surround and define a metallic cap central aperture 526. The metallic cap central aperture comprises 526 a “U” shape, with an opening toward the golf club head lower heel portion 108.

The insert perimeter 550 comprises an insert perimeter top portion 551, an insert perimeter upper toe portion 553, and insert perimeter lower toe portion 555, an insert perimeter bottom portion 557, and an insert perimeter heel portion 559. When the insert 500 is received within the golf club head back cavity 116, to properly align the insert 500 with the back cavity, the insert top portion 551 is proximate to and abuts the rear perimeter extension top portion 125 and the insert perimeter upper toe portion 553 is proximate to and abuts the rear perimeter extension toe portion 131. In this embodiment, the damping member extension tip 536 contacts the rear wall extension perimeter top portion 125. Specifically, the damping member extension tip 536 contacts the top portion rear wall perimeter 160.

Insert 500 may have a plurality of damping members 530. Each damping member 530 comprises a damping member base portion 532, a damping member extension 534 and a damping member extension tip 536. Insert embodiments comprising more than one damping member extension 534 will serve to divide the metallic cap 520 and carbon fiber inserts 515 into more sections, form more apertures in the metallic cap, and form more gaps 540. Multiple damping member extension tips 536 may contact the top portion rear wall perimeter 160 at multiple, discrete locations.

F) Fourth Back Cavity Insert Embodiment

Referring to FIGS. 19-22, insert 600 is similar to insert 500. The back cavity insert 600 is a multi-material insert. The insert 600 comprises an adhesive layer 604, an elastomeric layer 610, a carbon fiber insert 615, a metallic cap 620, and a damping member 630. An insert perimeter 650 is defined by the area of the adhesive layer 604. Any portion of the back cavity insert 600 extending beyond the adhesive layer area extends beyond the insert perimeter 650. The metallic cap 620 may comprise one, two, three, or four pieces. The carbon fiber insert 615 may comprise one, two, three, or four pieces. The adhesive layer 604, the elastomeric layer 610, the carbon fiber insert 615, the metallic cap 620, and the damping member 630 each comprise a forwardmost surface closest to the strikeface rear surface 118 and a rearwardmost surface closest to the back portion exterior surface 120. The damping member 630 comprises a damping member base portion 632, at least one damping member extension 634 that extends from the damping member base portion 632 toward the insert perimeter 650, wherein each damping member extension 634 further comprises a damping member extension tip 636 distal from the damping member base portion 632. In this embodiment, the damping member extension tip 636 extends beyond the insert perimeter 650. Similar to previously discussed inserts, the multi-material insert 600 further comprises gaps 640 between the damping member 630 and the elastomeric layer 610, allowing the insert 600 to flex when the golf club head strikes a golf ball. The gaps 640 have characteristics similar to the gaps 440 discussed above.

The insert 600 has a layered construction. The insert 600 comprises an insert exterior surface 625. The insert exterior surface 625 may comprise an insert most rearward surface. The adhesive layer 604 is proximate the strikeface rear surface 118. The elastomeric layer 610 is proximate and rearward of the adhesive layer 604, the metallic cap 620 and the carbon fiber insert 615. In this embodiment the damping member 630 may also be proximate and rearward of the elastomeric layer 610, separating portions of the metallic cap 620 and the carbon fiber insert 615. As such, the damping member 630, the metallic cap 620, and the carbon fiber insert 615 together constitute a third layer of insert 600. Further, a notch 611 may be removed from the elastomeric layer 610 such that the damping member 630 does not extend as far rearward but is received within the notch 611, attached directly to the adhesive layer 604 instead to the elastomeric layer 610.

The damping member 630 comprises a flexible, compressible material. The damping member material may be a natural or synthetic rubber, a thermoplastic, a resin, a felt, or cork. The damping member material has a Shore A hardness in a range between 10 and 60. The damping member material Shore A hardness may be 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, or 60. The damping member 630 reduces the vibrational amplitude of the club head when struck at the point of contact between the damping member and the golf club head.

The metallic cap 620 comprises a plurality of metallic cap portions 622. The metallic cap 620 comprises a metallic cap upper portion 623, a metallic cap toeward portion 624, and a metallic cap soleward portion 625. The metallic cap upper portion 623, the metallic cap toeward portion 624, and the metallic cap soleward portion 625 surround and define a metallic cap central aperture 626. Insert embodiments comprising more than one damping member extension will serve to divide the metallic cap and carbon fiber inserts into more sections, and form more apertures in the metallic cap.

The insert perimeter 650 comprises an insert perimeter top portion 651, an insert perimeter upper toe portion 653, and insert perimeter lower toe portion 655, an insert perimeter bottom portion 657, and an insert perimeter heel portion 659. The damping member extension tip 636 extends beyond the insert perimeter 650. Because the damping member extension tip 636 is received within notch 611, the damping member extension tip 636 does not extend as far rearwardly as the damping member extension tip 536. Instead of contacting the top portion rear wall perimeter 160, the extension tip 636 contacts the top portion inner surface 162 within the undercut recess 133.

Referring to FIG. 18, when the golf club head 100 strikes a golf ball without a back cavity insert, one or more high amplitude vibrational zones 701 may occur. If the high amplitude vibrational zone 701 is not dampened to reduce the vibrational amplitude, then the golf club user may experience an unpleasant “feel”. To reduce the amplitude in zone 701, the damping member extension tip 636 may be located such that tip contacts the zone 701 to dampen the amplitude of vibration in that zone. The damping member extension tip 636 may be compressively inserted into the undercut recess 133 with the damping member extension tip 636 width configured to be wider than the undercut recess 133. The damping member extension tip 636 is positioned within the undercut recess 133 to dampen the maximum vibrational mode at the high amplitude zone 701 of the top rail 105. If more than one zone is present for a given golf club head design, then the damping member 630 may have more than one damping member extension 634 such that a plurality of extension tips 636 are in contact with each zone 701 to reduce the amplitude of vibration in each zone.

G) Fifth Back Cavity Insert Embodiment

A multi-material insert 800 having an expanded area of contact with the undercut recess is shown if FIGS. 23-30, More specifically, while the insert 800 is similar to multi-material insert 600, it comprises a tip lateral arm 838 to provide additional damping contact with the high amplitude zone 701. Multi-material insert 800 comprises an adhesive layer 804, an elastomeric layer 810, a carbon fiber insert 822, and a damping member 830 having the lateral arm 838. An insert perimeter 850 is defined by the area of the adhesive layer 804. Any portion of the back cavity insert 800 extending beyond the adhesive layer area extends beyond the insert perimeter 850. Similar to previously discussed inserts, the multi-material insert 800 further comprises gaps 840 between the damping member 830 and the elastomeric layer 810, allowing the insert 800 to flex when the golf club head strikes a golf ball. The gaps 840 comprises a gap width measured perpendicularly to a damping member 830 edge to an elastomeric layer 810 edge. The gap width is in a range from 0.005 inch to 0.010 inch. The minimum gap width may be 0.005 inch, 0.006 inch, 0.007 inch, 0.008 inch, 0.009 inch, or 0.010 inch. The minimum gap width is not less than 0.005 inch to prevent interference from edges of insert sections.

The adhesive layer 804, the elastomeric layer 810, the carbon fiber insert 822, and the damping member 830 each comprise a rearwardmost surface and a forwardmost surface. The adhesive layer 804 comprises a single piece of flexible, compressible tape cut to fit the golf club head rear cavity. The adhesive layer forwardmost surface adheres to the strikeface rear surface. The elastomeric layer 810 comprises an elastomeric layer toeward component 819 and an elastomeric layer heelward component 817. Both elastomeric components comprise a forwardmost surface and a rearwardmost surface. The forwardmost surface of each elastomeric component (817 and 819) are adhesively coupled to the adhesive layer rearwardmost surface. The elastomeric heelward component 817 and the elastomeric toeward component 819 are separated by a notch 811. The adhesive layer 804 is exposed within the notch 811 until the damping member 830 is placed within the notch 811. The elastomeric heelward component 817 and the elastomeric toeward component 819 may each further comprise strikeface rear surface pairing geometry. The adhesive layer 804 is easily compressible, and any variation in the strikeface rear surface will protrude into the adhesive layer. In turn, the forwardmost surface of each elastomeric component (817 and 819) is shaped to receive any strikeface rear surface geometry. The elastomeric layer 810 rearwardmost surface further comprises a metallic coating. The carbon fiber insert 822 comprises a carbon fiber insert heelward piece 823 and a carbon fiber insert toeward piece 824 adhesively attached to the elastomeric layer 810 on the rearwardmost surface of each elastomeric component (817 and 819).

The damping member 830 comprises a damping member base portion 832 and at least one damping member extension 834 that extends from the damping member base portion 832 toward the insert perimeter 850. Each damping member extension 834 further comprises a damping member extension tip 836 distal from the damping member base portion 832. A toeward edge of the damping member extension 834 forms a damping member extension angle 835 with an upper edge of the damping member base portion 832. The damping member extension angle is in a range of 60 degrees to 120 degrees. The damping member extension angle may be 60 degrees, 65 degrees, 70 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, or 120 degrees. The damping member 830 comprises a damping member height 831 measured perpendicular to a tangent to a damping member most soleward point to a damping member most topward point. The damping member height 831 is in a range of 1.0 inch to 2.5 inches. The damping member height may be 1.0 inch, 1.1 inches, 1.2 inches, 1.3 inches, 1.4 inches, 1.5 inches, 1.6 inches, 1.7 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, or 2.5 inches. The damping member extension 834 comprises a damping member extension width 833 measured perpendicularly from a damping member extension most toeward edge to a damping member most heelward edge. The damping member extension width 833 is in a range of 0.1 inch to 1.0 inch. The damping member extension width may be 0.1 inch, 0.2 inch, 0.3 inch, 0.4 inch, 0.5 inch, 0.6 inch, 0.7 inch, 0.8 inch, 0.9 inch, 1.0 inch.

In this embodiment, the damping member extension tip 836 extends beyond the insert perimeter 850. Further, the damping member extension tip 836 further comprises a tip lateral arm 838 extending toward along the insert perimeter 850 and contacting the top portion inner surface 162 within the undercut recess 133.

The damping member forwardmost surface 863 is closest to the strikeface rear surface 118 and adhesively attaches to the adhesive layer 804. Damping member 830 is positioned in notch 811 between the elastomeric heelward component 817 and the elastomeric toeward component 819 such that the damping member 830 is in direct contact with the adhesive layer 804. The elastomeric toeward component 819 further comprises a plurality of elastomeric layer recesses 818 configured to receive damping member alignment tabs 865. The alignment tabs 865 allow positive positioning of the damping member 830 within the notch 811, setting the width of gaps 840.

The damping member 830 comprises a flexible, compressible material. The damping member material may be a natural or synthetic rubber, a thermoplastic, a resin, a felt, or cork. The damping member material has a Shore A hardness in a range between 10 and 60. The damping member material Shore A hardness may be 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, or 60. The damping member 830 reduces the vibrational amplitude of the club head when struck at the point of contact between the damping member and the golf club head.

The tip lateral arm 838 comprises a lateral arm length 837, a lateral arm width 839, and a lateral arm thickness 841. The lateral arm length 837 is measured as the shortest distance from a lateral arm heelwardmost surface to a lateral arm toewardmost surface. The lateral arm length 837 is in a range of 0.10 inch to 0.75 inch. The lateral arm length 837 may be 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, or 0.75 inch. The lateral arm width 839 conforms to an undercut recess width, to fully contact each of the frontmost undercut recess surface and the rearwardmost undercut recess surface. The lateral arm width 839 may be constant along the lateral arm length 837, or the lateral arm width 839 may vary along the lateral arm length 837. The lateral arm width 839 may be in a range of 0.10 inch to 0.50 inch. The lateral arm width 839 may be 0.10 inch, 0.15-inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, or 0.50 inch. The lateral arm thickness 841 is configured to conform to the distance from the uppermost insert perimeter to the top portion inner surface 162 such that the lateral arm 838 is in contact with the top portion inner surface 162. The lateral arm thickness 841 may be constant along the lateral arm length 837, or the lateral arm thickness 841 may vary along the lateral arm length 837. The lateral arm thickness 841 is in a range of 0.10 inch to 0.50 inch. The lateral arm thickness may be 0.10 inch, 0.15-inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, or 0.50 inch.

The lateral arm 838 comprises the same material as the rest of the damping member 830. The lateral arm may be adhesively attached to the top portion inner surface 162 within the undercut recess 133. Alternatively, the lateral arm may be compressively inserted into the undercut recess 133 with the lateral arm width configured to be wider than the undercut recess 133. The lateral arm 838 is positioned within the undercut recess 133 to dampen the maximum vibrational mode at the high amplitude zone 701 of the top rail 105.

Example 1

Referring to FIGS. 14A-14E, a comparison was conducted of two inserts. The first insert was the flexible insert 300 described in the first embodiment above. The second (control) insert was exactly identical to the first insert 300, except lacking the gaps creating separate sections or panels. The first embodiment insert 300 with a plurality of insert sections 324 having gaps 340 between them showed improved performance (as discussed below) over the identical comparison insert (in the control club) that had continuous, unbroken adhesive, elastomeric, and cap layers. Both were placed in identical 7-iron golf club heads having a loft of 29 degrees. The test incorporated player testing, robotic testing, and FEA simulation. The player test had 20 players each hitting ten shots with each of the two golf 7-iron golf clubs. The robotic testing had the robot hitting the golf ball for 5 shots at each or 9 different face positions for each of the two 7-iron golf clubs. For each hit, the initial ball speed, ball spin, launch angle, distance traveled, and maximum trajectory height was measured. The data referred to in this example is drawn from all of the above tests.

The iron-type golf club head and insert design were identical between the flexible (with gaps) and stiff (without gaps) inserts, except that the flexible insert 300 had the gaps 340 and insert sections 324 as described in the first insert 300 embodiment. Referring to FIG. 14A, the iron-type golf club head having flexible insert 300 comprising the gaps 340 and insert sections 324 provided an almost 1 mile per hour higher initial ball speed than the iron-type golf club head comprising the insert without gaps. The additional ball speed upon impact results from less energy lost during the ball impact due to the flexibility provided by the insert gaps. Referring to FIG. 14B, the iron-type golf club head having flexible insert 300 comprising the gaps 340 and insert sections 324 provided a 2-yard additional carry distance. Referring to FIGS. 14C and 14D, the iron-type golf club head having flexible insert 300 comprising the gaps 340 and insert sections 324 provided a marginally higher launch angle and maximum height. Referring to FIG. 14E, the iron-type golf club head having flexible insert 300 comprising the gaps 340 and insert sections 324 provided an almost 80 rpm lower spin rate. The 7-iron golf clubs tested in this Example 1 were similar in construction except for the gaps in the back cavity insert applied only to one of the 7-irons. The 7-iron having an insert with gaps had the surprising result of improved average carry distance, which was only attributable to the gaps provided in the back cavity insert applied to this 7-iron.

In summary, the Example 1 iron-type golf club having an iron-type golf club head comprising the flexible insert 300 comprising the gaps 340 and insert sections 324 only differed from the control iron-type golf club head back cavity insert in having the insert with gaps 340. All other factors were controlled to be identical. In this Example 1, the improved flight characteristics of higher launch angle, maximum ball flight height, greater ball speed, and lower launch spin rates cooperated to provide a 2-yard carry distance improvement.

Example 2

Referring to FIGS. 19A and 19B, and 21A and 21B, insert back cavity 600 comprises a damping member 630 having a damping member extension 634 with an extension tip 636. Referring to FIG. 18, club head 1000 forms a high amplitude vibrational zone 701 when striking a golf ball. The user of a golf club assembled with club head 1000 can hear the vibration created at the vibrational zone 701. However, in comparing the club head 1000 with and without the back cavity insert 600, it was found that the amplitude (volume) of the vibration was decreased 30%. The damping member extension tip 639 was oriented to extend into an undercut of the rear cavity, touching the underside of the top rail directly below the highest amplitude vibrational area. The damping member successfully lowered the vibrational amplitude in that area, reducing the volume of the sound generated by striking the golf club head.

As the rules to golf may change from time to time (e.g., new regulations may be adopted, or old rules may be eliminated or modified by golf standard organizations and/or governing bodies such as the United States Golf Association (USGA), the Royal and Ancient Golf Club of St. Andrews (R&A), etc.), golf equipment related to the apparatus, methods, and articles of manufacture described herein may be conforming or non-conforming to the rules of golf at any particular time. Accordingly, golf equipment related to the apparatus, methods, and articles of manufacture described herein may be advertised, offered for sale, and/or sold as conforming or non-conforming golf equipment. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

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

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

	Number	Date	Country
	63600523	Nov 2023	US
	63108226	Oct 2020	US

	Number	Date	Country
Parent	17453162	Nov 2021	US
Child	18460364		US

	Number	Date	Country
Parent	18460364	Sep 2023	US
Child	18950999		US

GOLF CLUB HEAD WITH UNDERCUT AND INSERT

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