GOLF CLUB HEAD WITH VIBRATIONAL DAMPING SYSTEM

Abstract

Embodiments of an iron-type golf club head comprising a damping system. The damping system includes an insert covering a lower portion of the back face and a badge covering an upper portion of the back face. The damping system covers a large proportion of the back face and provides a club head with desirable sound and feel characteristics. The iron-type golf club head further comprises one or more features that promote a high moment of inertia and a CG position substantially aligned with an impact axis to improve ball speed and club head sound and feel at impact.

Description

TECHNICAL FIELD

This disclosure relates generally to golf club heads and, more particularly, relates to golf club heads comprising a high moment of inertia and damping systems configured to damp club head vibrations at impact.

BACKGROUND

Golf club design balances several performance characteristics including ball flight, sound, and feel. Ball flight characteristics (such as ball speed, launch angle, spin rate, forgiveness, etc.) generally depend on club head mass properties, including center of gravity (CG) position and club head moment of inertia (MOI). Club head sound characteristics (e.g. the acoustic response of the club head at impact) and the feel characteristics (e.g. the vibrations of the club head felt in the hands of the golfer at impact) generally depend on the vibrational response of the club head at impact.

Club head sound and feel are determined by the club head vibrational response at impact. Sound and feel can be improved by damping dominant vibrations in the club head via mass damping (i.e., allocating mass to high-vibration areas), viscoelastic damping (i.e., placing vibration-damping material on or near high-vibration areas), or aligning the club head CG with the impact location.

An ideal club head achieves a combination of desirable ball flight, sound, and feel characteristics. However, design features that improve certain club head ball flight characteristics may have a negative effect on the sound and feel of the club head, and vice versa. For example, a cavity-back iron with large amounts of perimeter weighting may be very forgiving, but sound and feel harsh and/or “clacky.” In contrast, a forged or muscle-back iron may sound and feel desirable but lack forgiveness.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate further description of the embodiments, the following drawings are provided in which:

FIG. 1A is a front elevation view of a golf club head according to the present disclosure.

FIG. 1B is a toe-side elevation view of the golf club head of FIG. 1A.

FIG. 1C is a front elevation view of the golf club head of FIG. 1A.

FIG. 1D is a toe-side elevation view, in cross-section of the golf club head of FIG. 1A.

FIG. 2 is a rear elevation view of a golf club head according to the present disclosure.

FIG. 3 is a rear elevation view of the golf club head of FIG. 2, further comprising a badge.

FIG. 4 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 2.

FIG. 5A is a toe-side elevation view, in cross-section, of the golf club head of FIG. 2, further comprising a badge.

FIG. 5B is a detailed, toe-side elevation view, in cross-section, of the golf club head of FIG. 5A.

FIG. 6 is a rear, bottom perspective view of an insert.

FIG. 7 is a rear elevation view, in cross-section of the golf club head of FIG. 1.

FIG. 8 is a rear, bottom, toe-side perspective view of the golf club head of FIG. 1.

FIG. 9 is a rear elevation view of a golf club head according to the present disclosure.

FIG. 10 is a rear, bottom, toe-side perspective view of the golf club head of FIG. 9.

FIG. 11 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 9.

FIG. 12 is a rear elevation view of a golf club head according to the present disclosure.

FIG. 13 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 12.

FIG. 14 is a rear elevation view of a golf club head according to the present disclosure.

FIG. 15 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 14.

FIG. 16 is a front, top, toe-side, exploded, perspective view of a golf club head according to the present disclosure.

FIG. 17 is a rear elevation view of the golf club head of FIG. 16.

FIG. 18 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 16.

FIG. 19 is a front, top, toe-side, exploded, perspective view of a golf club head according to the present disclosure.

FIG. 20 is a rear elevation view of the golf club head of FIG. 19.

FIG. 21 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 19.

FIG. 22A is a graphical representation an amplitude and a frequency of a control club head.

FIG. 22B is a graphical representation of an amplitude and a frequency of an exemplary club head.

FIG. 23A-23C is elevation views, in cross-section, of various embodiments of a badge.

FIG. 24 is a rear elevation view of a golf club head according to the present disclosure.

FIG. 25 is a rear elevation view of the golf club head of FIG. 24, further comprising a badge and an insert.

FIG. 26 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 25.

FIG. 27 is a rear elevation view of the badge illustrated in FIG. 25.

FIG. 28 is a rear, bottom, toe-side, exploded, perspective view of the golf club head of FIG. 25.

FIG. 29 is a sole plan view of the golf club head of FIG. 28.

FIG. 30 is a toe-side elevation view, in cross-section, of a golf club head according to the present disclosure.

FIG. 31 is a front elevation view of the golf club head of FIG. 30.

FIG. 32 is a toe-side elevation view, in cross-section, of the golf club head of FIG. 30.

FIG. 33 is a rear elevation view of a club head according to the present disclosure.

FIG. 34 is a rear, top, heel-side perspective view of the golf club head of FIG. 33, omitting the badge and insert.

FIG. 35 is a rear elevation view of the golf club head of FIG. 33, omitting the badge and insert.

FIG. 36 is a rear elevation view of the golf club head of FIG. 33, omitting the badge and insert.

FIG. 37 illustrates a rear elevation view of a golf club head according to the present disclosure, omitting the insert and back plate.

FIG. 38 illustrates a toe-side elevation view, in cross-section, of the golf club head of FIG. 37, omitting the insert and back plate.

FIG. 39 illustrates a toe-side elevation view, in cross-section, of the golf club head of FIG. 37.

FIG. 40 illustrates a rear elevation view of a back plate.

FIG. 41 illustrates a toe-side elevation view, in cross-section, of a golf club head according to the present disclosure.

FIG. 42 illustrates a rear elevation view of the golf club head of FIG. 41.

DEFINITIONS

I. Introduction

Described herein are embodiments of an iron-type golf club head with high forgiveness further having a desirable sound and feel. The club head comprises a cavity-back construction comprising a rear cavity and significant perimeter weighting that provides a high moment of inertia and increases forgiveness. The club head further comprises a damping system including an insert and a badge each made of a material suitable to damp vibrations. The damping system covers a large percentage of the back of the strike face with said damping material to damp vibrations at impact and provide a desirable sound and feel to the club head. The damping system can comprise a coverage area greater than 85% of an available surface area of the back face, greater than 75% of a surface area of the scoring area, and greater than 60% of the total surface area of the strike face. The high damping system coverage area leads to reducing the amplitude of certain vibrations by over 40%. The badge can also serve to visually fill the rear cavity to provide the appearance of a muscle-back club head. The club head comprises the forgiveness of a cavity-back iron with the sound, feel, and appearance of a muscle-back iron.

II. Definitions

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

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 invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and/or otherwise.

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

The term “strike face perimeter,” as used herein, can refer to an edge of the strike face. The strike face perimeter can be located along an outer edge of the strike face where the curvature deviates from a bulge and/or roll of the strike face.

The term “geometric centerpoint,” or “geometric center” as used herein, can refer to a geometric centerpoint of the strike face perimeter, and at a midpoint of the face height of the strike face. In the same or other examples, the geometric centerpoint also can be centered with respect to an engineered impact zone, which can be defined by a region of grooves on the strike face. As another approach, the geometric centerpoint of the strike face can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA). For example, the geometric centerpoint of the strike face can be determined in accordance with Section 6.1 of the USGA's Procedure for Measuring the Flexibility of a Golf Clubhead.

The term “ground plane,” as used herein, can refer to a reference plane associated with the surface on which a golf ball is placed. The ground plane can be a horizontal plane tangent to the sole at an address position.

The term “loft plane,” as used herein, can refer to a reference plane that is tangent to the geometric centerpoint of the strike face.

The term “loft angle,” as used herein, can refer to an angle measured between the loft plane and the XY plane (defined below).

The term “face height,” as used herein, can refer to a distance measured parallel to loft plane between a top end of the strike face perimeter and a bottom end of the strike face perimeter.

The term “blade length,” as used herein, can refer to a heel-to-toe distance measured between the scoring area heel boundary 196 and the heel-most extent of the strike face.

The term “lie angle,” as used herein, can refer to an angle between a hosel axis, extending through the hosel, and the ground plane. The lie angle is measured from a front view.

The term “iron,” as used herein, can, in some embodiments, refer to an iron-type golf club head having a loft angle that is 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, or less than approximately 40 degrees. Further, in many embodiments, the loft angle of the club head is 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.

In many embodiments, such as for “game improvement irons”, the volume of the club head is less than approximately 65 cc, less than approximately 60 cc, less than approximately 55 cc, or less than approximately 50 cc. In some embodiments, the volume of the club head can be approximately 50 cc to 60 cc, approximately 51 cc-53 cc, approximately 53 cc-55 cc, approximately 55 cc-57 cc, or approximately 57 cc-59 cc.

In many embodiments, such as for “player's irons”, the volume of the club head is less than approximately 45 cc, less than approximately 40 cc, less than approximately 35 cc, or less than approximately 30 cc. In some embodiments, the volume of the club head can be approximately 31 cc-38 cc (1.9 cubic inches to 2.3 cubic inches), approximately 31 cc-33 cc, approximately 33 cc-35 cc, approximately 35 cc-37 cc, or approximately 37 cc-39 cc.

The term or phrase “cavity-back” as used herein, can refer to a perimeter weighted iron-type golf club head comprising a rear cavity exposed to the rear exterior of the club head.

The term or phrase “muscle-back” as used herein, can refer to an iron-type golf club head comprising a substantially solid construction wherein the club head does not comprise a rear cavity, but instead comprises a full back or rear of the club head.

Club head sound and feel are influenced by the vibrational response at impact. At impact, the club head vibrates at a variety of natural frequencies (also known as “modes” of vibration) comprising a variety of different amplitudes. The club head design and construction determine the variety of different amplitudes that occur at the variety of natural frequencies. Natural frequencies with high amplitudes are considered “dominant” and contribute most significantly to the sound of the club head. If the amplitude of the dominant frequencies is too high, the club head can sound loud and displeasing to the golfer. Natural frequencies with amplitudes lower than that of the dominant frequency are considered “residual” and contribute to a “ringing” sensation in the club head, wherein the sound of impact and the vibrational sensation felt in the golfer's hands are undesirably sustained.

By reducing the amplitude of said natural frequencies, the overall volume, harshness, and ringing of the club head can be minimized, providing a muted, pleasing sound and feel at impact. The process of reducing said amplitudes is hereafter referred to as “damping.” “Mass damping” refers to the damping of vibrations by increasing mass at or near the location where the vibration occurs. “Viscoelastic damping” refers to the damping of vibrations by applying a material with viscoelastic properties at or near the location where the vibration occurs.

III. General Description—Golf Club Head

FIGS. 1-42 schematically illustrate various embodiments of an iron-type golf club head in various views. The features discussed below are demonstrated on club head 100. For ease of discussion, the features shown on club head 100 are applicable to various embodiments of the club head according to the present invention. Any one or more of the features described in the various embodiments below can be used in combination with one another. Further, while different embodiments may comprise different numbering schemes (i.e. 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e. club head 100 comprises a top rail 120 and a sole 118, whereas club head 200 comprises a top rail 220 and a sole 218).

Referring to FIGS. 1 and 2, the club head comprises a club head body forming a strike face 102 having a geometric center 101, a back face 104 opposite the strike face 102, a top rail 120, a sole 118 opposite the top rail 120, a toe 110, a heel 106 opposite the toe 110, and a leading edge 115 defining a transition between the strike face 102 and the sole 118. The top rail 120, sole 118, toe 110, and heel 106 each extend rearwardly from the perimeter of the strike face 102. The club head 100 further comprises a rear wall 114 extending upward from the sole 118, at least partially between the sole 118 and the top rail 120. In some embodiments, as illustrated in FIG. 2, the rear wall 114 only extends partially between the sole 118 and the top rail 120, thereby creating a rear cavity 160 exposed to the club head exterior. The club head 100 further comprises a hosel 103 located proximate the heel 106 and configured to receive a golf club shaft (not shown). The strike face 102 further defines a plurality of score lines 105 extending in a heel-toe toe direction parallel to the ground plane 1000.

Referring to FIG. 1, the club head 100 further comprises a scoring area 194 defined as the area of the strike face 102 occupied by the plurality of score lines 105. The scoring area 194 comprises a scoring area heel boundary 196 defined by a line connecting the heel-most extent of the plurality of score lines 105 and a scoring area toe a 197 defined by a line connecting the toe-most extent of the plurality of score lines 105. The scoring area 194 can extend from the strike face perimeter near the top rail 120 to the strike face perimeter near the sole 118. The scoring area 194 can be bounded on the top by the top rail 120 and on bottom by the leading edge 115.

Referring to FIG. 1B, the strike face 102 comprises an impact point 113 representing a target impact location. The impact point 113 is centered between the scoring area heel boundary 196 and the scoring area toe boundary 197 and is located at a distance D_I of 0.70 inch above the leading edge 115, measured parallel to the loft plane. The club head 100 further defines an impact axis 117 that extends through the impact point 113, perpendicular to the loft plane. In some embodiments, the impact point 113 may be located at the geometric center 101. In other embodiments, the impact point 113 and the geometric center 101 can be at distinct locations.

As illustrated in FIGS. 1A and 1B, the golf club head comprises a primary coordinate system centered about the geometric center 101. The primary coordinate system comprises an X-axis 5000, a Y-axis 6000, and a Z-axis 7000. The X-axis 5000 extends in a heel-to-toe direction, parallel to the ground plane 1000. The X-axis 5000 is positive towards the heel 106 and negative towards the toe 110. The Y-axis 6000 extends in a vertical direction and is orthogonal to both the ground plane 1000 and the X-axis 5000. The Y-axis 6000 is positive towards the top rail 120 and negative towards the sole 118. The Z-axis 7000 extends in a front-to-rear direction, parallel to the ground plane 1000, and is orthogonal to both the X-axis 5000 and the Y-axis 6000. The Z-axis 7000 is positive towards the strike face 102 and negative towards the rear wall 114.

The primary coordinate system, as described herein, defines an XY plane (XY) as a vertical plane extending along the X-axis 5000 and the Y-axis 6000. The primary coordinate system defines an XZ plane (XZ) as a horizontal plane extending along the X-axis 5000 and the Z-axis 7000. The primary coordinate system further defines a YZ plane (YZ) as a vertical plane extending along the Y-axis 6000 and the Z-axis 7000. The XY plane (XY), the XZ plane (XZ), and the YZ plane (YZ) 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 (XY). Further, in these or other embodiments, the golf club head 100 can be viewed from a side view when the heel 106 or the toe 110 is viewed from a direction perpendicular to the YZ plane (YZ).

The golf club head 100 comprises a club head center of gravity 199 (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 199 is illustrated in FIGS. 1A-1D.

The club head CG position can be described with respect to the primary coordinate system, wherein the club head CG position is characterized by locations along the X-axis 5000, the Y-axis 6000, and the Z-axis 7000. The term “CG_X” can refer to the club head CG location along the X-axis 5000, measured from the geometric center 101. The term “CG height” can refer to the club head CG location along the Y-axis 6000, measured from the geometric center 101. The term “CG_Y” can be synonymous with the CG height. The term “CG depth” can refer to the club head CG location along the Z-axis 7000, measured from the geometric center 101. The term “CG_Z” can be synonymous with the CG depth. Alternatively, the club head CG position can be described with respect to the leading edge 115, the ground plane 1000, or any other reference point, reference plane, or coordinate system. In some embodiments, the CG position can be described in relation to the impact axis. In such embodiments, the CG position can be described by a distance from the impact axis in the X-axis direction and/or a distance from the impact axis in a “vertical loft direction” defined parallel to both the loft plane and the YZ plane.

The term or phrase “moment of inertia” (hereafter “MOI”) can refer to values measured about the CG. The term “MOIxx” or “Ixx” can refer to the MOI measured in the heel-to-toe direction, parallel to the X-axis 5000. The term “MOIyy” or “Iyy” can refer to the MOI measured in the sole-to-top rail direction, parallel to the Y-axis 6000. The MOI values MOIxx and MOIyy determine how forgiving the club head is for off-center impacts with a golf ball.

The golf club head 100 further comprises a secondary coordinate system centered about the club head CG 199. As illustrated in FIGS. 1A and 1B, the secondary coordinate system comprises an X′-axis 5500, a Y′-axis 6500, and a Z′-axis 7500. The X′-axis 5500 extends in a heel-to-toe direction. The X′-axis 5500 is positive towards the heel 106 and negative towards the toe 110. The Y′-axis 6500 extends in a top rail-to-sole direction and is orthogonal to both the Z′-axis 7500 and the X′-axis 5500. The Y′-axis 6500 is positive towards the top rail 120 and negative towards the sole 118. The Z′-axis 7500 extends front-to-rear direction, parallel to the ground plane 1000 and is orthogonal to both the X′-axis 5500 and the Y′-axis 6500. The Z′-axis 7500 is positive towards the strike face 102 and negative towards the rear wall 114.

The golf club head 100 comprises one or more moment of inertia values (hereafter “club head MOI”) with respect to the secondary coordinate system. The term “I_XX” can refer to the club head MOI measured about the X′-axis 5500. The term “I_YY” can refer to the club head MOI measured about the Y′-axis 6500. The term “I_ZZ” can refer to the club head MOI measured about the Z′-axis 7500.

DESCRIPTION

IV. Club Head with Damping System

Described herein are various embodiments of an iron-type golf club head with high forgiveness and a desirable sound and feel. The iron-type golf club head comprises a damping system including an insert and a badge. The insert and badge are made from one or more damping materials. The damping system covers a large percentage of the back of the strike face with said damping material, thereby damping impact vibrations and improving club head sound and feel. The damping system can comprise a coverage area greater than 85% of an available back face surface area, greater than 75% of a scoring area surface area, and greater than 60% of the total strike face surface area. The high damping system coverage area reduces certain vibration amplitudes by over 40%.

In some embodiments, the badge visually fills the rear cavity to provide the appearance of a muscle-back club head. The club head can be a cavity-back club head comprising various perimeter weighting features. Applying the damping system to a cavity-back club head balances ball flight, sound, and feel, all while providing the appearance of a muscle-back iron. The damping system combined with the high forgiveness of a cavity-back iron creates an appealing iron-type golf club head.

In some embodiments, the club head CG is substantially aligned with respect to the impact axis. Aligning the CG with the impact axis improves ball flight by increasing ball speed. Further, aligning the CG with the impact axis improves club head sound and feel by reducing club head rotation and vibration. In such embodiments, the club head can comprise a lightweight badge having a mass less than 5 grams and a badge MOI less than 7.5 g·cm² that lowers the club head CGy position toward the impact axis. Such embodiments can also include a pronounced toe mass that counteracts the mass of the hosel and centers the club head CG_X position about the impact axis. In some embodiments, the club head CG is within 0.050 inch of the impact axis in the X-axis direction and within 0.025 inch of the impact axis in the vertical loft direction.

a) Insert Cavity and Rear Wall

Referring to FIGS. 2 and 4, the club head 100 defines an insert cavity 122 formed between the rear wall 114 and the back face 104. The insert cavity 122 can extend generally soleward from a rear wall top edge 134, between the rear wall inner surface 126 and a back face lower portion 132. In many embodiments, the insert cavity 122 is bounded by the rear wall inner surface 126, the back face lower portion 132, a toe inner surface 130, a heel inner surface 128, an inner surface of the sole 118, or a combination thereof. As illustrated in FIG. 4, the insert cavity 122 comprises an insert cavity opening 124 proximate the rear wall top edge 134. The insert cavity opening 124 provides access to the insert cavity 122 from the exterior of the club head 100 to allow the insert cavity 122 to receive an insert 140, as discussed in further detail below. In many embodiments, as illustrated in FIG. 4, the inner surface of the sole 118 forms a cavity base 136 upon which the insert 140 can rest when secured within the insert cavity 122.

The size and shape of the insert cavity 122 is at least partially defined by the shape of the rear wall 114. As discussed above and illustrated in FIG. 2, the rear wall 114 extends upward from the sole 118 at least partially towards the top rail 120. The rear wall 114 does not extend all the way to the top rail 120 and does not contact the top rail 120. By only extending upward only a portion of the distance between the sole 118 and the top rail 120, the rear wall 114 creates a club head 100 with a cavity-back construction wherein a rear cavity 160 is formed and at least a portion of the back face 104 is exposed.

Referring to FIG. 2, the rear wall 114 defines a rear wall height 2150 measured vertically between the ground plane 1000 and the rear wall top edge 134. In some embodiments, rear wall height 2150 can be substantially constant in a heel-to-toe direction. In other embodiments, the rear wall height 2150 can vary between the heel 106 and the toe 110. In some embodiments, referring to FIG. 2, the rear wall height 2150 can increase from the heel 106 to the toe 110 in a substantially linear fashion. In many embodiments, the rear wall height 2150 can vary linearly or non-linearly. The rear wall height 2150 can be greater near the heel 106 than near the toe 110 or greater near the toe 110 than near the heel 106. In some embodiments, discussed in further detail below, the rear wall height 2150 can comprise a maximum or a minimum approximately halfway between the heel 106 and the toe 110 such that the rear wall 114 forms an apex or a nadir. The rear wall height 2150 can influence the club head CG position. In some embodiments, described in further detail below, the rear wall height 2150 can vary to achieve a desired club head CG position. In some embodiments, for example, the rear wall height 2150 can be greater near the toe 110 than near the heel 106 to balance the mass of the hosel 103 and align the club head CG with the impact axis 117.

In some embodiments, the rear wall height 2150 can be between 0.25 and 1.50 inch. In some embodiments, one or more portions of the rear wall 114 can comprise a rear wall height 2150 between 0.25 and 0.50 inch, between 0.30 and 0.55 inch, between 0.35 and 0.60 inch, between 0.40 and 0.65 inch, between 0.45 and 0.70 inch, between 0.50 and 0.75 inch, between 0.55 and 0.80 inch, between 0.60 and 0.85 inch, between 0.65 and 0.90 inch, between 0.70 and 0.95 inch, between 0.75 and 1.00 inch, between 0.80 and 1.05 inches, between 0.85 and 1.10 inches, between 0.90 and 1.15 inches, between 0.95 and 1.20 inches, between 1.00 and 1.25 inches, between 1.05 and 1.30 inches, between 1.10 and 1.35 inches, between 1.15 and 1.40 inches, between 1.20 and 1.45 inches, or between 1.25 and 1.50 inches.

As illustrated in FIG. 4, the rear wall 114 can form a rear wall lip 137 on an inner side of the rear wall top edge 134. As discussed in further detail below, the rear wall lip 137 serves to create a gap 168 between the rear wall top edge 134 and the badge 170 and/or the insert 140. In many embodiments, the insert cavity opening 124 can be located at the transition between the rear wall lip 137 and the rear wall inner surface 126.

As discussed above, the insert cavity 122 extends soleward from the insert cavity opening 124 located near the rear wall top edge 134 to the insert cavity base 136. As such, the size and shape of the insert cavity 122 depends on the geometry of the rear wall 114 and the rear wall height 2150. For example, providing a greater rear wall height 2150 can increase the cavity depth 2200.

As illustrated by FIG. 4, the insert cavity 122 comprises an insert cavity depth 2200 measured parallel to the strike face 102 between the insert cavity base 136 and insert cavity opening 124. In many embodiments, the insert cavity depth 2200 can range between 0.25 inch and 0.75 inch. In some embodiments, the insert cavity depth 2200 can range inclusively between 0.25 inch and 0.35 inch, between 0.35 inch and 0.45 inch, between 0.45 inch and 0.55 inch, between 0.55 inch and 0.65 inch, or between 0.65 inch and 0.75 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.25 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.35 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.45 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.55 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.65 inch. In some embodiments, the insert cavity depth 2200 can be greater than 0.75 inch.

In many embodiments, the insert cavity 122 comprises a volume greater than 0.15 in³. In many embodiments, the insert cavity 122 comprises a volume greater than 0.175 in³. In many embodiments, the insert cavity 122 comprises a volume greater than 0.20 in³. In many embodiments, the insert cavity 122 comprises a volume greater than 0.225 in³. In many embodiments, the insert cavity 122 comprises a volume greater than 0.25 in³.

b) Heel and Toe Masses

As illustrated by FIG. 2, the heel 106 and the toe 110 form a heel mass 108 and a toe mass 112, respectively. The heel mass 108 and the toe mass 112 comprise concentrations of mass configured to increase the perimeter weighting of the club head 100 and increase MOI. In many embodiments, the heel mass 108 and the toe mass 112 are integral with the club head and can be integrally formed with the club head 100, such as through a casting process. Referring to FIG. 7, the heel mass 108 forms the heel inner surface 128 and the toe mass 112 forms the toe inner surface 130. The heel mass 108 and the toe mass 112 can be situated at the heel and toe ends of the insert cavity 122, such that the insert cavity 122 is situated directly between the heel mass 108 and the toe mass 112. The heel inner surface 128 and the toe inner surface 130 can therefore define the heel side and toe side boundaries of the insert cavity 122. In addition to increasing MOI, in some embodiments, the heel mass 108 and toe mass 112 can improve club head CG position. For example, in some embodiments (described in further detail below), the club head 100 can comprised a pronounced toe mass that balances the hosel mass and aligns the CG_X position with the impact axis 117.

c) Insert

As illustrated in FIG. 5A, the club head 100 comprises an insert 140 configured to be secured within the insert cavity 122. The insert 140 can be inserted through the insert cavity opening 124 and mechanically and/or adhesively secured within the insert cavity 122. In the embodiment illustrated by FIG. 5A, when inserted into the insert cavity 122, a front surface 150 of the insert 140 abuts the back face lower portion 132, a toe surface 144 of the insert 140 abuts the toe inner surface 130, a heel surface 148 of the insert 140 abuts the heel inner surface 128, and a rear surface 152 of the insert 140 abuts the rear wall inner surface 126, and a bottom surface 146 of the insert 140 abuts the insert cavity base 136. The insert 140 can further comprise a top surface 142 opposite the bottom surface 146 and proximate the insert cavity opening 124.

The insert 140 can be made of a material comprising viscoelastic properties. In this way, the insert 140 provides viscoelastic vibration damping benefits to the club head by placing the insert 140 material in contact with the back face lower portion 132, the rear wall inner surface 126, the toe inner surface 130, the heel inner surface 128, and/or the insert cavity base 136. The contact between these areas of the club head 100 and the insert 140 damps vibrations occurring in and around said areas. In this way, the inclusion of the insert 140 within the insert cavity 122 provides a more desirable sound and feel to the club head 100.

The insert 140 at least partially fills the insert cavity 122. In many embodiments, such as the embodiment illustrated in FIG. 5A, the insert 140 substantially fills the entire volume of the insert cavity 122. In such embodiments, the insert 140 is complementarily shaped to the geometry of the insert cavity 122 and a top surface 142 of the insert 140 is flush with the insert cavity opening 124. In other embodiments, the insert 140 may only partially fill the volume of the insert cavity 122, such that the insert top surface 142 is recessed within the cavity. In other embodiments, the insert 140 may overfill the insert cavity 122 such that at least a portion of the insert 140 including the insert top surface 142 extends above the insert cavity opening 124. In many embodiments, the insert 140 can fill between 75% and 100% of the volume of the insert cavity 122. In many embodiments, the insert 140 can fill a range varying inclusively between 75% and 80%, 80% and 85%, 85% and 90%, 90% and 95%, or between 95% and 100% of the volume of the insert cavity 122. In some embodiments, the insert 140 can fill approximately 75%, 80%, 85%, 90%, 95%, or 100% of the volume of the insert cavity. In some embodiments, the insert 140 can fill between 75% and 85%, 85% and 95%, 80% and 90%, 75% and 90%, or between 85% and 100% of the volume of the insert cavity 122.

In many embodiments, the insert 140 comprises a contact area defined between the insert front surface 150 and the back face lower portion 132. In many embodiments, the contact area between the insert front surface 150 and the back face lower portion 132 can range between 0.70 in² and 1.5 in². In some embodiments, the contact area between the insert front surface 150 and the back face lower portion 132 can be between 0.70 in² and 0.80 in², between 0.80 in² and 0.90 in², between 0.90 in² and 1.0 in², between 1.0 in² and 1.1 in², between 1.1 in² and 1.2 in², between 1.2 in² and 1.3 in², between 1.3 in² and 1.4 in², or between 1.4 in² and 1.5 in². In some embodiments, the contact area between the insert front surface 150 and the back face lower portion 132 is greater than 0.70 in², greater than 0.80 in², greater than 0.90 in², greater than 1.0 in², greater than 1.1 in², greater than 1.2 in², greater than 1.3 in², greater than 1.4 in², or greater than 1.5 in².

In many embodiments, referring to FIG. 5A, the insert 140 can be located substantially low with respect to the strike face 102. For example, the insert 140 can be located entirely below the geometric center 101 of the strike face 102. As illustrated by FIG. 5A, the insert top surface 142 is below the geometric center 101 of the strike face 102. If any portion of the insert 140 is located too high with respect to the strike face 102 (e.g. if a portion of the insert 140 is located at or above the geometric center 101), the insert 140 itself may vibrate or rattle and contribute to an undesirable sound and feel at impact. Further, if the insert 140 is too high, the club head CG 199 may be raised away from the impact axis 117. Positioning the insert 140 below the geometric center 101 of the strike face 102 minimizes insert vibration and aligns the club head CG 199 with the impact axis 117, thus improving sound, feel, and performance.

As discussed above, the insert 140 can be formed of a material comprising viscoelastic and/or damping properties. In many embodiments, the material of the insert 140 can comprise a polymer, a urethane material, a urethane-based material, an elastomer material, a thermoplastic material, other suitable types of material, a composite, or a combination thereof. In some embodiments, the material of the insert 140 can comprise a thermoplastic elastomer, thermoplastic polyurethane, resin, or resin mixed with powdered metals. In some embodiments, the resin can comprise a thermoplastic elastomer, or thermoplastic polyurethane.

In embodiments wherein the insert 140 comprises a resin mixed with powdered metal, the powdered metal can comprise steel, stainless steel, tungsten, or another suitable metal. In some embodiments, the insert 140 can comprise one powdered metal. In other embodiments, the insert 140 can comprise multiple types of powdered metals. For example, the insert 140 can comprise the resin and the stainless steel powdered metal, the resin and the tungsten powdered metal, or the resin, the stainless steel powdered metal, and the tungsten powdered metal. The insert 140 can further comprise a percentage of powdered metal by volume. The insert 140 can comprise 0% to 50% powdered metal by volume. In some embodiments, the insert 140 can comprise 0% to 10%, 10% to 20%, 20% to 30%, 30% to 40%, or 40% to 50% powdered metal by volume. For example, the insert 140 can comprise 0%, 1%, 10%, 20%, 30%, 40%, or 50% powdered metal by volume. The powdered metal percentage varies approximately linearly with the mass of the insert 140. As the mass of the insert 140 increases, the powdered metal percentage increases.

In many embodiments, the insert 140 comprises a hardness that can range from Shore A 10 to Shore A 55. In some embodiments, the hardness of the insert 140 can range from Shore A 10 to Shore A 25, Shore A 15 to Shore A 25, Shore A 20 to Shore A 30, Shore A 25 to Shore A 35, Shore A 25 to Shore A 40, or Shore A 40 to Shore A 55. For example, the hardness of the insert 140 can have a Shore A value of 10, 15, 25, 30, 35, 40, 45, 50, or 50. The hardness of the insert 140 is designed to allow the insert 140 damp vibrations while still allowing the strike face 102 to flex.

Because the insert 140 is located in a central portion of the club head 100 (i.e. in a position near the club head CG 199), it is desirable for the insert 140 to be substantially lightweight. Providing a lightweight insert 140 allows a greater amount of mass to be distributed to the periphery of the club head 100, increasing MOI. In many embodiments, the insert 140 comprises a density or specific gravity less than the club head body material. In many embodiments, the insert 140 can comprise a specific gravity between 0.5 and 5.0. In many embodiments, the insert 140 can comprise a specific gravity between 0.5 and 1.0, 1.0 and 1.5, 1.5 and 2.0, 2.0 and 2.5, 2.5 and 3.0, 3.0 and 3.5, 3.5 and 4.0, 4.0 and 4.5, or between 4.5 and 5.0. In some embodiments, the insert 140 can comprise a specific gravity of approximately 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, or 5.0. In some embodiments, the insert 140 can comprise a specific gravity ranging inclusively between 0.5 and 1.5, 1.5 and 3.0, 3.0 and 4.0, or between 4.0 and 5.0.

In many embodiments, the insert 140 can comprise a mass between 1 g and 10 g. In many embodiments, the insert 140 can comprise a mass ranging inclusively between 1 g and 2 g, 2 g and 3 g, 3 g and 4 g, 4 g and 5 g, 5 g and 6 g, 6 g and 7 g, 7 g and 8 g, 8 g and 9 g, or between 9 g and 10 g. In some embodiments, the insert 140 can comprise a mass ranging inclusively between 1 g and 4 g, 4 g and 7 g, or between 7 g and 10 g. In some embodiments, the insert 140 can comprise a mass of approximately 1 g, 2 g, 3 g, 4 g, 5 g, 6 g, 7 g, 8 g, 9 g, or 10 g.

Referring now to FIG. 6, the insert 140 comprises a top surface 142, a bottom surface 146 opposite the top surface 142, a front surface 150, a rear surface 152 opposite the front surface 150, a heel surface 148, and a toe surface 144 opposite the heel surface 148.

In many embodiments, such as the embodiment illustrated in FIG. 6, the insert can be asymmetric. The insert 140 can define a height measured between the bottom surface 146 and the top surface 142. In many embodiments, the height of the insert 140 can vary in a heel-toe-toe direction. For example, in the embodiment of FIG. 6, the height of the insert 140 can increase from the insert heel surface 148 to the insert toe surface 144. In other embodiments, the height of the insert can increase from the insert toe surface 144 to the insert heel surface 148. In other embodiments, discussed in further detail below, the insert 140 can comprise a maximum or minimum height between the insert heel surface 148 and the insert toe surface 144, such that the insert forms either an apex or a nadir. In some embodiments, the height of the insert 140 can remain constant in a heel-to-toe direction.

The insert 140 can also define a thickness measured between the insert front surface 150 and the insert rear surface 152. In some embodiments, the thickness of the insert 140 is substantially constant. In some embodiments, the thickness of the insert 140 can vary in a heel-to-toe direction and/or between the top surface 142 and the bottom surface 146. In many embodiments, such as the embodiment illustrated in FIG. 6, the thickness of the insert 140 can be greater near the insert toe surface 144 than near the insert heel surface 148.

As illustrated by way of example in FIG. 6, the insert 140 can further comprise one or more recesses 156 on the front surface 150. In some embodiments the one or more recesses 156 can be positioned on the front surface 150. In other embodiments, the one or more recesses 156 can be positioned on a combination of the front surface 150 of the insert 140 and the rear surface 152 of the insert 140. In some embodiments, the one or more recesses 156 can be positioned centrally on the front surface 150 and/or the rear surface 152 in between the heel surface 148 and the toe surface 144 of the insert 140. In other embodiments, the one or more recesses 156 can be positioned near the heel surface 148 or near the toe surface 144 of the insert 140. In some embodiments, the insert 140 can comprise one, two, three, four, five, or six recesses 156. In these embodiments, the one or more recesses 156 can be spaced equidistant from one another; while in other embodiments, the one or more recesses 156 can be spaced any distance from one another. In these embodiments, the one or more recesses 156 allows for a greater flow of an adhesive (such as epoxy) into the insert cavity 122 and more adhesive to be positioned between the insert cavity 122 and the insert 140. The greater amount of adhesive positioned between the insert cavity 122 and the insert 140 allows for more surface area of the insert 140 to couple with back face lower portion 132. The greater adhesive surface area secures the insert 140 within the insert cavity 122 and prevents the insert 140 from dislodging during use. The one or more grooves 158 (as described below), the one or more recesses 156, and one or more ribs 154 (as described below) together provide an optimal coupling of the surfaces of the insert 140 within the insert cavity 122. In an exemplary embodiment, as illustrated in FIG. 6, the one or more recesses 156 can comprise three recesses positioned centrally on the front surface 150 of the insert 140 that are spaced equidistant from one another.

The insert 140 can further comprise one or more grooves 158. The one or more grooves 158 can be positioned on the rear surface 152 of the insert 140. In some embodiments the one or more grooves 158 can be positioned on the front surface 150. In other embodiments, the one or more grooves 158 can be positioned on a combination of the front surface 150 of the insert 140 and the rear surface 152 of the insert 140. The one or more grooves 158 can receive one or more protrusions (not shown) from the insert cavity 122 to secure the insert 140. The one or more protrusions of the insert cavity 122 and the one or more grooves 158 of the insert 140 have complementary geometries to allow for a mechanical interlock. In addition to the mechanical interlock between the one or more protrusions, and the one or more grooves 158, the insert 140 can be secured within the insert cavity 122 with a press-fit, a friction fit, an adhesive, or any combination thereof. In some embodiments, the insert 140 can be secured within the insert cavity 122 without the use of threads. The structural interlock between the one or more protrusions and the one or more grooves 158 secures the insert 140 within the insert cavity 122, lowering the likelihood of the insert 140 dislodging during use.

The insert 140 can further comprise one or more ribs 154. The one or more ribs 154 can be positioned on the rear surface 152 of the insert 140. In some embodiments, the one or more ribs 154 can be positioned on the front surface 150. In other embodiments, the one or more ribs 154 can be positioned on the front surface 150, the rear surface 152, the heel surface 148, the toe surface 144, or any combination thereof. In some embodiments, the one or more ribs 154 can be positioned near the heel surface 148 or near the toe surface 144 on the insert 140. Furthermore, the one or more ribs 154 can be orientated perpendicular (straight up and down) relative to the top surface 142 of the insert 140. In other embodiments, the one or more ribs 154 can be orientated at various angles relative to top surface 142. In some embodiments, the insert 140 can comprise one, two, three, four, five, six, seven, eight, nine, ten, eleven, or twelve ribs 154. In some embodiments, the one or more ribs 154 are oriented in the same direction. In other embodiments, the one or more ribs 154 are oriented in different directions than the other one or more ribs 154. In embodiments with more than one rib 154, the ribs 154 can be spaced equidistant from one another, or spaced any distance from one another. In some embodiments, an adhesive is applied within the insert cavity 122 to help secure the insert 140. The combination of the adhesive and the one or more ribs 154 prevents the insert 140 from shifting within the insert cavity 122. In many embodiments, the one or more ribs 154 allow for the insert 140 to compress as it is being positioned within the insert cavity 122.

d) Rear Cavity

Referring to FIGS. 2 and 4, the club head 100 comprises a rear cavity 160. In the present embodiment, the rear cavity 160 is bounded, at least partially, by the top rail 120, the heel 106, the toe 110, and the rear wall 114. In the present embodiment, a top rail rear edge 186, a heel rear edge 188, a toe rear edge 190, and the rear wall top edge 134 form a rear perimeter 182 circumscribing the rear cavity 160. As such, in the present embodiment, the rear cavity 160 is positioned above both the rear wall 114 and the insert cavity 122. Referring to FIG. 4, the rear cavity 160 forms a rear cavity opening 164 located above the rear wall 114 and formed between the top rail rear edge 186 and the rear wall top edge 134. The rear cavity 160 extends inward from the exterior of the club head, from the rear cavity opening 164 to a back face upper portion 162.

In many embodiments, the volume of the rear cavity 160 can range between 0.4 in³ and 0.8 in³. In other embodiments, the volume of the rear cavity 160 can range inclusively between 0.4 in³ and 0.5 in³, 0.5 in³ and 0.6 in³, 0.6 in³ and 0.7 in³, or between 0.7 in³ and 0.8 in³. In some embodiments, the volume of the rear cavity can be approximately 0.4 in³, 0.5 in³, 0.6 in³, 0.7 in³, or 0.8 in³. In some embodiments, the volume of the rear cavity 160 can be greater than 0.4 in³. In some embodiments, the volume of the rear cavity 160 can be greater than 0.5 in³. In some embodiments, the volume of the rear cavity 160 can be greater than 0.6 in³. In some embodiments, the volume of the rear cavity 160 can be greater than 0.7 in³. In some embodiments, the volume of the rear cavity 160 can be greater than 0.8 in³.

The inclusion of the rear cavity 160 provides the club head 100 with a perimeter-weighted, cavity-back construction. The rear cavity 160 shifts mass away from the club head CG 199 and towards the periphery of the club head 100. This peripheral shift of mass increases the MOI and forgiveness of the club head 100. As a result, the club head 100 can be more forgiving than a muscle-back style iron or another iron devoid of a rear cavity.

e) Central Support Bar

Referring to FIG. 2, the club head 100 comprises a central support bar 116 located on the back face 104. The central support bar 116 comprises an area of increased thickness extending from the back face 104 and into the rear cavity 160. The central support bar 116 provides structural reinforcement to certain areas of the strike face 102 and allows other areas of the strike face 102 to be thinned. In many embodiments, such as the embodiment of FIG. 2, the central support bar 116 is formed on the back face upper portion 162. In other embodiments, the central support bar 116 can additionally form at least a portion of the back face lower portion 132.

The central support bar 116 comprises a thickness characterized by the distance that the central support bar 116 extends into the rear cavity 160 relative to the back face 104. In many embodiments, the thickness of the central support bar 116 can range between 0.01 inch and 0.10 inch. In many embodiments, the thickness of the central support bar 116 can range inclusively between 0.01 inch and 0.025 inch, 0.025 inch and 0.05 inch, 0.05 inch and 0.075 inch, or between 0.075 inch and 0.10 inch. In some embodiments, the thickness of the central support bar 116 can be approximately 0.01 inch, 0.02 inch, 0.03 inch, 0.04 inch, 0.05 inch, 0.06 inch, 0.07 inch, 0.08 inch, 0.09 inch, or approximately 0.10 inch.

Referring to FIG. 7, In some embodiments, the central support bar 116 comprises a central support bar width 2350 extending in a heel-to-toe direction. In many embodiments, the central support bar width 2350 can increase in a top rail-to-sole direction. In other embodiments, the central support bar width 2350 can be substantially constant or the central support bar width 2350 can decrease in a top rail-to-sole direction.

In many embodiments, the central support bar 116 is centrally located on the back face 104 to provide structural reinforcement areas of the strike face 102 where impact forces are the greatest. Providing structural reinforcement in a central area of the strike face 102 allows other areas of the strike face 102 to be thinned, thus increasing ball speed without sacrificing structural integrity.

f) Badge

As illustrated by FIGS. 3 and 5A, the rear cavity 160 is configured to receive a badge 170 to damp vibrations within the club head 100. The badge 170 comprises viscoelastic properties to damp vibrations and produce a club head 100 with desirable sound and feel. In some embodiments, the badge 170 comprises a relatively high mass (compared to prior art badges or medallions) that improves sound and feel through mass damping. In other embodiments, as described in further detail below, the badge 170 can be substantially lightweight to reduce vibrations by aligning the club head CG with the impact axis 117. The badge 170 can be housed within the rear cavity 160 and coupled to the back face upper portion 162. The badge 170 can serve to damp vibrations occurring at or near the back face upper portion 162 including vibrations occurring in the strike face 102 and/or the top rail 120.

In many embodiments, the badge 170 comprises a contact area defined between badge 170 and the back face upper portion 162. In many embodiments, the contact area between the badge 170 and the back face upper portion 162 can range between 2.0 in² and 3.0 in². In some embodiments, the contact area between the badge 170 and the back face upper portion 162 can be between 2.0 in² and 2.1 in², between 2.1 in² and 2.2 in², between 2.2 in² and 2.3 in², between 2.3 in² and 2.4 in², between 2.4 in² and 2.5 in², between 2.5 in² and 2.6 in², between 2.6 in² and 2.7 in², between 2.7 in² and 2.8 in², between 2.8 in² and 2.9 in², or between 2.9 in² and 3.0 in². In some embodiments, the contact area between the insert front surface 150 and the back face lower portion 132 is greater than 2.0 in², greater than 2.1 in², greater than 2.2 in², greater than 2.3 in², greater than 2.4 in², greater than 2.5 in², greater than 2.6 in², greater than 2.7 in², greater than 2.8 in², greater than 2.9 in², or greater than 3.0 in².

Referring to FIG. 3, the badge 170 is configured to visually fill the rear cavity 160 to provide the club head 100 with the appearance of a solidly constructed iron, such as a forged or muscle-back iron. In many embodiments, the badge 170 can fill between 75% and 99% of the volume of the rear cavity 160. In many embodiments, the badge 170 can fill between 75% and 80%, 80% and 85%, 85% and 90%, 90% and 95%, or between 95% and 99% of the volume of the rear cavity 160. In some embodiments, the badge 170 can fill greater than 75%, greater than 80%, greater than 85%, greater than 90%, greater than 95%, or greater than 99% of the volume of the rear cavity 160.

Referring to FIG. 5A, the badge 170 comprises a badge thickness 2300 measured from the inner-most surface of the badge 170 to an outer-most surface. In many embodiments, the badge thickness 2300 can increase from the badge top edge 172 to the badge bottom edge 174. The increase in badge thickness 2300 can roughly correspond to the contour of the club head 100, wherein the thickness of the club head 100 generally increases from the top rail 120 to the sole 118. In many embodiments, the badge thickness 2300 at or near the badge top edge 172 can be substantially similar to the distance between the back face 104 and the top rail rear edge 186. In many embodiments, the badge thickness 2300 at or near the badge bottom edge 174 can be substantially similar to the distance between the back face 104 and the rear wall top edge 134. Matching the badge thickness 2300 to the geometry of the club head 100 allows the badge 170 to visually fill the rear cavity 160 and provide the club head 100 with the appearance of a muscle-back iron.

In many embodiments, the badge thickness 2300 can range between 0.05 inch and 0.80 inch. In many embodiments, the badge thickness 2300 can range inclusively between 0.05 inch and 0.15 inch, 0.15 inch and 0.30 inch, 0.30 inch and 0.45 inch, 0.45 inch and 0.60 inch, 0.60 inch 0.70 inch, or between 0.70 inch and 0.80 inch. In some embodiments, the badge thickness 2300 can be approximately 0.05 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, or approximately 0.80 inch.

In some embodiments, the badge 170 may be slightly recessed with respect to the rear perimeter 182. For example, the badge thickness 2300 near the badge top edge 172 can be slightly less than the distance between the back face 104 and the top rail rear edge 186, and the badge thickness 2300 near the badge bottom edge 174 can be slightly less than the distance between the back face 104 and the rear wall top edge 134. As such, the outer-most surface of the badge 170 can be slightly recessed within the rear cavity 160. Recessing the badge 170 within the rear cavity 160 protects the surface of the badge 170 from damage while still allowing the badge to i fill the rear cavity 160.

In many embodiments, the badge 170 can comprise one or more layers. In some embodiments, the badge 170 can comprise one or more adhesive layers 176, one or more filler layers 180, one or more rigid layers 178, or any combination thereof. In the embodiment of FIG. 5A, the badge 170 includes an adhesive layer 176 in contact with the back face upper portion 162, a rigid layer 178 opposite the adhesive layer 176 and exposed to the rear exterior of the club head 100, and a filler layer 180 disposed between the adhesive layer 176 and the rigid layer 178. The adhesive layer 176 forms the inner-most surface of the badge 170 and serves to secure the badge 170 to the back face 104 as well as assist in the damping of vibrations. The filler layer 180 can serve to increase the thickness of the badge 170 to allow the badge 170 to visually fill the rear cavity 160 without significantly contributing to the mass of the badge 170 and compromising the mass properties of the club head 100. The rigid layer 178 forms the outer-most surface of the badge 170 and serves to protect the badge 170 from damage, such as scratching or denting.

In many embodiments, the adhesive layer 176 comprises both adhesive and damping properties. In many embodiments, the adhesive layer 176 can comprise a viscoelastic material. In many embodiments, the adhesive layer 176 can be a foam-based very high bond tape (e.g. VHB tape). In many embodiments, the adhesive layer 176 can be a tape or other adhesive material with viscoelastic properties. In many embodiments, the adhesive layer 176 can comprise a polymeric material, a resin material, an elastomeric material, or any other material suitable of both adhering the badge 170 to the back face 104 and damping vibrations.

In many embodiments, the adhesive layer 176 can comprise a thickness ranging between 0.02 inch and 0.08 inch. In many embodiments, the adhesive layer 176 can comprise a thickness ranging inclusively between 0.02 inch and 0.03 inch, 0.03 inch and 0.04 inch, 0.04 inch and 0.05 inch, 0.05 inch and 0.06 inch, 0.06 inch and 0.07 inch, or 0.07 inch and 0.08 inch. In some embodiments, the adhesive layer can comprise a thickness of approximately 0.02 inch, 0.03 inch, 0.04 inch, 0.05 inch, 0.06 inch, 0.07 inch, or 0.08 inch.

If the adhesive layer 176 is not sufficiently thick, the connection between the badge 170 and the back face 104 may not be durable, and the badge 170 may become decoupled from the back face 104 during impact. If the adhesive layer 176 is too thick, flexure of the strike face 102 may be restricted and ball speed may be reduced. The thickness of the adhesive layer 176 is designed to provide a secure connection between the badge 170 and the back face 104 without negatively impacting ball speed.

In many embodiments, the adhesive layer 176 can be the only portion of the badge 170 in contact with the back face 104. In such embodiments, the adhesive layer 176 comprises the entire contact area between the badge 170 and the back face upper portion 162. In such embodiments, the adhesive layer 176 is a significant contributor to the damping properties of the badge 170. An increased contact area between the adhesive layer 176 and the back face upper portion 162 can increase vibration damping the connection between the badge 170 and the back face 104. In other embodiments, one or more other layers (such as the filler layer 180 and/or the rigid layer 178) can form a portion of the contact area between the badge 170 and the back face 104.

In many embodiments, the adhesive layer 176 can be the only portion of the badge 170 that contacts any portion of the club head 100. In such embodiments, the adhesive layer 176 is solely responsible for securing the badge 170 to the club head 100. In such embodiments, neither the club head 100 nor the badge 170 comprise any additional retaining features to secure the badge 170 to the club head 100.

In many embodiments, the filler layer 180 can comprise a lightweight material that allows the thickness of the badge 170 to be increased without adding a significant amount of mass. In some embodiments, the filler layer 180 can comprise viscoelastic or other damping properties to assist in the damping of vibrations in the club head 100. In many embodiments, the filler layer 180 can be a viscoelastic polymer configured to dissipate vibrations by converting kinetic energy into heat. The filler layer 180 can comprise any viscoelastic polymer or material such as an elastomer, butyl rubber, silicone rubber, a thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), or other suitable material with viscoelastic properties. In other embodiments, the filler layer 180 can comprise a foam material, a composite material, a plastic material or any other suitable, lightweight material.

In many embodiments, the rigid layer 178 is a single, continuous layer that forms substantially the entire rear surface of the badge 170. In other embodiments, described in further detail below, the rigid layer 178 may be divided into discrete sections separated by gaps, such that portions of the filler layer 180 are exposed to the rear exterior of the club head 100.

In many embodiments, the rigid layer 178 is formed of a relatively hard, protective material. In many embodiments, the rigid layer 178 can be a metallic material such as steel, a steel alloy, aluminum, an aluminum alloy, titanium, a titanium alloy, or any other suitable material or alloy. In some embodiments, the rigid layer 178 can be 304 stainless steel, 17-4 stainless steel, 606 aluminum, 7071 aluminum, 6061 aluminum, or any other suitable material.

In many embodiments, the rigid layer 178 can comprise a hardness between 80 HRB and 110 HRB. In some embodiments, the hardness of the rigid layer 178 can be between 80 HRB and 85 HRB, between 85 HRB and 90 HRB, between 90 HRB and 95 HRB, between 95 HRB and 100 HRB, between 100 HRB and 105 HRB, or between 105 HRB and 110 HRB. In many embodiments the hardness of the rigid layer 178 can be greater than 80 HRB, greater than 85 HRB, greater than 90 HRB, greater than 95 HRB, greater than 100 HRB, greater than 105 HRB, or greater than 110 HRB. In many embodiments, the hardness of the rigid layer 178 can range between 5 HRC and 35 HRC. In some embodiments, the hardness of the rigid layer 178 can be between 5 HRC and 10 HRC, between 10 HRC and 15 HRC, between 15 HRC and 20 HRC, between 25 HRC and 30 HRC, or between 30 HRC and 35 HRC. In some embodiments, the hardness of the rigid layer 178 can be greater than 5 HRC, greater than 10 HRC, greater than 15 HRC, greater than 20 HRC, greater than 25 HRC, greater than 30 HRC, or greater than 35 HRC. Providing a sufficient hardness allows the rigid layer 178, which forms the visual exterior of the badge 170, to be resistant to superficial and/or structural damage, such as scratching or denting.

In many embodiments, the rigid layer 178 can comprise a density ranging between 6.0 g/cm³ and 10.0 g/cm³. In many embodiments, the rigid layer 178 can comprise a density ranging inclusively between 6.0 g/cm³ and 7.0 g/cm³, 7.0 g/cm³ and 8.0 g/cm³, 8.0 g/cm³ and 9.0 g/cm³, or between 9.0 g/cm³ and 10.0 g/cm³. In some embodiments, the rigid layer 178 can comprise a density greater than 6.0 g/cm³. In some embodiments, the rigid layer 178 can comprise a density greater than 7.0 g/cm³. In some embodiments, the rigid layer 178 can comprise a density greater than 8.0 g/cm³. In some embodiments, the rigid layer 178 can comprise a density greater than 9.0 g/cm³. In some embodiments, the rigid layer 178 can comprise a density greater than 10.0 g/cm³.

Providing a sufficient density increases the effectiveness with which the badge 170 can dampen vibrations in the club head 100 by increasing the mass damping abilities of the badge 170. The density of the rigid layer 178 can be designed to provide the badge 170 with sufficient mass to effectively damp vibrations without negatively impacting the mass characteristics of the club head 100. In some embodiments, described in further detail

Additionally, in some embodiments, a surface coating can be applied to the rigid layer 178 to further protect the badge 170. The surface coating can have scratch resistant properties that protect the exterior surface of the rigid layer 178. In many embodiments, the surface coating can be a clear coating that protects the rigid layer 178 without affecting the aesthetic appearance of the badge 170. In many applications, acrylic and urethane paints or primers can be applied as the surface coating to enhance the durability of the badge 170. Generally, acrylic-based primers are flexible and exhibit ample UV-resistance. Urethane-based primers can promote physical durability and chemical resistance. In many embodiments, a clear coat combining acrylic and urethane paints or primers is applied to the badge 170, providing a protective layer that offers UV resistance, dent resistance, and abrasion resistance.

The badge 170 further contributes to the club head 100 having the appearance of a muscle-back iron by concealing the insert 140 and the central support bar 116. Referring to FIG. 5A, the badge 170 can be configured to cover the insert cavity opening 124 and conceal the insert 140 within the insert cavity 122. The badge bottom edge 174 can be configured to extend over the insert cavity opening 124, covering the entire top surface 142 of the insert 140. Covering the insert cavity opening 124 and concealing the insert 140 within the insert cavity 122 allows the insert 140 to be hidden when viewing the exterior of the club head 100 (see FIG. 3). The badge 170 can be configured to substantially cover the entire back face upper portion 162, including the central support bar 116. As such, the central support bar 116 is hidden when viewing the exterior of the club head 100.

In many embodiments, the badge 170 does not contact the rear wall 114. As illustrated by FIG. 5B, a gap 168 can be formed between the rigid layer 178 and the rear wall lip 137. The gap 168 provides sufficient space between the badge 170 and the rear wall 114 so that as the club head 100 flexes at impact, the badge 170 does not collide with the rear wall 114. If a sufficient gap 168 were not provided, the collision between the badge 170 and the rear wall 114 at impact could damage the badge 170 or allow the badge 170 to separate entirely from the club head 100. The inclusion of the gap 168 increases the durability of the club head 100 by protecting the badge 170 and its connection to the back face 104. The inclusion of the gap 168 provides that the insert cavity 122 is not sealed off from the exterior of the club head 100.

Referring again to FIG. 5B, the insert 140 and the badge 170 can be spaced apart from one another, such that the insert 140 and the badge 170 do not contact one another. As such, a clearance gap 165 can be formed between the insert 140 and the badge 170. Specifically, the clearance gap 165 is formed between the badge bottom edge 174 and the insert top surface 142. The clearance gap 165 can provide a greater manufacturing tolerance for forming the insert 140 and/or the badge 170 so that the insert 140 and badge 170 do not contact and damage one another.

In many embodiments, the clearance gap 165 can range between 0.01 inch and 0.04 inch. In some embodiments, the clearance gap 165 can range inclusively between 0.01 inch and 0.02 inch, between 0.02 inch and 0.03 inch, or between 0.03 inch and 0.04 inch. In some embodiments, the clearance gap 165 can be approximately 0.01 inch, 0.015 inch, 0.02 inch, 0.025 inch, 0.03 inch, 0.035 inch, or approximately 0.04 inch.

In some embodiments, the badge 170 can be substantially lightweight. The lightweight badge 170 creates discretionary mass that can be redistributed to areas of the club head that strategically improve club head mass properties. For example, in some embodiments, the discretionary mass created by the lightweight badge 170 can be added to a pronounced toe mass (described in further detail below) that lowers the club head CG 199 and counterbalances the hosel mass. As such, the lightweight badge 170 helps align the club head CG 199 with the impact point 113, thereby improving ball speed and vibrational response (as described above). Because the badge 170 is typically located above the insert cavity 122 and coupled to the back face upper portion 162, the badge mass can raise the club head CG 199 above the impact point 113. The lightweight badge 170 lessens the effect of the badge mass on the club head CG position, thereby lowering the club head CG 199 near the impact point 113. The lightweight badge 170 damps vibrations while keeping the club head CG low.

In some embodiments, the lightweight badge 170 can comprise a reduced thickness compared to other badges described herein. In such embodiments, the lightweight badge 170 may not visually fill the entire rear cavity 160 or conceal the insert 140. In such embodiments, the lightweight badge 170 can comprise a maximum badge thickness 2300 less than 0.50 inch. In some embodiments, the maximum badge thickness 2300 can be less than 0.45 inch, less than 0.40 inch, less than 0.35 inch, less than 0.30 inch, less than 0.25 inch, less than 0.20 inch, less than 0.15 inch, less than 0.10 inch, or less than 0.05 inch.

The lightweight badge 170 can be constructed of relatively lightweight materials to create discretionary mass (relative to a badge constructed of heavier materials). In some embodiments, the lightweight badge 170 comprises one or more rigid layers 178 formed of a relatively lightweight, yet rigid material. In many embodiments, the lightweight badge 170 comprises one or more rigid layers 178 formed of a non-metallic material, such as a plastic or composite material including, but not limited to acrylonitrile butadiene styrene (ABS), polyactic acid (PLA), polycarbonate, polyvinyl chloride, nylon, polypropylene, high impact polystyrene, acetal, high-density polyethylene, acrylic, reinforced polyamide, polycarbonate blends, or a fiber-reinforced resin. In some embodiments, the one or more lightweight rigid layers 178 can comprise a lightweight metal alloy such as aluminum, an aluminum alloy, magnesium, or a magnesium alloy, or a reinforced metal alloy or lightweight metal alloy with a protective covering or coating. In other embodiments, the one or more lightweight rigid layers 178 can comprise another suitable lightweight material such as one or more ceramics, glass, natural fibers, or engineering woods.

The rigid layer material can be selected to balance discretionary mass and badge durability. For example, in some embodiments, the one or more lightweight rigid layers 178 can be ABS or another suitable plastic. Such ABS or other plastic materials are both low-density (as outlined in the following paragraph) and durable. Certain lightweight metals, while creating discretionary mass, can be susceptible to denting. In comparison to lightweight metals, ABS and other suitable plastics have a high level of dent resistance and can absorb energy through deformation without permanent damage. Although the lightweight badge 170 may comprise relatively soft material that is otherwise susceptible to scratches, the lightweight badge 170 can further comprise one or more layers covered in a scratch resistant surface coating similar to those described above. The surface coating can have scratch resistant properties that protect any exterior or exposed badge surfaces from abrasion. The lightweight badge, although formed of lightweight materials, creates discretionary mass without compromising durability.

The one or more lightweight rigid layers 178 can comprise a relatively low density to create discretionary mass. In some embodiments, the one or more lightweight rigid layers 178 can comprise a density between 0.5 g/cm³ and 3.0 g/cm³. In some embodiments, the one or more lightweight rigid layers 178 can comprise a density between 0.5 and 1.5 g/cm³, between 0.75 and 1.75 g/cm³, between 1.0 and 2.0 g/cm³, between 1.25 and 2.25 g/cm³, between 1.5 and 2.5 g/cm³, between 1.75 and 2.75 g/cm³, or between 2.0 and 3.0 g/cm³. In some embodiments, the one or more lightweight rigid layers 178 can comprise a density less than 3.0 g/cm³, less than 2.75 g/cm³, less than 2.5 g/cm³, less than 2.25 g/cm³, less than 2.0 g/cm³, less than 1.75 g/cm³, less than 1.5 g/cm³, less than 1.25 g/cm³, or less than 1.0 g/cm³.

In some embodiments, the lightweight badge 170 can be devoid of a filler layer. Removal of the filler layer further reduces mass and aligns the club head CG with the impact axis 117. In such embodiments, the one or more rigid layers 178 can be coupled directly to the adhesive layer 176. The lack of filler layer reduces the lightweight badge mass while still damping vibrations.

In some embodiments, the badge mass can be between 1 and 10 grams. In some embodiments, the badge mass can be less than 10 grams, less than 9.5 grams, less than 9.0 grams, less than 8.5 grams, less than 8.0 grams, less than 7.5 grams, less than 7.0 grams, less than 6.5 grams, less than 6.0 grams, less than 5.5 grams, less than 5.0 grams, less than 4.5 grams, less than 4.0 grams, less than 3.5 grams, less than 3.0 grams, less than 2.5 grams, or less than 2.0 grams.

In some embodiments, the badge mass distribution aligns the club head CG 199 with the impact axis 117. The amount of badge mass distributed above and/or far from the impact axis 117 is reduced, thereby reducing the effect the badge 170 has on raising the club head CG 199 above the impact axis 117. In some embodiments, the badge mass distribution can be characterized by a badge MOI. The badge MOI can be defined as the MOI of the badge 170 about the impact axis 117. For simplicity, the badge MOI can be determined with the badge 170 being treated as a point mass located at a badge center of gravity 173 (or “badge CG 173”). As illustrated in FIG. 30, the badge CG 173 comprises a perpendicular distance D_BCG to the impact axis 117. As such, the badge MOI can be calculated using the following equation, wherein M_B is the badge mass:

Badge MOI=M_B*(D_BCG)²

In some embodiments, the badge MOI can be between 2.0 and 15 g·cm². In some embodiments, the badge MOI can be between 2.0 and 5.0 g·cm², between 2.5 and 5.5 g·cm², between 3.0 and 6.0 g·cm², between 3.5 and 6.5 g·cm², between 4.0 and 7.0 g·cm², between 4.5 and 7.5 g·cm², between 5.0 and 8.0 g·cm², between 5.5 and 8.5 g·cm², between 6.0 and 9.0 g·cm², between 6.5 and 9.5 g·cm², between 7.0 and 10.0 g·cm², between 7.5 and 10.5 g·cm², between 8.0 and 11.0 g·cm², between 8.5 and 11.5 g·cm², between 9.0 and 12.0 g·cm², between 9.5 and 12.5 g·cm², between 10.0 and 13.0 g·cm², between 10.5 and 13.5 g·cm², between 11.0 and 14.0 g·cm², between 11.5 and 14.5 g·cm², or between 12.0 and 15.0 g·cm². In some embodiments, the badge MOI can be less than 15.0 g·cm². In some embodiments, the badge MOI can be less than 14.5 g·cm², less than 14.0 g·cm², less than 13.5 g·cm², less than 13.0 g·cm², less than 12.5 g·cm², less than 12.0 g·cm², less than 11.5 g·cm², less than 11.0 g·cm², less than 10.5 g·cm², less than 10.0 g·cm², less than 9.5 g·cm², less than 9.0 g·cm², less than 8.5 g·cm², less than 8.0 g·cm², less than 7.5 g·cm², less than 7.0 g·cm², less than 6.5 g·cm², less than 6.0 g·cm², less than 5.5 g·cm², less than 5.0 g·cm², less than 4.5 g·cm², less than 4.0 g·cm², less than 3.5 g·cm², less than 3.0 g·cm², less than 2.5 g·cm², or less than 2.0 g·cm². The lightweight badge 170 with a low badge MOI helps align the club head CG 199 with the impact axis 117.

The badge mass distribution can further be characterized by the percentage of the badge mass located within an impact cylinder (IC) centered about the impact axis 117. A greater percentage of the badge mass within the impact cylinder (IC) concentrates mass near the impact axis 117, thereby reducing the effect the badge 170 has on moving the club head CG 199 away from the impact axis 117. As illustrated in FIGS. 31 and 32, the impact cylinder (IC) is a reference cylinder centered about the impact axis 117 and comprising an impact cylinder radius (R_IC) of 0.5 inch.

In some embodiments, between 15% and 50% of the badge mass is located within the impact cylinder (IC). In some embodiments, greater than 15%, greater than 20%, greater than 25%, greater than 30%, greater than 35%, greater than 40%, greater than 45%, or greater than 50% of the badge mass is located within the impact cylinder (IC). The lightweight badge 170 with a large percentage of badge mass within the impact cylinder (IC) helps align the club head CG 199 with the impact axis 117.

The badge mass distribution can further be characterized by the badge mass located above the impact axis 117. As described above, the location of the badge 170 on the back face upper portion 162 can raise the club head CG 199 above the impact axis 117. The lightweight badge 170 reduces the amount of badge mass above the impact axis 117, thereby mitigating the effect the badge 170 would otherwise have on raising the club head CG 199. In some embodiments, although at least a portion of the lightweight badge 170 is above the impact axis 117, the badge mass above the impact axis 117 can be between 0.5 and 5.0 grams. In some embodiments, the badge mass above the impact axis 117 can be less than 5.0 grams, less than 4.5 grams, less than 4.0 grams, less than 3.5 grams, less than 3.0 grams, less than 2.5 grams, less than 2.0 grams, less than 1.5 grams, less than 1.0 grams, or less than 0.5 grams.

g) Segmented Badge

As discussed above, some badge embodiments can be provided with one or more layers formed of two or more discrete sections. Dividing one or more layers (i.e. the filler layer 180 and/or the rigid layer 178) provides the badge 170 expansion and flexing gaps. Referring to FIGS. 23A-23C, one or more badge layers are separated into multiple discrete badge sections 193. As explained here and below, the separation of one or more layers of the badge 170 into multiple sections 193 enables a better badge flexural response when the strike face 102 deforms under impact with a golf ball. Embodiments wherein the badge 170 comprises a plurality of individual sections 193 may comprise any suitable number of discrete sections. In some embodiments, the badge 170 can comprise two or more discrete sections. In some embodiments, the badge 170 can comprise 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 individual sections 193. Any one or combination of badge layers can comprise multiple discrete sections. For example, the adhesive layer, the filler layer, the rigid layer, or any combination thereof can comprise multiple discrete sections.

In many embodiments, the adhesive layer 176 is a single, continuous piece that is unitary and without discrete sections. In some embodiments, referring to FIG. 23A, the filler layer 180 and the adhesive layer 176 are configured to form a plurality of discrete sections. The filler layer 180 is discontinuous, comprising a plurality of filler layer portions 198. The rigid layer 178 is also discontinuous, comprising a plurality of rigid layer portions 195. Each one of the plurality of filler layer portions 198 is correspondingly bonded with one of the rigid layer portions 195 to form a plurality of badge sections 193. Each of the filler layer portions 198 is shaped congruently to its corresponding rigid layer portion 195. Each badge section 193 is affixed to the adhesive layer 176 such that the filler layer portions 198 are each entirely affixed to the adhesive layer 176. The plurality of badge sections 193 are not continuous. The adhesive layer 176 is not completely covered by the badge sections 193. The badge sections 193 are positioned on the adhesive layer 176 such that the outer edges of any one badge section 193 do not directly abut the outer edges of any adjacent badge section 193. Adjacent badge sections 193 are separated by a plurality of gaps 141 between the respective edges of each badge section 193. As explained further below, the plurality of gaps 141 increase badge flexibility energy transfer to the golf ball at impact.

Referring to FIG. 23B, some embodiments, the filler layer 180 can be a single continuous piece congruent to and entirely covering the adhesive layer 176. In such embodiments, the filler layer 180 is not divided into distinct portions. In this embodiment, the rigid layer 178 comprises a plurality of discrete rigid layer portions 195, forming multiple badge sections 193. In this embodiment, the adhesive layer 176 is not exposed in the gaps 141 between the badge sections 193, as it is covered by the filler layer 180. Instead, the continuous filler layer 180 is exposed between the gaps 141, spacing the badge sections 193 from one another.

Referring to FIG. 23C, in some embodiments, the badge 170 can be devoid of a filler layer. In the present embodiment, the badge comprises an adhesive layer 176 and a rigid layer 178 comprising a plurality of discrete rigid layer portions 195. The adhesive layer 176 is, again, a single continuous piece. However, in this embodiment, the badge sections 193 consist only of the rigid layer portions 195 attached directly to the adhesive layer 176. In the present embodiment, the adhesive layer 176 is not completely covered by the rigid layer portions 195. Instead, the rigid layer portions 195 are separated by gaps 141 between the spaced-apart, outside edges of adjacent rigid layer portions 195.

The discrete badge sections 193 reduce the flexural resistance of the badge 170. As the strike face 102 flexes rearward at impact, the adhesive layer 176 also flexes rearward, curving to match the rearward flexing of the strike face 102. As the adhesive layer 176 flexes rearward at impact, the gaps 141 between individual badge sections 193 allow the badge sections 193 to spread apart, thereby increasing the gap width 143 between the individual badge sections 193. This, in turn, increases energy transfer to the golf ball at impact.

Referring to FIGS. 23A-23C, the gaps 141 have a minimum or resting gap width 143 that ranges from 0.005 inch to 0.010 inch. The minimum gap width 143 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 143 is not less than 0.005 inch to prevent interference from outer edges of adjacent badge sections 193.

At impact, the flexed or maximum gap width 143 between the individual badge sections 193 may be up to 0.010 inch greater than the minimum gap width 143, depending on the location of the individual gap 141 on the badge 170. The maximum gap width 143 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. Gaps 141 between individual badge sections 193 closer to the geometric center 101 will increase in width to a larger extent than those further from the geometric center 101, because the strike face 102 flexes to a greater degree near the geometric center 101 when striking a golf ball. Again, the gaps 141 reduce flexural resistance increase energy transfer.

The strike face 102 typically flexes the most near the geometric center 101. It is, therefore, advantageous for badge sections 193 to be arranged such that gaps 141 between badge sections 193 are on or very near the geometric center 101. It is advantageous for a plurality of badge section outer edges to be within 0.1 inch to 0.5 inch of the geometric center 101. One or more of the plurality of badge section outer edges can be 0.1 inch, 0.2 inch, 0.3 inch, 0.4 inch, or 0.5 inch from the strike face geometric center 101 for increased flexing. The badge sections 193 may be arranged in a variety of configurations. In some embodiments, polygonal badge sections 193 can be arranged around the geometric center 101 such that a vertex of each polygonal badge section 193 is on or near the geometric center 101, therefore providing a gap 141 on or near the geometric center 101. Providing gaps 141 at or near the geometric center 101 allows the badge 170 to expand at the area of greatest strike face deformation under impact. Specific embodiments of badge section configurations are described in further detail below.

h) Mass Properties

As discussed above, the club head 100 is a cavity-back construction that comprises various perimeter weighting features such as the heel mass 108 and the toe mass 112 to improve forgiveness. As such, the club head 100 comprises high moments of inertia in comparison to conventional muscle back or non-perimeter weighted irons.

In some embodiments, the club head 100 has an I_XX moment of inertia between 80 g·in² and 160 g·in². In some embodiments, the club head 100 comprises an I_XX from 80 g·in² to 120 g·in², 120 g·in² to 140 g·in², or 140 g·in² to 160 g·in². For example, the I_XX can be 80 g·in², 100 g·in², 120 g·in², 140 g·in², or 160 g·in². In some embodiments, the I_XX can be greater than 80 g·in². In some embodiments, the Ixx can be greater than 90 g·in², greater than 100 g·in², greater than 110 g·in², greater than 120 g·in², greater than 130 g·in², greater than 140 g·in², greater than 150 g·in² or greater than 160 g·in².

In some embodiments, the club head 100 has an I_YY moment of inertia between 390 g·in² and 500 g·in². In some embodiments, the club head comprises an I_YY from 390 g·in² to 420 g·in², 420 g·in² to 460 g·in², or 460 g·in² to 500 g·in². For example, the I_YY can be 390 g·in², 410 g·in², 420 g·in², 430 g·in², 440 g·in², 450 g·in², 460 g·in², 470 g·in², 480 g·in², 490 g·in², or 500 g·in². In some embodiments, the Iyy can be greater than 390 g·in², greater than 400 g·in², greater than 410 g·in², greater than 420 g·in², greater than 430 g·in², greater than 440 g·in², greater than 450 g·in², greater than 460 g·in², greater than 470 g·in², greater than 480 g·in², greater than 490 g·in², or greater than 500 g·in².

In many embodiments, the club head 100 comprises a blade length 2100. Wherein the blade length 2100 ranges between 2.5 inches and 3.0 inches. The blade length 2100 can be between 2.5 inches to 2.6 inches, 2.6 inches, to 2.7 inches, 2.8 inches to 2.9 inches, or 2.9 inches to 3.0 inches. The blade length 2100 can be less than 3.0 inches, less than 2.9 inches, less than 2.8 inches, less than 2.7 inches, less than 2.6 inches, or less than 2.5 inches. The blade length 2100 can be greater than 2.5 inches, greater than 2.6 inches, greater than 2.7 inches, greater than 2.8 inches, greater than 2.9 inches, or greater than 3.0 inches. In many embodiments, the blade length 2100 of the club head 100 can be less than the blade length of a typical prior art cavity-back iron.

The club head 100 can comprises an I_YY/BL ratio determined by dividing the I_YY the moment of inertia by the blade length 2100. The I_YY/BL ratio characterizes the forgiveness with respect to club head size, wherein a high I_YY/BL ratio represents a forgiving club head for a given size. In some embodiments, the I_YY/BL ratio can be between 100 grams·inches (g·in) and 200 g·in. In some embodiments, the I_YY/BL ratio can be between 120 g·in and 180 g·in, between 130 g·in and 180 g·in, or between 140 g·in and 200 g·in. In some embodiments, the I_YY/BL ratio can be greater than 100 g·in, greater than 110 g·in, greater than 120 g·in, greater than 130 g·in, greater than 140 g·in, greater than 150 g·in, greater than 160 g·in, greater than 170 g·in, greater than 180 g·in, greater than 190 g·in, or greater than 200 g·in.

As described above, the club head 100 comprises a CG position substantially aligned with the impact axis 117, which improves sound, feel, and ball flight performance. This CG position is achieved through one or more of the various features described herein, including a lightweight badge, a pronounced toe mass, a lightweight insert, one or more perimeter weighting features, or any combination thereof.

In some embodiments, the club head 100 comprises a CG_X position near zero. In some embodiments, the CG_X position can be between 0.005 and 0.050 inch. In some embodiments, the CG_X position can be between 0.005 and 0.010 inch, between 0.010 and 0.020 inch, between 0.015 and 0.025 inch, between 0.020 and 0.030 inch, between 0.025 and 0.035 inch, between 0.030 and 0.040 inch, between 0.035 and 0.045 inch, or between 0.040 and 0.050 inch, In some embodiments, the CG_X position can be less than 0.050 inch, less than 0.045 inch, less than 0.040 inch, less than 0.035 inch, less than 0.030 inch, less than 0.025 inch, less than 0.020 inch, less than 0.015 inch, less than 0.010 inch, or less than 0.005 inch. A CG_X position near zero aligns the club head CG 199 with the impact axis 117 in the horizontal direction. Specific relationships between the CG 199 and the impact axis 117 are described in further detail below.

In some embodiments, the club head 100 comprises a low CG_Y position. In some embodiments, the CG_Y position can be between 0.030 inch and (−0.030) inch (wherein a negative CG_Y value denotes a club head CG position below the strike face geometric center 101). In some embodiments, the CG_Y position can be less than 0.030 inch, less than 0.025 inch, less than 0.020 inch less than 0.015 inch, less than 0.010 inch, less than 0.005 inch, less than 0.00 inch, less than (−0.005) inch, less than (−0.010) inch, less than (−0.015) inch, less than (−0.020) inch, less than (−0.025) inch, or less than (−0.030) inch. In general, the lower the CG_Y position, the more closely the club head CG 199 is aligned with the impact axis 117 in the vertical loft direction. Specific relationships between the CG 199 and the impact axis 117 are described in further detail below.

i) Damping System

The insert 140 and the badge 170 combine to create a damping system that covers a large portion of back face 104 with material suitable for damping vibrations. Covering a large portion of the back face 104 with damping material provides a desirable sound and soft feel in the club head 100 at impact.

In many embodiments, the damping system can reduce the amplitude of undesirable vibrations by 40% or greater. In some embodiments, the damping system can reduce the amplitude of residual vibrations (which contribute to a ringing sound and reverberating feel) by greater than 10%, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, or greater than 70%. In one example, the damping system can reduce the amplitude of a residual vibration from a magnitude of 1.3-10⁶ to a magnitude of 7.8·10⁵. In another example, the damping system can reduce the amplitude of a residual vibration from a magnitude of 6.0-10⁶ to a magnitude of 2.5-10⁵.

The interaction between the back face 104 and the damping system can be characterized by a damping system coverage area. The damping system coverage area is defined as the overall surface area of the back face 104 covered by the damping system. The damping system coverage area therefore can also be defined as the sum of the surface area of the insert 140 in contact with the back face 104 and the surface area of the badge 170 in contact with the back face 104.

In many embodiments, the damping system coverage area can be between 2.5 in² (1613 mm²) and 5.0 in². In many embodiments, the damping system coverage area can range inclusively between 2.5 in² (1613 mm²) and 3.0 in² (1935.5 mm²), 3.0 in² (1935.5 mm²) and 3.5 in² (2258 mm²), 3.5 in² (2258 mm²) and 4.0 in² (2580.6 mm²), 4.0 in² (2580.6 mm²) and 4.5 in² (2903.2 mm²), or between 4.5 in² (2903.2 mm²) and 5.0 in² (3225.8 mm²). In many embodiments, the damping system coverage area can be greater than 2.5 in² (1613 mm²). In some embodiments, the damping system coverage area can be greater than 3.0 in² (1935.5 mm²). In some embodiments, the damping system coverage area can be greater than 3.5 in² (2258 mm²). In some embodiments, the damping system coverage area can be greater than 4.0 in² (2580.6 mm²). In some embodiments, the damping system coverage area can be greater than 4.5 in² (2903.2 mm²). In some embodiments, the damping system coverage area can be greater than 5.0 in² (3225.8 mm²).

In general, the damping system coverage area that can be provided is limited by the surface area of the back face 104 that is suitable to be contacted by the insert 140 and/or the badge 170. Referring to FIG. 7, the club head 100 comprises a back face available surface 2400. The back face available surface 2400 is defined as any surface of the back face 104 that is exposed to the insert cavity 122 and/or the rear cavity 160. The back face available surface 2400 comprises any surface of the back face 104 that is suitable to be contacted by the damping system. As illustrated by FIG. 7, portions of the sole 118, the heel 106, the toe 110, the heel mass 108, the toe mass 112, and the top rail 120 cover certain portions of the back face 104. The back face available surface 2400 occupies an area of the back face 104 that is not covered by any of the sole 118, the heel 106, the toe 110, the heel mass 108, the toe mass 112, or the top rail 120.

In many embodiments, the back face available surface 2400 comprises an area between 3.0 in² (19.4 cm²) and 4.5 in² (29.0 cm²). In many embodiments, the area of the back face available surface 2400 can be greater than 3.0 in² (19.4 cm²). In some embodiments, the area of the back face available surface 2400 can be greater than 3.5 in² (22.6 cm²). In some embodiments, the area of the back face available surface 2400 can be greater than 4.0 in² (25.8 cm²). In some embodiments, the area of the back face available surface 2400 can be greater than 4.5 in² (29.0 cm²). In many embodiments, the area of the back face available surface 2400 can be less than 4.5 in² (29.0 cm²). In some embodiments, the area of the back face available surface 2400 can be less than 4.0 in² (25.8 cm²). In some embodiments, the area of the back face available surface 2400 can be less than 3.5 in² (22.6 cm²). In some embodiments, the area of the back face available surface 2400 can be less than 3.0 in² (19.4 cm²).

The surface area of the back face available surface 2400 is dependent on the geometry and mass distribution of the club head 100. For example, the surface area of the back face available surface 2400 can depend on the face height 2050 and blade length 2100. For example, a club head with a reduced face height and/or a reduced blade length may necessarily comprise a smaller back face available surface 2400 area due to the overall smaller size of the club head. The surface area of the back face available surface 2400 can also depend on the inclusion of certain perimeter weighting features, such as the heel mass 108 and/or the toe mass 112, as well as the shape and size of said features. In general, the further mass is allocated towards the perimeter of the club head 100, the greater the surface area of the back face available surface 2400 can be. In general, the larger the size of the heel mass 108 and/or the toe mass 112, the surface area of the back face available surface 2400 is reduced, as the heel mass 108 and the toe mass 112 each cover a portion of the back face 104.

As discussed above, the club head 100 can comprise a blade length 2100 less than the blade length of a typical cavity-back iron. The decreased blade length 2100 limits the size of the back face available surface 2400. However, the club head 100 also comprises a significant amount of perimeter weighting. The inclusion of the rear cavity 160 and the insert cavity 122 moves a significant amount of mass away from the club head CG 199 and replaces said mass with the lightweight badge 170 and insert 140 housed within the rear cavity 160, and the insert cavity 122 respectively. The perimeter weighting of the club head 100 provides a large back face available surface 2400 area, despite the relatively short blade length 2100 and despite the fact that the club head 100 comprises a heel mass 108 and a toe mass 112 each covering a portion of the back face 104.

The amount of back face 104 coverage provided by the damping system can be characterized by the relationship between the area of the back face available surface 2400 and the damping system coverage area. In many embodiments, the damping system coverage area can be between 85% and 99% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be between 85% and 87%, 87% and 89%, 89% and 91%, 91% and 93%, 93% and 95%, 95% and 97%, or between 97% and 99% of the area of the back face available surface 2400. In many embodiments, the damping system coverage area can be greater than 85% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be greater than 90% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be greater than 95% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be greater than 99% of the area of the back face available surface 2400. In many embodiments, the damping system coverage area can be less than 99% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be less than 95% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be less than 90% of the area of the back face available surface 2400. In some embodiments, the damping system coverage area can be less than 85% of the area of the back face available surface 2400.

The amount of back face 104 coverage provided by the damping system can further be characterized by the relationship between the damping system coverage area and the scoring area. As discussed above, the region of the strike face 102 occupied by the plurality of score lines 105 defines a scoring area 194. In many embodiments, the scoring area 194 can range between 3.0 in² and 4.0 in². In many embodiments, the scoring area 194 can range inclusively between 3.0 in² and 3.2 in², 3.2 in² and 3.4 in², 3.4 in² and 3.6 in², 3.6 in² and 3.8 in², or between 3.8 in² and 4.0 in². In some embodiments, the scoring area 194 can be approximately 3.0 in², 3.2 in², 3.4 in², 3.6 in², 3.8 in², or approximately 4.0 in².

The club head 100 can define a projection (not shown) of the scoring area 194 on the back face 104. The projection corresponds to the location of the scoring area 194 such that the projection is the area of the back face 104 directly opposite the scoring area 194. In many embodiments, a portion of the damping system coverage area can overlap the projection. In many embodiments, the portion of the damping system coverage area that overlaps the projection can range between 2.0 in² and 3.5 in². In some embodiments, the portion of the damping system coverage area that overlaps the projection can be between 2.0 in² and 2.5 in², between 2.5 in² and 3.0 in², or between 3.0 in² and 3.5 in². In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 2.0 in², greater than 2.5 in², greater than 3.0 in², or greater than 3.5 in².

In many embodiments, the portion of the damping system coverage area that overlaps the projection can be between 75% and 99% of the surface area of the scoring area 194. In many embodiments, the portion of the damping system coverage area that overlaps the projection can range inclusively between 75% and 80%, 80% and 85%, 85% and 90%, 90% and 95%, or between 95% and 99% of the surface area of the scoring area 194. In further embodiments, the portion of the damping system coverage area that overlaps the projection can range inclusively between 75% and 85%, between 80% and 90%, between 85% and 95%, or between 75% and 95%. In many embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 75% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 80% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 85% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 90% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 95% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be greater than 99% of the surface area of the scoring area 194. In many embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 99% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 99% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 95% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 90% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 85% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 80% of the surface area of the scoring area 194. In some embodiments, the portion of the damping system coverage area that overlaps the projection can be less than 75% of the surface area of the scoring area 194.

The amount of back face 104 coverage provided by the damping system can further be characterized by the relationship between the damping system coverage area and the total surface area of the strike face 102. Referring to FIG. 1, the total surface area of the strike face 102 can be measured between the scoring area heel boundary 196 and the toe-most extent of the strike face 102. In many embodiments, the total surface area of the strike face 102 can range between 4.0 in² (2580.6 mm²) and 5.5 in² (3548.4 mm²). In many embodiments, the total surface area of the strike face 102 can range inclusively between 4.0 in² (2580.6 mm²) and 4.5 in² (2903.2 mm²), 4.5 in² (2903.2 mm²) and 5.0 in² (3225.8 mm²), or between 5.0 in² (3225.8 mm²) and 5.5 in² (3548.4 mm²). In some embodiments, the total surface area of the strike face 102 can be approximately 4.0 in² (2580.6 mm²), 4.25 in² (2741.9 mm²), 4.5 in² (2903.2 mm²), 4.75 in² (3064.5 mm²), 5.0 in² (3225.8 mm²), 5.25 in² (3387.1 mm²), or approximately 5.5 in² (3548.4 mm²).

In many embodiments, the damping system coverage can be between 60% and 85% of the total surface area of the strike face. In many embodiments, the damping system coverage can range inclusively between 60% and 65%, 65% and 70%, 70% and 75%, 75% and 80%, or between 80% and 85% of the total surface area of the strike face. In some embodiments, the damping system coverage can range between 60% and 80%, 65% and 85%, 70% and 80%, or between 75% and 85% of the total surface area of the strike face. In some examples, the damping system coverage can be approximately 60%, 65%, 70%, 75%, 80%, or 85% of the total surface area of the strike face.

The club head 100 balances a high MOI with the ability to effectively damp vibrations. In general, the greater the damping system coverage area, the more effective the damping of club head vibrations. As discussed above, the damping system coverage area is limited by the back face available surface 2400 area. As discussed above, the club head 100 comprises a large back face available surface 2400 area, despite having a relatively short blade length 2100 and despite the club head 100 comprising a heel mass 108 and a toe mass 112 that cover a portion of the back face 104. To provide effective damping, the damping system covers the greatest amount of the back face available surface 2400 possible. Overall, the perimeter weighting of the club head 100 provides a high MOI while allowing for a significant damping system coverage area. The result is a club head with high forgiveness and the ability to damp vibrations by 40% or greater.

j) Top Rail Thickness

The damping system allows for the dissipation of unwanted vibrations at impact and provides the club head 100 with a desirable sound and feel. Additionally, the vibrational response of the club head 100 can be improved by increasing the mass in areas of the club head 100 where dominant vibrations occur. In many cavity-back irons, dominant vibrations occur in the top rail. Referring to FIG. 5A, the club head 100 can comprise a top rail 120 configured to damp dominant vibrations. The top rail 120 comprises a top rail thickness 2250 measured as a perpendicular distance between the strike face 102 and the top rail rear edge 186. In many embodiments, the top rail thickness 2250 can range between 0.15 inch and 0.30 inch. In some embodiments, the top rail thickness can range inclusively between 0.15 inch and 0.20 inch, 0.20 inch and 0.25 inch, or between 0.25 inch and 0.30 inch. In many embodiments, the top rail thickness 2250 can be greater than 0.15 inch. In some embodiments, the top rail thickness 2250 can be greater than 0.20 inch. In some embodiments, the top rail thickness 2250 can be greater than 0.25 inch. In some embodiments, the top rail thickness 2250 can be greater than 0.30 inch. The top rail thickness 2250 is designed to prevent dominant vibrations in the top rail 120 without compromising the mass properties of the club head 100 (e.g. MOI and/or CG position).

V. Club Head with Damping System and Recessed Rear Wall

In many embodiments, referring to FIG. 8, the rear wall 114 is located at the rear periphery of the club head 100. The rear wall 114 can be flush with a sole rear edge 192. Providing the rear wall 114 flush with the sole rear edge 192 makes the club head 100 appear as a muscle-back iron, despite the fact that the club head 100 comprises perimeter weighting, an insert cavity 122, and a rear cavity 160 (described in further detail below).

In alternative embodiments, the club head can comprise rear wall recessed with respect to the rear periphery, creating a club head with the appearance resembling a cavity-back iron. FIGS. 9-11 illustrate a second embodiment of a club head 200 according to the present invention with an alternative rear wall 214 design, wherein the rear wall 214 is recessed with respect to the rear periphery of the club head 200. Club head 200 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 200 are numbered similar to those of club head 100, but with a 200 numbering scheme (e.g. club head 200 comprises a strike face 202, etc.)

In the present embodiment, the rear wall 214 can be recessed with respect to the rear periphery of the club head 200. As illustrated by FIG. 9, the rear perimeter 282 of the club head 200 is formed by the top rail rear edge 286, the heel rear edge 288, the toe rear edge 290, and the sole rear edge 292. As such, the rear perimeter 282 circumscribes the entire rear periphery of the club head 200. The rear perimeter 282 forms the boundary for the rear cavity 260. In contrast to rear cavity 160, which is bounded on the bottom by rear wall top edge 134 and sits above the rear wall 114 and the insert cavity 122, rear cavity 260 is bounded on the bottom by the sole rear edge 292 and extends over the entire rear periphery of the club head 200, from the top rail 220 to the sole 218.

Referring to FIG. 11, the offset of the rear wall 214 can be characterized by a rear wall offset distance 2500 measured between the sole rear edge 292 and the base of the rear wall 214. In many embodiments, the rear wall offset distance 2500 can range between 0.010 inch and 0.060 inch. In some embodiments, the rear wall offset distance 2500 can range between 0.010 inch and 0.020 inch, between 0.020 inch and 0.030 inch, between 0.030 inch and 0.040 inch, between 0.040 inch and 0.050 inch, or between 0.050 inch and 0.060 in. In some embodiments, the rear wall offset distance can be approximately 0.010 inch, 0.015 inch, 0.020 inch, 0.025 inch, 0.030 inch, 0.035 inch, 0.040 inch, 0.045 inch, 0.050 inch, 0.055 inch, or 0.060 inch.

Providing a rear perimeter 282 that circumscribes the entire periphery by recessing the rear wall 214 with respect to the sole rear edge 292 increases the perimeter weighting of the club head 200, therefore increasing MOI and producing a more forgiving club head 200. As mentioned above, recessing the rear wall 214 with respect to the sole rear edge 292 also increases the volume of the rear cavity 260. As illustrated by FIG. 9, the rear cavity 260 is more visually prominent than the rear cavity 160 of club head 100. In addition to providing a more forgiving club head by increasing the perimeter weighting of the club head 200, the visually enlarged rear cavity 260 provides the appearance of a more forgiving club head 200 in comparison to a club head with a less prominent rear cavity. This appearance of increased forgiveness increases the confidence of the golfer. The enlarged rear cavity 260 can be particularly beneficial in long irons (3-irons, 4-irons, 5-irons, etc.) with low loft angles, which are typically more difficult to hit straight.

VI. Club Head with Damping System and Apexed Rear Wall

FIGS. 12 and 13 illustrate an embodiment of a club head 300 according to the present invention, wherein the rear wall 314 forms an apex 335. Referring to FIG. 12, the rear wall height 2150 varies in a heel to toe direction such that the rear wall height 2150 is greatest near the center of the club head 300 and smallest near the heel 306 and the toe 310. The rear wall top edge 334 forms the apex 335 at the point where the rear wall height 2150 is at a maximum. Club head 300 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 300 are numbered similar to those of club head 100, but with a 300 numbering scheme (e.g. club head 300 comprises a strike face 302, etc.).

The shape of the insert cavity 322 can correspond to the shape of the apexed rear wall 314. The insert cavity 322 can be tallest and/or deepest near the apex 335 of the rear wall 314 and shortest and/or shallowest near the heel mass 308 and the toe mass 312. In many embodiments, the insert 340 can be shaped complementarily to the insert cavity 322 such that the insert 340 substantially fills the entire insert cavity 322 without overfilling the insert cavity 322. In such embodiments, as illustrated by FIG. 13, the top surface 342 of the insert 340 can be flush with the rear wall top edge 434. In such embodiments, the insert 340 can match the shape of the rear wall 314 in that the height of the insert 340 corresponds to the rear wall height 2150. The height of the insert 340 can be greatest near the center of the club head 300 and smallest near the heel mass 308 and the toe mass 312. In other embodiments (not shown), the insert 340 may not be shaped complementarily to the insert cavity 322. In such embodiments, the insert 340 can underfill the insert cavity 322 such that the insert top surface 342 is recessed within the insert cavity 322 or overfill the insert cavity 322 such that the insert 340 extends out of the insert cavity 322.

The apexed rear wall 314 and correspondingly shaped insert 340 illustrated in FIGS. 12 and 13 provides an increased contact area between the insert 340 and the back face lower portion 332. In some embodiments, the contact area between the insert 340 and the back face lower portion 332 can be greater than 0.8 in² (516.1 mm²). In some embodiments, the contact area between the insert 340 and the back face lower portion 332 can be greater than 0.9 in² (580.6 mm²). In some embodiments, the contact area between the insert 340 and the back face lower portion 332 can be greater than 1.0 in² (645.2 mm²). In some embodiments, the contact area between the insert 340 and the back face lower portion 332 can be greater than 1.1 in² (709.7 mm²). In some embodiments, the contact area between the insert 340 and the back face lower portion 332 can be greater than 1.2 in² (774.2 mm²). Because the insert 340 is an effective vibration damper, increasing the contact area between the insert 340 and the back face lower portion 332 can more effectively damp vibrations in the club head 300, providing a club head 300 with a more desirable sound and feel.

In the embodiment illustrated in FIGS. 12 and 13, the badge 370 does not conceal the insert 340 within the insert cavity 322. The badge 370 can be disposed within the rear cavity 360, similar to the badges 170, 270 described in previous embodiments, except that the badge 370 does not substantially fill the rear cavity 360. In many embodiments, the badge thickness 2300 is reduced in comparison to the badges 170, 270 of previous embodiments. In such embodiments, the badge bottom edge 374 may cover only a portion of the insert top surface 342 or may not cover any portion of the insert top surface 342. Providing a badge 370 with a reduced badge thickness 2300 can create discretionary mass that can be allocated to other portions of the club head 300 to increase MOI, improve CG position, or damp vibrations. Further, providing a badge 370 that does not visually fill the rear cavity 360 can create the appearance of a more forgiving club head 300 that increases the confidence of the golfer.

The apexed rear wall 314 can be combined with any insert or badge configuration described above or below, including a badge that substantially fills the rear cavity 360 and conceals the insert 340 within the insert cavity 322.

VII. Club Head with Damping System and Rear Wall Comprising a Nadir

FIGS. 14 and 15 illustrate an embodiment of a club head 400 according to the present invention, wherein the rear wall 414 forms a nadir 445. Referring to FIG. 14, the rear wall height 2150 varies in a heel to toe direction such that the rear wall height 2150 is greatest near the heel 406 and the toe 410 and smallest near the center of the club head 400. The rear wall top edge 434 forms the nadir 445 at the point where the rear wall height 2150 is at a minimum. Club head 400 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 400 are numbered similar to those of club head 100, but with a 400 numbering scheme (e.g. club head 400 comprises a strike face 402, etc.).

The shape of the insert cavity 422 can correspond to the shape of the rear wall 414 comprising the nadir 445. The insert cavity 422 can be shallowest near the nadir 445 and deepest near the heel mass 408 and the toe mass 412. In many embodiments, the insert 440 can be shaped complementarily to the insert cavity 422 such that the insert 440 substantially fills the entire insert cavity 422 without overfilling the insert cavity 422. In such embodiments, as illustrated by FIG. 15, the top surface 442 of the insert 440 can be flush with the rear wall top edge 434. In such embodiments, the insert 440 can match the shape of the rear wall 314 in that the height of the insert 440 corresponds to the rear wall height 2150. The height of the insert 440 can be smallest near the nadir 445 and greatest near the heel mass 408 and the toe mass 412. In other embodiments (not shown), the insert 440 may not be shaped complementarily to the insert cavity 422. In such embodiments, the insert 440 can underfill the insert cavity 422 such that the insert top surface 442 is recessed within the insert cavity 422 or overfill the insert cavity 422 such that the insert 440 extends out of the insert cavity 422.

The rear wall 414 comprising the nadir 445 and correspondingly shaped insert 440 illustrated in FIGS. 14 and 15 can reduce the mass of the rear wall 414. The reduction of the rear wall 414 mass creates discretionary mass that can be allocated to other portions of the club head 400 to increase MOI, improve club head CG position, or damp vibrations.

The rear wall 414 comprising a nadir 445 can be combined with any insert or badge configuration described above or below. In some embodiments, such as the illustrated embodiments of FIGS. 14 and 15, the rear wall 414 comprising a nadir 445 can be combined with a badge 470 similar to badge 370, wherein the badge 470 does not substantially fill the rear cavity 460 and does not conceal the insert 440. In such embodiments, the thin badge 470 creates discretionary mass and provides the appearance of a club head 400 with high forgiveness. In other embodiments, the rear wall 414 comprising the nadir 445 can be combined with a badge similar to badge 170 or badge 270 that substantially fills the rear cavity 460, concealing the insert 440 and providing the appearance of a solidly constructed iron.

VIII. Club Head with Damping System and Crosspiece

FIGS. 24-27 illustrate an embodiment of a club head 700 according to the present invention, wherein the club head 700 comprises a crosspiece 766 on the back face 704 and a badge 770 that does not visually fill the rear cavity 760. In the present embodiment, the badge 770 does not cover or conceal the insert 740 and the club head 700 is provided with the appearance of a cavity-back iron. Although the club head 700 appears more as a cavity-back iron, the damping system provides the club head 700 with the desirable feel of a muscle-back and/or forged iron.

As described above, the club head 700 comprises a crosspiece 766 on the back face 704. The crosspiece 766 can structurally reinforce certain portions of the strike face 702. The crosspiece 766 can also retain and locate the insert 740 and badge 770. Club head 700 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 700 are numbered similarly to those of club head 100, but with a 700 numbering scheme (e.g. club head 700 comprises a strike face 702, etc.).

Referring to FIG. 24, the club head 700 comprises a back face 704 with both a central support bar 716 and a crosspiece 766. The central support bar 716 can be substantially similar to any of the central support bar embodiments described herein. The crosspiece 766 and the central support bar 716 can work together to structurally reinforce a central portion of the strike face 702. This structural reinforcement allows peripheral portions of the strike face 702 to be thinned, thereby creating discretionary mass and increasing ball speed. In some embodiments, as illustrated in FIG. 24, the crosspiece 766 and the central support bar 716 can run transverse to one another. The crosspiece 766 can extend in a substantially heel-to-toe direction across the back face 704, whereas the central support bar 716 can extend in a substantially vertical direction.

Referring to FIG. 24, the crosspiece 766 extends along the back face 704. In some embodiments, such as the illustrated embodiment of FIG. 24, the crosspiece 766 extends across the entirety of the back face 704 in a heel-to-toe direction. The crosspiece 766 can comprise a crosspiece heel end 767 located proximate the heel inner surface 728 and a crosspiece toe end 768 located proximate the toe inner surface 730. The crosspiece 766 can separate the back face lower portion 732 from the back face upper portion 762. In some embodiments, the height of the crosspiece 766 (measured from the sole 718) can vary in a heel-to-toe direction. In the illustrated embodiment of FIG. 24, the crosspiece 766 comprises a maximum height near the center of the club head 700 and minimum height near the heel 706 or the toe 710. The crosspiece 766 forms a crosspiece apex 775 at the point of the maximum crosspiece height. In some embodiments, the crosspiece apex 775 can be located approximately halfway between the heel 706 and the toe 710.

The crosspiece 766 defines a crosspiece thickness measured from the back face 704. In many embodiments, the crosspiece 766 comprises a thickness (hereafter the “crosspiece thickness”) greater than the thickness of the central support bar 716. In many embodiments, the crosspiece thickness can range inclusively between 0.05 inch and 0.25 inch. In some embodiments, the crosspiece thickness can be between 0.05 inch and 0.075 inch, between 0.075 inch and 0.10 inch, between 0.10 inch and 0.125 inch, between 0.125 inch and 0.15 inch, between 0.15 inch and 0.175 inch, between 0.175 inch and 0.20 inch, between 0.20 inch and 0.225 inch, or between 0.225 inch and 0.25 inch. Although the crosspiece 766 and the central support bar 716 both structurally reinforce the strike face 702, the crosspiece 766 can comprise a greater thickness than the central support bar 716 to help retain and locate the insert 740 and badge 770. The relationship between the crosspiece 766, the insert 740, and the badge 770 is described in further detail below.

The club head 700 includes a damping system comprising an insert 740 and a badge 770. The insert 740 and badge 770 can be substantially similar to any one or combination of the inserts and badges described herein. Referring to FIGS. 25 and 26, the badge 770 is located in the rear cavity 760 and contacts the back face upper portion 762. In many embodiments, the badge 770 can be shaped to correspond to the crosspiece 766. In many embodiments, the crosspiece 766 can form the lower boundary of the back face upper portion 762. In some embodiments, the badge bottom edge 774 can abut the crosspiece 766. In some embodiments, the badge bottom edge 774 can match the shape of the crosspiece 766 such that the badge 770 abuts the crosspiece 766 along the entire length of the badge bottom edge 774. In some embodiments, the badge 770 substantially or entirely covers the back face upper portion 762. The badge 770 can be configured such that it covers the central support bar 716, but not the crosspiece 766.

As discussed above, in many embodiments, as illustrated in FIG. 26, the badge 770 is not configured to visually fill the entire rear cavity 760 or conceal the insert 740. In many embodiments, the badge thickness 2300 can be the same or substantially similar to the crosspiece thickness, such that the badge rigid layer 778 is approximately flush with the crosspiece 766. Although the illustrated embodiment comprises a badge 770 that does not visually fill the rear cavity 760, in other embodiments, the badge 770 may comprise a greater thickness and/or a variable thickness such that it covers the insert 740 and visually fills the entire rear cavity 760. In such embodiments, the badge 770 provides the club head 700 with the appearance of a muscle-back iron.

The badge 770 can be constructed similarly to one or more of the various other badges described herein. In particular, the badge 770 can comprise an adhesive layer 776 in contact with the back face upper portion 762, a rigid layer 778 opposite the adhesive layer 776 and exposed to the rear exterior of the club head 700, and a filler layer 780 disposed between the adhesive layer 776 and the rigid layer 778.

In some embodiments, as illustrated in FIGS. 25 and 27, the badge 770 can be a flexible badge, wherein the rigid layer 778 comprises a plurality of discrete rigid layer portions 795. The badge 770 can comprise a continuous adhesive layer 776, a continuous filler layer 780, and a plurality of rigid layer portions 795 coupled to the filler layer 780. A plurality of gaps 741 can be formed between the plurality of rigid layer portions 795, such that portions of the filler layer 780 are exposed through said gaps 741.

Referring to FIG. 27, the plurality of rigid layer portions 795 comprises a central section 795a, an upper heel-side section 795b, a lower heel-side section 795c, an upper toe-side section 795d, and a lower toe-side section 795e. The central section 795a is located in the center of the badge 770 and extends all the way from the badge bottom edge 774 to the badge top edge 772. As such, the central section 795a can abut both the top rail 720 and the crosspiece 766. The upper heel-side section 795b is located along the badge top edge 772 and abuts portions of both the top rail 720 and the heel inner surface 728. The lower heel-side section 795c is located along the badge bottom edge 774 and abuts portions of both the heel inner surface 728 and the crosspiece 766. The upper toe-side section 795d is located along the badge top edge 772 and abuts portions of both the top rail 720 and the toe inner surface 730. The lower toe-side section 795e is located along the badge bottom edge 774 and abuts portions of both the toe inner surface 730 and the crosspiece 766. The central section 795a is located closest to the strike face geometric center 701. The central section 795a can be provided as the smallest of the rigid layer portions 795, such that a greater area of gaps 741 is provided proximate the geometric center 701. For example, the gaps 741 formed between the central section 795a and the lower heel-side section 795c and between the central section 795a and the lower toe-side section 795e can be substantially close to one another and substantially close to the geometric center 701. Providing gaps 741 proximate the geometric center 701 increases strike face flexure.

Although the club head 700 is illustrated as comprising a badge 770 with a plurality of badge sections, in other embodiments, the club head 700 can utilize any one or combination of the various badge embodiments and/or characteristics described herein.

Similar to the badge 770, the insert 740 can also be shaped to correspond to the crosspiece 766. The crosspiece 766 can be located directly above the insert cavity opening 724. The crosspiece 766 can therefore operate as an upper boundary of both the back face lower portion 732 and the insert cavity 722. In many embodiments, a portion of the insert top surface 742 can abut the underside of the crosspiece 766. In some embodiments, the insert top surface 742 can match the shape of the crosspiece 766 such that the insert 740 abuts the crosspiece 766 along the entire length of the insert top surface 742. The crosspiece 766 can extend over a portion of the insert top surface 742, since the insert 740 is flush with the back face 704 and the crosspiece 766 extends outward from the back face 704. The engagement between the crosspiece 766 and the insert top surface 742 can help retain the insert 740 within the insert cavity 722. As discussed above, because the badge 770 and the insert 740 both correspond to the shape of the crosspiece 766, the crosspiece 766 can act as a locating feature for both the badge 770 and the insert 740. The crosspiece 766 can therefore provide a simpler and more accurate installation process for the badge 770 and insert 740. In some cases, the crosspiece 766 can also act as a strike face reinforcement, allowing the strike face 702 to be thinned and thereby promoting ball speed.

IX. Club Head with Damping System and Insert Cavity Formed within a Badge

In some embodiments, referring to FIGS. 16-18, the club head 500 comprises an insert cavity 522 formed within a portion of the badge 570. In such embodiments, rather than the badge 570 and the insert 540 being separate, the insert 540 can be housed by the badge 570. The insert 540 can be secured within the insert cavity 522 of the badge 570 and the badge 570 and insert 540 can be coupled to the back face 504. Club head 500 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 500 are numbered similar to those of club head 100, but with a 500 numbering scheme (e.g. club head 500 comprises a strike face 502, etc.).

As illustrated by FIG. 16, the badge 570 comprises a badge inner surface 579 configured to contact the back face 504. In many embodiments, the badge inner surface 579 is formed by an adhesive layer (similar to adhesive layer 176 described above). The insert cavity 522 can be formed as a recess extending into the badge 570 from the badge inner surface 579 to an insert cavity base 536. Referring to FIG. 18, The insert cavity 522 can comprise a cavity depth 2200 measured from the badge inner surface 579 to the insert cavity base 536. In many embodiments, the insert cavity depth 2200 can range between 0.15 inch and 0.35 inch. In some embodiments, the insert cavity depth 2200 can range inclusively between 0.15 inch and 0.20 inch, 0.20 inch and 0.25 inch, 0.25 inch and 0.30 inch, or between 0.30 inch and 0.35 inch. The insert cavity depth 2200 can be approximately 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, or approximately 0.35 inch. The insert 540 can be shaped complementarily to the insert cavity 522 such that the insert 540 substantially fills the volume of the insert cavity 522.

Housing the insert 540 within the badge 570 rather than within an insert cavity formed by the rear wall 514 of the club head 500 allows the rear wall 514 to be minimized. Referring to FIG. 17, rear wall height 2150 of club head 500 can be substantially shorter than the rear wall height 2150 of previous embodiments. In many embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.40 inch. In some embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.35 inch. In some embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.30 inch. In some embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.25 inch. In some embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.20 inch. In some embodiments, the rear wall height 2150 along at least a portion of the rear wall 514 of club head 500 can be less than 0.15 inch. Because the rear wall 514 does not form the insert cavity 522, the rear wall 514 does not require a certain rear wall height 2150 to be able to retain the insert 540.

Minimizing the rear wall 514 creates discretionary mass that can be allocated to other portions of the club head 500 to increase MOI, improve CG position, or damp vibrations. For example, as illustrated in the embodiment of FIG. 17, discretionary mass created by reducing the rear wall height 2150 can be used to increase the perimeter of the club head 500 by providing a larger heel mass 508 and/or toe mass 512. As illustrated by FIG. 17, the rear wall height 2150 can be greater near the heel mass 508 and the toe mass 512 and lesser near the center in order to increase the perimeter weighting of the club head 500. In some embodiments, minimizing the rear wall 514 can also increase the area of the back face available surface 2400, which in turn allows for an increase in the damping system coverage area and an increase in vibration damping.

As illustrated by FIG. 18, the badge 570 and the insert 540 housed within combine to form a damping system. In many embodiments, when the insert 540 is housed within the insert cavity 522 formed within the badge 570, the insert top surface 542 can be flush with the badge inner surface 579. In many embodiments, the insert top surface 542 is not covered by any portion of the badge 570. The insert top surface 542 and the badge inner surface 579 can both be configured to contact the back face 504 to provide vibration damping benefit to the club head 500. As illustrated, in FIG. 18, there are no spaces or gaps in between the insert top surface 542 and the badge inner surface 579. Because of this, the damping system can cover a greater proportion of the available surface of the back face.

In some embodiments, referring to FIGS. 19-21, the club head 600 comprises an insert 640 entirely enclosed within the badge 670. The insert 640 and the badge 670 combine to form a damping system. In the embodiment of FIGS. 19-21, the insert cavity 622 is recessed into the badge inner surface 679 and extends to an insert cavity base 636. In many embodiments, the insert cavity 622 can be substantially similar to insert cavity 522 and can comprise an insert cavity depth 2200 substantially similar to the depth 2200 of insert cavity 522. Club head 600 can be substantially similar to club head 100, except for the differences described below, and like terms relating to club head 600 are numbered similar to those of club head 100, but with a 600 numbering scheme (e.g. club head 600 comprises a strike face 602, etc.).

In many embodiments, the insert 640 can be shaped complementarily to the insert cavity 622 such that the insert 640 substantially fills the volume of the insert cavity 622. Referring to FIGS. 19 and 21, the badge 670 can comprise an adhesive layer 676 that covers and conceals the insert 640 within the insert cavity 622. The adhesive layer 676 can be applied to the badge 670 after the insert 640 is inserted into the insert cavity 622 and can serve to secure the insert 640 within the insert cavity 622. In many embodiments, the adhesive layer 676 covers the badge inner surface 679 and the insert top surface 642. In many embodiments, the adhesive layer 676 can form the entirety of the contact area between the damping system and the back face 604 (e.g. the adhesive layer 676 can form the entire damping system coverage area). Providing an adhesive layer 676 that forms the entire damping system coverage area provides the most secure connection possible between the damping system and the back face 604. In many embodiments, the damping system coverage area of club head 600 can be similar to the damping system coverage area of club head 500.

Similar to club head 500, the rear wall 614 of club head 600 can be minimized in comparison to a club head wherein the rear wall forms the insert cavity. The rear wall height 2150 of club head 600 can be similar to the rear wall height 2150 of club head 500. As discussed above, minimizing the rear wall 614 creates discretionary mass that can be allocated to other portions of the club head 600 to increase MOI, improve CG position, or damp vibrations. Minimizing the rear wall 614 can also increase the area of the back face available surface 2400.

X. Golf Club Head with Damping System and Pronounced Toe Mass

In some embodiments, the club head comprises a pronounced toe mass that balances vibration damping with club head mass properties such as club head CG position. FIGS. 33-36 illustrate a club head 800 with a damping system and a pronounced toe mass 812 that centers the club head CG_X position relative to the impact axis (club head 800 includes an impact axis similar to impact axis 117 described above). As described above, aligning the CG_X position with the impact axis reduces vibrations on center strikes, thereby improving sound and feel at impact. As described above, the closer the CG is aligned with the impact axis, the less the club head 800 rotates and vibrates at impact. Aligning the club head CG_X with the impact axis reduces club head rotation about the CG at impact. This reduced club head rotation imparts less undesirable impact sidespin on the golf ball, thereby producing straighter shots. In many conventional iron-type golf club heads, the club head CG is located heelward of the strike face geometric center due to the mass of the hosel. The pronounced toe mass 812 (described in further detail below) distributes mass toward the toe 810. In some embodiments, the toe mass 812 can distribute between 5 and 15 grams of discretionary mass toward the toe 810. The toe mass 812 counterbalances the mass of the hosel 803, thereby moving the club head CG closer to the toe 810 and the impact axis. As described in further detail below, the club head CG can be within 0.050 inch in both the horizontal and loft vertical directions.

Referring to FIG. 34, the club head 800 comprises a rear cavity 860 and an insert cavity 822. The rear cavity 860 is substantially similar to the rear cavities described above, in that the top rail 820, the heel 806, the toe 810, and the rear wall 814 form boundaries of the rear cavity 860. The insert cavity 822 is similar to one or more of the insert cavities described above, in that the rear wall inner surface, the back face lower portion 832, the toe inner surface 830, the heel inner surface 828, and the inner surface of the sole 818 form boundaries of the insert cavity 822.

As described above, the toe mass 812 is formed by a solid portion of the club head that concentrates mass toward the toe 810. As shown in FIG. 34, the toe mass 812 is generally located toeward of the insert cavity 822 and near the sole 818. The toe mass 812 is created by a variation in the rear wall weight 2150. As illustrated by FIG. 35, the rear wall 814 is taller near the toe 810 than near the heel 806. The rear wall height 2150 is approximately constant near the heel 806 and the center of the club head 800. In the illustrated embodiment, the section of the rear wall 814 that is approximately constant height corresponds to the location of the insert cavity 822. Near the toe 810, the rear wall top edge 834 juts upward at an angle, and the rear wall height 2150 increases towards the toe 810. This configuration pushes mass toward the periphery and concentrates mass near the sole 818 to lower the club head CG toward the impact axis.

The toe mass 812 extends laterally in the X-axis direction from near the toe inner surface 830 to a toe exterior surface 811. Additionally, the toe mass 812 extends in the Z-axis direction between the rear wall 814 and the back face lower portion 832. Still further, the toe mass 812 extends in the Y-axis direction between a toe mass upper surface 813, extending between the rear wall top edge 834 and the back face lower portion 832, to the sole 818. The bounds of the toe mass 812 can be defined by a toe segment 835 of the rear wall top edge 834. As illustrated in FIG. 35, the toe segment 835 extends upward from the remainder of the rear wall top edge 834 toward the toe 810. The club head 800 defines a toe mass plane 891 extending perpendicular to the ground plane 1000 in a front-to-back direction. The toe mass plane 891 extends through the intersection of the toe segment 835 and the remainder of the rear wall top edge 834. The toe mass plane 891 defines the heelward-most boundary of the toe mass 812.

In the illustrated embodiment, the toe mass 812 increases in height toward the toe exterior surface 811, thereby concentrating mass toeward. As described above, the toe segment 835 extends upward toward the toe 810 from the remainder of the rear wall top edge 834. As such, the rear wall height 2150 is greater at the toe mass 812 than at any other portion of the rear wall 814. A rear wall ratio can be defined as the maximum rear wall height 2150 within the toe segment 835 divided by the maximum rear wall height 2150 within the remainder of the rear wall 814. In some embodiments, the rear wall ratio can be between 1.5 and 3.0. In some embodiments, the rear wall ratio can be greater than 1.5, greater than 1.75, greater than 2.0, greater than 2.25, greater than 2.50, greater than 2.75, or greater than 3.0. A greater rear wall ratio creates a more pronounced toe mass 812 and concentrates more mass near the toe 810. In many embodiments, the toe mass upper surface 813 increases in height as the rear wall height 2150 increases.

As illustrated in FIG. 35, the toe segment 835 defines a toe segment angle α_T relative to the ground plane 1000. The toe segment angle α_T further characterizes toeward mass concentration. A greater toe segment angle α_T represents increased mass concentration near the toe 810. In many embodiments the toe segment angle α_T can be between 15° and 75° In many embodiments, the toe segment angle α_T can be greater than 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, or greater than 75°. The toe mass 812 comprises a large toe segment angle α_T that concentrates mass near the toe 810 and balances the mass of the hosel 803.

The insert cavity 822 is offset toward the heel 806 to increase the available area for the toe mass 812. As illustrated in FIG. 36, the toe inner surface 830 forms a toeward-most boundary of the insert cavity 822, and the heel inner surface 828 forms a heelward-most boundary of the insert cavity 822. In the illustrated embodiment, the boundaries of the insert cavity 822 are shifted towards the heel 806. The heel inner surface 828 is closer to the exterior surface of the heel 806 than the toe inner surface 830 is to the exterior surface of the toe 810, as measured in a heel-to-toe direction. The heelward offset of the insert cavity 822 creates space for the toe mass 812 to concentrate mass toward the toe 810.

The insert cavity 822 defines an insert cavity length L_C measured between the heel inner surface 828 and the toe inner surface 830 in a heel-to-toe direction parallel to the ground plane 1000. The club head 800 reduces the insert cavity length L_C relative to other club head embodiments herein to provide room for the pronounced toe mass 812. The insert cavity length L_C balances providing room for the pronounced toe mass 812 with a large enough insert cavity 822 to sufficiently damp vibrations on the back face lower portion 832. Club head 800 can comprise an insert cavity length L_C between 1.5 inches and 2.5 inches. In some embodiments, the club head 800 comprises an insert cavity length L_C less than 2.5 inches, less than 2.25 inches, less than 2.0 inches, less than 1.75 inches, or less than 1.5 inches.

The heelward offset of the insert cavity 822 can further be characterized by an insert cavity center point 829 located equidistant between the insert cavity heel and toe boundaries. In some embodiments comprising a toe mass 812, the insert cavity center point 829 can be heelward of the YZ plane (YZ) and/or heelward of the impact point. In some embodiments, the insert cavity center point 829 can be heelward of the YZ plane (YZ) by a distance between 0.05 and 0.75 inch. In some embodiments, the insert cavity center point 829 can be heelward of the YZ plane (YZ) by a distance between 0.05 and 0.25 inch, between 0.10 and 0.30 inch, between 0.15 and 0.35 inch, between 0.20 and 0.40 inch, between 0.25 and 0.45 inch, between 0.30 and 0.50 inch, between 0.35 and 0.55 inch, between 0.40 and 0.60 inch, between 0.45 and 0.65 inch, between 0.50 and 0.70 inch, or between 0.55 and 0.75 inch. In some embodiments, the insert cavity center point 829 can be heelward of the YZ plane (YZ) by a distance greater than 0.05 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, or greater than 0.75 inch.

In some embodiments, the toe mass 812 is formed integrally with the club head body, such as through a casting process. In other embodiments, all or a portion of the toe mass 812 is formed separately from the club head body and subsequently coupled thereto. In such embodiments, the toe mass 812 can be formed from a different material than the club head body. In some embodiments, a high-density toe mass can further increase mass concentration towards the toe 810. In some embodiments, the toe mass 812 can be combined with a removable weight 861 located in the toe 810, as illustrated in FIG. 31. The removable weight 861 can be substantially similar to the removable weight 161 described in further detail below.

As discussed above, the toe mass 812 counterbalances the mass of the hosel 803 to improve ball flight performance and vibrational response by aligning the club head CG_X with the impact point. Accordingly, the club head 800 can comprise a balanced mass distribution between the heel 806 and the toe 810. The balanced mass distribution can be described in terms of the relationship between a heel section mass and a toe section mass. The heel section mass is defined as any club head mass heelward of the scoring area heel boundary 196 (as defined in reference to FIG. 1A). The toe section mass is defined as any club head mass toeward of the scoring area toe boundary 197 (as defined in reference to FIG. 1A). The heel section mass and the toe section mass are based on the fully-built club head, including any additional or separately attached weight members, such as any tip weights, fixed weights, or removable weights, as described herein.

The club head 800 can be perimeter weighted through various perimeter weighting features described herein to improve MOI. The perimeter weighting created by these features and/or the pronounced toe mass 812 leads to a high percentage of the total club head mass being located in the heel section and the toe section. In some embodiments, the heel section mass can be between 10 and 40% of the total club head mass. In some embodiments, the heel section mass can be greater than 10%, greater than 15%, greater than 20%, greater than 25%, greater than 30%, greater than 35%, or greater than 40% of the total club head mass. The heel section volume can be between 10 and 40% of the total club head volume. In some embodiments, the heel section volume can be less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, or less than 10% of the total club head volume. Similarly, in some embodiments, the toe section mass can be between 10 and 40% of the total club head mass. In some embodiments, the toe section mass can be greater than 10%, greater than 15%, greater than 20%, greater than 25%, greater than 30%, greater than 35%, or greater than 40% of the total club head mass. The toe section volume can be between 10 and 40% of the total club head volume. In some embodiments, the toe section volume can be less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, or less than 10% of the total club head volume.

In some embodiments, the heel section mass and the toe section mass can be substantially balanced to align the club head CG with the impact axis. In some embodiments, the difference between the heel section mass and the toe section mass can be less than 10 grams, less than 9.5 grams, less than 9.0 grams, less than 8.5 grams, less than 8.0 grams, less than 7.5 grams, less than 7.0 grams, less than 6.5 grams, less than 6.0 grams, less than 5.5 grams, less than 5.0 grams, less than 4.5 grams, less than 4.0 grams, less than 3.5 grams, less than 3.0 grams, less than 2.5 grams, less than 2.0 grams, less than 1.5 grams, less than 1.0 grams, or less than 0.5 grams. In some embodiments, the heel section mass and the toe section mass can be identical or substantially identical. In some embodiments, the percentage difference between the heel section mass and the toe section mass can be less than 10%, less than 9.5%, less than 9.0%, less than 8.5%, less than 8.0%, less than 7.5%, less than 7.0%, less than 6.5%, less than 6.0%, less than 5.5%, less than 5.0%, less than 4.5%, less than 4.0%, less than 3.5%, less than 3.0%, less than 2.5%, less than 2.0%, less than 1.5%, less than 1.0%, or less than 0.5%.

As described above, the club head 800 comprising a pronounced toe mass 812 can have a damping system including a badge 870 and an insert 840, similar to one or more damping systems described herein. The toe mass 812 can be applied to any club head detailed above or below and/or combined with any club head feature disclosed above according to the present invention. The pronounced toe mass 812 complements the damping system to further damp vibrations and improve club head sound and feel. In some embodiments, referring to FIG. 33, the club head 800 comprises a lightweight badge 870, as described above. The discretionary mass created by the lightweight badge 870 can be distributed into the toe mass 812 to better align the club head CG_X position with the impact axis. As described above, the lightweight badge 870 lowers the club head CG_Y position to more closely align with the impact axis.

The combination of the pronounced toe mass 812 and the lightweight badge 870 align the club head CG position with the impact axis in both the horizontal direction and the vertical loft direction. As similarly described above in reference to FIG. 1C, the club head 800 defines a horizontal distance CG_IX between the club head CG and the impact axis in the horizontal direction. In some embodiments, the CG_IX can be near zero. In some embodiments, the CG_IX can be between 0.005 and 0.050 inch. In some embodiments, the CG_IX can be between 0.005 and 0.010 inch, between 0.010 and 0.020 inch, between 0.015 and 0.025 inch, between 0.020 and 0.030 inch, between 0.025 and 0.035 inch, between 0.030 and 0.040 inch, between 0.035 and 0.045 inch, or between 0.040 and 0.050 inch. In some embodiments, the CG_Lx can be less than 0.050 inch, less than 0.045 inch, less than 0.040 inch, less than 0.035 inch, less than 0.030 inch, less than 0.025 inch, less than 0.020 inch, less than 0.015 inch, less than 0.010 inch, or less than 0.005 inch.

Further, the club head 800 defines a distance CG_IY between the club head CG and the impact axis in the vertical loft direction. In some embodiments, the CG_IY can be between 0.005 and 0.050 inch. In some embodiments, the CG_IY can be between 0.005 and 0.010 inch, between 0.010 and 0.020 inch, between 0.015 and 0.025 inch, between 0.020 and 0.030 inch, between 0.025 and 0.035 inch, between 0.030 and 0.040 inch, between 0.035 and 0.045 inch, or between 0.040 and 0.050 inch. In some embodiments, the CG_IY can be less than 0.050 inch, less than 0.045 inch, less than 0.040 inch, less than 0.035 inch, less than 0.030 inch, less than 0.025 inch, less than 0.020 inch, less than 0.015 inch, less than 0.010 inch, or less than 0.005 inch. The club head comprising both a pronounced toe mass 812 and a lightweight badge 870 effectively aligns the club head CG with the impact axis, whereby the toe mass 812 reduces the CG_IX distance and the lightweight badge 870 reduces the CG_IY distance. As described herein, aligning the club head CG with the impact axis improves ball speed and reduces club head rotation and vibration at impact, thereby improving impact sound and feel.

XI. Golf Club Head with Damping System and Back Plate

As described above, some club head embodiments improve both vibration damping and club head mass properties. FIGS. 37-42 illustrate a club head 900 that damps vibrations while improving MOI and lowering the club head CG toward the impact axis. The club head 900 creates discretionary mass by minimizing the rear wall and improves vibration damping by increasing the insert size. The club head increases MOI by redistributing discretionary mass to the club head perimeter and lowers the club head CG by redistributing discretionary mass near the sole.

The club head 900 forms a large rear cavity 960. As illustrated in FIG. 37, the back face 904, the top rail 920, the sole 918, the heel 906, and the toe 910 all combine to form the rear cavity 960. The club head 900 does not form an insert cavity separate from the rear cavity 960. The club head 900 further comprises an insert 940 coupled to the club head body and occupying at least a portion of the rear cavity 960. Rather than an insert cavity base, the insert 940 rests on an insert shelf 936 formed by an interior surface of the sole 918. The insert shelf 936 forms a bottom boundary of the rear cavity 960 and provides a large surface to which the insert base 946 can couple. A separate back plate 981 is coupled to the club head body and covers the insert rear surface 952. In many embodiments, the back plate 981 comprises a lighter material than the club head body. The back plate 981 can be a lightweight material comprising a lower density than club head body material. The lightweight back plate 981 thereby secures the insert 940 and creates discretionary mass over a club head wherein the insert is secured by the rear wall. As discussed in further detail below, the back plate 981 allows the insert size and shape to improve mass properties.

The lightweight back plate 981 increases discretionary mass by replacing portions of the rear wall 914 that would otherwise be needed to retain the insert 940. As illustrated in FIG. 37, the rear wall 914 is shorter near the center of the club head 900 than near the heel 906 and toe 910. In some embodiments, the rear wall 914 does not extend upward from the sole 918 near the center of the club head 900. In the illustrated embodiment, the majority of the rear wall 914 is located near the heel 906 and toe 910, thereby increasing perimeter weighting and club head MOI.

In some embodiments, the club head 900 comprises a sole lip 915 that extends upward from a rear end of the sole 918. The sole lip 915, illustrated in FIG. 38, can be located near the center of the club head 900. The sole lip 915 can be substantially shorter than the surrounding rear wall 914. In some embodiments, the sole lip 915 can comprise a sole lip height H_SL between 0.05 and 0.50 inch. The sole lip 915 can guide installation of the insert 940 to its intended position. In some embodiments, referring to FIGS. 37 and 38, the club head 900 further comprises a crosspiece 966 protruding from the back face 904. The crosspiece 966 can extend in a heel-to-toe direction and can divide the back face 904 into a back face upper portion 962 and a back face lower portion 932. In some embodiments, the insert 940 primarily contacts the back face lower portion 932. In such embodiments, the crosspiece 966 can guide installation of the insert 940 to its intended position.

The back plate 981 allows the insert size to be increased. A large, cast rear wall limits the insert cavity size and geometry. Typically, forming an insert cavity with an integrally cast rear wall requires a neutral or positive draft angle between the rear wall and the back face lower portion. In such cases, manufacturability requires that the rear wall and back face lower portion are either parallel to one another or diverge in a sole-to-top rail direction. The insert size and shape are thereby limited by the rear wall geometry. In such embodiments, the insert thickness (measured in a strike-face-to-rear direction) cannot be greater at the insert base than at the insert top surface. In contrast, the present back plate 981, which is separately formed and attached, removes the draft angle constraints. Because the back plate 981 is separately attached, the draft angle can be negative. In embodiments with a back plate 981, the insert 940 can be thicker near the insert base 946 and a larger proportion of the insert volume and mass can be located near the insert base 946, thereby lowering the club head CG.

As discussed above, the back plate 981 allows the insert 940 to be thicker at the insert base 946 than at the insert top surface 942, thereby lowering the club head CG. As illustrated in FIG. 39, the insert 940 defines an insert thickness T_I measured from the insert front surface 950 to the insert rear surface 952. In many embodiments, the insert thickness T_I is greater at the insert base 946 than at the insert top surface 942. In many embodiments, insert base 946 comprises the maximum insert thickness T_I, while the insert top surface 942 comprises the minimum insert thickness T_I. In some embodiments, the insert thickness T_I continuously and/or linearly increases from the insert top surface 942 to the insert base 946. In other embodiments, the insert thickness T_I can increase non-linearly or discontinuously from the insert top surface 942 to the insert base 946.

The club head 900 defines an insert thickness ratio as the insert thickness T_I at the insert base 946 divided by the insert thickness T_I at the insert top surface 942. In many embodiments, the insert thickness ratio can be between 1.5 and 4.0. In some embodiments, the insert thickness ratio can be between 1.5 and 2.0, between 2.0 and 2.5, between 2.5 and 3.0, between 3.0 and 3.5, or between 3.5 and 4.0. In many embodiments, the insert thickness ratio can be greater than 1.5. In some embodiments, the insert thickness ratio can be greater than 2.0, greater than 2.5, greater than 3.0, greater than 3.5, or greater than 4.0.

The lightweight back plate 981 creates discretionary mass and allows the insert size to be increased. A larger insert 940 increases vibrational damping. However, if the insert 940 is too massive, less discretionary mass is available to improve club head mass properties. The insert 940 balances damping benefits with club head mass properties.

In many embodiments, the insert volume can be between 0.15 in³ and 3.0 in³. In some embodiments, the insert volume can be greater than 0.15 in³, greater than 1.0 in³, greater than 2.0 in³, or greater than 3.0 in³. In many embodiments, the insert mass can be between 0.5 and 5.0 grams. In some embodiments, the insert mass can be greater than 0.5 gram, greater than 1.0 gram, greater than 1.5 grams, greater than 2.0 grams, greater than 2.5 grams, greater than 3.0 grams, greater than 3.5 grams, greater than 4.0 grams, greater than 4.5 grams, or greater than 5.0 grams. In some embodiments, the insert mass can be less than 5.0 grams, less than 4.0 grams, less than 3.0 grams, less than 2.0 grams, or less than 1.0 gram.

The increased insert size can increase the insert coverage area. In some embodiments, the insert 940 is the only component making up the damping system, since there might be no additional badge covering the back face upper portion 962. In such embodiments, the damping system coverage area is the surface area of the back face 904 covered by the insert 940 and is equivalent to the insert coverage area. In some embodiments, the insert coverage area can be between 0.70 in² and 1.5 in². In some embodiments, the insert coverage area can be between 0.70 in² and 0.80 in², between 0.80 in² and 0.90 in², between 0.90 in² and 1.0 in², between 1.0 in² and 1.1 in², between 1.1 in² and 1.2 in², between 1.2 in² and 1.3 in², between 1.3 in² and 1.4 in², or between 1.4 in² and 1.5 in². In some embodiments, the insert coverage area is greater than 0.70 in², greater than 0.80 in², greater than 0.90 in², greater than 1.0 in², greater than 1.1 in², greater than 1.2 in², greater than 1.3 in², greater than 1.4 in², or greater than 1.5 in².

In other embodiments, the club head 900 can further comprise a badge. Any of the badges described herein can be applied to the club head 900 comprising a back plate 981. In such embodiments, the insert 940 and the badge combine to form a damping system. In such embodiments, the damping system coverage area can be between 1.0 in² and 5.0 in². In some embodiments, the damping system coverage area can be between 2.5 in² and 3.0 in², 3.0 in² and 3.5 in², 3.5 in² and 4.0 in², 4.0 in² and 4.5 in², or between 4.5 in² and 5.0 in².

As described above, the back plate 981 is substantially lightweight. The lightweight back plate 981 can comprise a low-density material and can be substantially thin. As such, the back plate mass is reduced. In some embodiments, the back plate 981 can comprise a lightweight metal material, such as steel, a steel alloy, aluminum, an aluminum alloy, titanium, a titanium alloy, or any other suitable material or alloy. In some embodiments, the back plate 981 can comprise 304 stainless steel, 17-4 stainless steel, 606 aluminum, 7071 aluminum, 6061 aluminum, or any other suitable material. In other embodiments, the back plate 981 can comprise a plastic material, a composite material, or any other suitable lightweight material.

In some embodiments, the back plate 981 can comprise a density between 0.5 and 8.0 g/cm³. In some embodiments, the back plate 981 comprises a density between 0.5 g/cm³ and 1.0 g/cm³, 1.0 g/cm³ and 2.0 g/cm³, 2.0 g/cm³ and 3.0 g/cm³, 3.0 g/cm³ and 4.0 g/cm³, 4.0 g/cm³ and 5.0 g/cm³, 5.0 g/cm³ and 6.0 g/cm³, 6.0 g/cm³ and 7.0 g/cm³, or 7.0 g/cm³ and 8.0 g/cm³.

In some embodiments, the back plate 981 can comprise a back plate mass between 0.5 and 5.0 grams. In some embodiments, the back plate mass can be less than 5.0 grams, less than 4.0 grams, less than 3.0 grams, less than 2.0 grams, or less than 1.0 gram.

In some embodiments, the back plate 981 comprises a back plate thickness measured between opposing back plate surfaces. In some embodiments, the back plate thickness can be between 0.05 and 0.50 inch. In some embodiments, the back plate thickness 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. The back plate thickness can be substantially less than the maximum insert thickness T_I. The club head 900 can comprise a back plate thickness ratio defined as the back plate thickness divided by the maximum insert thickness T_I. In some embodiments, the back plate thickness ratio can be between 0.05 and 0.50. In some embodiments, the back plate thickness ratio can be less than 0.50, less than 0.40, less than 0.30, less than 0.20, or less than 0.10.

The back plate 981 can be secured to the club head body through any suitable means. In some embodiments, the back plate 981 can be adhesively or mechanically coupled to the club head body or a combination thereof. In some embodiments, the back plate 981 can be coupled to the club head body via epoxy or an adhesive tape. In some embodiments, referring to FIG. 40, the back plate 981 can comprise one or more tabs 988 configured to engage the club head body. The tabs 988 can extend outward from the back plate perimeter. The club head body can comprise one or more notches, slots, and/or recesses configured to receive the tabs 988. For example, in some embodiments, the sole 918 forms a sole notch configured to receive a tab 988 extending from the back plate bottom edge 987. The back plate 981 can comprise any number of tabs 988 extending from any location along the back plate perimeter. The club head body can comprise any number of notches along the sole 918, the heel 906, or the toe 910, configured to engage the tabs 988. The tabs 988 can engage the notches, thereby interlocking and securing the back plate 981. In some embodiments, the tabs 988 can be adhered within the notches, further securing the back plate 981.

As described above, the club head 900 can comprise a negative draft angle α_D between the back plate 981 and the back face 904. As illustrated in FIG. 39, the draft angle α_D is the angle between the back face and an interior surface of the back plate 981 (i.e., the surface of the back plate 981 that interfaces the insert 940). A positive draft angle α_D denotes a back plate 981 that diverges from the back face 904 in a sole-to-top rail direction. A negative draft angle α_D denotes a back plate 981 that converges with the back face 904 in a sole-to-top rail direction. In some embodiments, the club head 900 comprises a draft angle α_D between −5 and −45 degrees. In some embodiments, the draft angle α_D can be less than −5 degrees, less than −10 degrees, less than −15 degrees, less than −20 degrees, less than −25 degrees, less than −30 degrees, less than −35 degrees, less than −40 degrees, or less than −45 degrees.

In some embodiments, referring to FIG. 39, the back plate 981 forms an insert top cover 990. The insert top cover 990 extends from the back plate top edge 989 towards the strike face 902, overlapping the insert top surface 942. In some embodiments, as illustrated in FIG. 39, The insert top surface 942 can comprise an insert notch 941 configured to receive a portion of the insert top cover 990 to ensure better fit between the insert 940 and the back plate 981. The insert top cover 990 conceals and protects the insert 940. In such embodiments, the back plate 981 can fully conceal the insert 940 such that the insert 940 is not visible from the club head exterior. The back plate 981 comprising an insert top cover 990 can create a more unitary, aesthetically pleasing appearance. In some embodiments, a separately formed badge can be applied to the back face upper portion 962, while in other embodiments, the back face upper portion 962 can be left exposed.

In some embodiments, referring to FIGS. 41 and 42, the back plate 981 can further comprise a badge portion 992. The badge portion 992 can extend upward from the insert top cover 990 and can cover the back face upper portion 962. The back plate 981 comprising a badge portion 992 can be a unitary piece that covers both the insert 940 and the back face upper portion 962. The back plate 981 comprising a badge portion 992 can create seamless appearance from the club head rear, thereby resembling a solidly constructed or forged iron.

In embodiments where the back plate 981 forms a badge portion 992 covering the back face upper portion 962, the club head comprises a damping system coverage area as the combined surface area of the back face 904 covered by the insert 940 and the badge portion 992. In such embodiments, the damping system coverage area can be between 1.0 and 5.0 in². The high damping system coverage area damps vibrations and improves club head sound and feel.

XII. Golf Club Set with Damping System

In many embodiments, one or more of the club heads 100, 200, 300, 400, 500, 600, 700, 800, 900 described herein can be part of a set comprising two or more club heads having loft angles varying incrementally across the two or more club heads. In many embodiments, the set of club heads can comprise at least a first club head having a first loft angle and a second club head having a second loft angle greater than the first loft angle. In many embodiments, the set can be divided into a subset of “long irons” and a subset of “short irons.” The long irons (e.g. 3-iron, 4-iron, and 5-iron) comprise club heads with relatively low loft angles and are configured to hit the golf ball long distances. The short irons (e.g. 6-iron, 7-iron, 8-iron, 9-iron, and/or any wedges) comprise club heads with relatively high loft angles and are configured to hit the golf ball shorter distances with greater accuracy.

The two or more club heads in the set can be any combination of club heads 100, 200, 300, 400, 500, 600, 700, 800, 900 described herein. In many embodiments, the short irons can be similar to club head 100, wherein the rear wall 114 is flush with the sole rear edge 192, the rear cavity 160 is formed above the rear wall 114, and the badge 170 visually fills the rear cavity 160. In such embodiments, the short irons comprise the appearance of a muscle-back construction, inspiring confidence in the performance of the club head 100. In many embodiments, the long irons can be provided similar to club head 200, wherein the rear wall 214 is offset from the sole rear edge 292, the rear cavity 260 extends over the entire rear periphery of the club head 200, and the badge 270 only fills a portion of the rear cavity 260 located above the rear wall 214. In such embodiments, the long irons comprise increased perimeter weighting and forgiveness. In such embodiments, the long irons also comprise the appearance of a cavity-back construction, inspiring confidence in the forgiveness of said long irons. The increased forgiveness achieved by the cavity-back construction is particularly valuable in long irons, as long irons are typically more difficult to hit straight than short irons.

In many sets of golf clubs, one or more of the characteristics discussed above can vary across at least two individual club heads within the set. In many embodiments, the blade length of each individual club head can vary in at least two or more individual club heads. In particular, the blade length may increase across at least two club heads as the loft angle decreases. For example, the set can comprise a first club head having a first loft angle and a first blade length, and a second club head having a second loft angle and a second blade length, where the first loft angle is less than the second loft angle and the first blade length is greater than the second blade length.

Similarly, in many embodiments, the face height of each individual club head can vary in at least two or more individual club heads. In particular, the face height may increase across at least two club heads as the loft angle increases. For example, the set can comprise a first club head having a first loft angle and a first face height, and a second club head having a second loft angle and a second face height, where the first loft angle is less than the second loft angle and the first face height is less than the second face height.

Similarly, in many embodiments, the top rail thickness of each individual club head can vary in at least two or more individual club heads. In particular, the top rail thickness may increase across at least two club heads as the loft angle decreases. For example, the set can comprise a first club head having a first loft angle and a first top rail thickness, and a second club head having a second loft angle and a second top rail thickness, where the first loft angle is less than the second loft angle and the first top rail thickness is less than the second top rail thickness. In some embodiments, the top rail thickness may be consistent throughout the short irons of the set while the top rail thickness may increase throughout the long irons as the loft angle decreases. Because the lower-lofted club heads (e.g. the long irons) in the set have shorter face heights and the position of the insert relative to the geometric center of the face is higher, the long irons tend to experience more undesirable vibrations than the short irons. Increasing the top rail thickness in club heads with lower loft angles provides extra vibration damping in such low-lofted club heads. Increasing the top rail thickness of the long irons creates a consistent vibrational response throughout the set, wherein every club head in the set comprises a desirable sound and feel.

Similarly, in some embodiments comprising a pronounced toe mass with an angled toe segment (similar to toe segment 835 illustrated in FIG. 35), the toe segment angle α_T can vary between at least two or more individual club heads. In particular, the toe segment angle α_T may increase across at least two club heads as the loft angle increases. For example, the set can comprise a first club head having a first loft angle and a first toe segment angle α_T, and a second club head having a second loft angle and a second toe segment angle α_T. In such a set, the second loft angle can be greater than the first loft angle and the second toe segment angle α_T can be greater than the first toe segment angle α_T. An increased toe angle helps to concentrate mass in the toe mass as the loft angle increases. Higher lofted clubs typically have shorter blade lengths and thereby have less horizontal space to concentrate mass near the toe. Increasing the toe segment angle α_T enlarges the toe mass without requiring extra horizontal space.

XIII. Additional Features

k) Weight System

In many embodiments, the club head 100 can further comprise a weight system configured to provide intended or desirable mass properties (such as CG position and MOI), as well as to provide the club head 100 with an intended swing weight. The club head 100 can comprise one or more removable weights, and/or one or more permanently coupled weights (hereafter “fixed weights”).

Referring to FIGS. 28 and 29, the club head 100 can comprise a fixed weight 151 coupled to the exterior of the club head body. Referring to FIG. 28, the club head body comprises a receptacle 153 configured to receive the fixed weight 151. The receptacle 153 can comprise a receptacle front wall 155, a receptacle back wall 157, and a receptacle floor 159 between the receptacle front wall 155 and the receptacle back wall 157. The receptacle 153 can be recessed into an exterior surface of the club head 100. In many embodiments, the receptacle 153 can be located within a portion of the sole 118 proximate the toe 110. In some embodiments, the receptacle 153 can extend into the toe 110. In many embodiments, the receptacle 153 forms a generally rectangular shape. In other embodiments, the receptacle 153 can have a circular, triangular, rectangular, trapezoidal, ovular, polygonal, kidney-bean, peanut, or any other suitable shape.

The fixed weight 151 can be a high-density weight portion formed of a material with a higher density than that of the club head body. In many embodiments, the fixed weight 151 can be formed of tungsten or a tungsten alloy. The fixed weight 151 is shaped corresponding to the shape of the receptacle 153 such that the fixed weight 151 is configured to sit flush within the receptacle 153. When the fixed weight 151 is received within the receptacle 153, the top surface of the fixed weight 151 can be configured to couple or abut against the receptacle floor 159, the front surface of the fixed weight 151 can be configured to couple or abut against the receptacle front wall 155, and the back surface of the fixed weight 151 can be configured to couple or abut against the receptacle back wall 157. In many embodiments, the bottom surface of the fixed weight 151 may not abut or contact any wall or surface of the receptacle 153. The bottom surface of the fixed weight 151 can be exposed to the exterior of the club head body and can be configured to form a portion of the sole 118. The bottom surface of the fixed weight 151 can follow the natural contour of the sole 118 and sit flush with respect to the surrounding surface of the sole 118 to create a smooth, continuous sole surface.

In some embodiments, the club head 100 can comprise a removable weight 161 coupled to the exterior of the club head body. Referring to FIG. 28, the club head body can comprise a removable weight port 163 configured to receive the removable weight 161. The removable weight port 163 can be recessed into the surface of the club head body. In the illustrated embodiment of FIGS. 28 and 29, the removable weight port 163 is recessed into the toe 110. The removable weight port 163 can be located within a portion of the toe 110 proximate the sole 118. In some embodiments, the removable weight port 163 can be at least partially in the toe 110.

The removable weight port 163 can comprise a removable weight port sidewall 167 and a removable weight port floor (not shown). In many embodiments, the removable weight port sidewall 167 can be cylindrical. In other embodiments, the removable weight port 163 can comprise a plurality of sidewalls forming a generally rectangular shape, triangular shape, square shape, semi-cylindrical shape, or any other suitable shape for receiving a correspondingly shaped removable weight 161. The removable weight port floor forms a base of the removable weight port 163 and prevents the removable weight port 163 from extending entirely through the toe 110.

The removable weight 161 is designed to be interchangeable with other similar removable weights comprising different densities and mass. The interchangeable removable weights allow the weighting of the club head body to be quickly and easily adjusted. The adjustability of the club head body weighting allow for control over the swing weight of the club head body to custom fit the specifications of a particular player. The removable weight 161 and the removable weight port 163 can comprise a threaded engagement to allow the removable weight 161 to be secured within the removable weight port 163 by screwing in.

In many embodiments, the removable weight 161 can comprise tungsten or a tungsten alloy such as a tungsten-nickel alloy, tungsten-carbide alloy, tungsten-iron alloy, or a similar suitable material. In many embodiments, the removable weight material can comprise a specific gravity ranging between 10 and 20. The removable weight material can comprise a specific gravity between 10 and 12, 12 and 14, 14 and 16, 16 and 18, or 18 and 20. For example, the removable weight material can have a specific gravity of 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20.

In some embodiments, the club head 100 can comprise a tip weight 171. The tip weight 171 can be located in the hosel 103. The tip weight 171 can be provided to increase the club head MOI and to balance the mass of the fixed weight 151 and the removable weight 161, which are often located towards the toe 110. In many embodiments, the tip weight 171 can be formed of steel, tungsten, or alloys thereof. The tip weight 171 can be secured within the hosel 103 by epoxy or other adhesive means.

The club head 100 can comprise one or more fixed weights, one or more removable weights, one or more tip weights, or any combination thereof. In the embodiment illustrated in FIGS. 28 and 29, the club head 100 comprises a fixed weight 151, a removable weight 161, and a tip weight 171. The fixed weight 151 is located in the sole 118, proximate the toe 110. The removable weight 161 is located in the toe 110, proximate the sole 118. As illustrated in FIG. 29, The fixed weight 151 and the removable weight 161 are located substantially close to one another. The fixed weight 151 and the removable weight 161 can act in unison as a single weight to concentrate a large portion of mass in the lower toe area of the club head 100. The weighting arrangement results in a club head 100 with a high MOI while still retaining swing weight adjustability.

The combination of the fixed weight 151 and the removable weight 161 allows a high amount of mass to be concentrated low and toe-ward in the club head body to provide a desirable lower CG position to increase ball speed and launch angle while providing the ability to adjust the weighting of the club head 100. The combination of the fixed weight 151 and the removable weight 161, both located in the lower toe area of the club head 100, allows the CG to be placed lower without sacrificing MOI. Many prior art club heads utilized a fixed weight or a removable weight, but not a combination of the two. The club head 100 comprising the combination of a fixed weight 151 and the removable weight 161 can lower the CG by up to 0.10 inch relative to a club head without both weights.

l) Tightly Spaced Grooves

In many embodiments, the plurality of score lines 105 can be substantially tightly spaced together. The plurality of score lines 105 can define a spacing distance measured as the perpendicular distance between each adjacent score line 105. In many embodiments, the spacing distance can be consistent between each of the plurality of score lines 105. In other embodiments, the spacing distance can vary, such that the spacing distance between a first pair of score lines 105 is different than the spacing distance between a second pair of score lines 105. In many embodiments, the spacing distance between the plurality of score lines 105 ranges between 0.08 inch and 0.12 inch. In some embodiments, the spacing distance between the plurality of score lines 105 can be between 0.08 inch and 0.09 inch, between 0.09 inch and 0.10 inch, between 0.10 inch and 0.11 inch, or between 0.11 inch and 0.12 inch. In some embodiments, the spacing distance between the plurality of score lines 105 can be less than 0.12 inch, less than 0.11 inch, less than 0.10 inch, less than 0.09 inch, or less than 0.08 inch.

The tightly spaced plurality of score lines 105 can be applied to any club head 100, 200, 300, 400, 500, 600 detailed above and/or combined with any club head feature disclosed above according to the present invention, including a damping system comprising an insert and a badge. The tightly spaced plurality of score lines 105 can be applied to a club head comprising any rear wall geometry detailed above, including a rear wall flush with the rear periphery of the club head, a rear wall recessed with respect to the rear periphery, a rear wall comprising a constant height, a rear wall comprising an apex, a rear wall comprising a nadir, or any combination thereof. The tightly spaced plurality of score lines 105 can be applied to a club head comprising any damping system described in the various embodiments above, including a damping system comprising an insert contacting the back face lower portion 132 and a badge contacting the back face upper portion 162, a damping system comprising an insert housed within an insert cavity recessed into a badge, a damping system comprising an insert completely enclosed within a badge, or any combination thereof.

The tight spacing of the plurality of score lines 105 normalizes the performance of the club head in wet conditions. In many prior art club heads, the performance of the club head differs significantly in wet conditions as compared to dry conditions (also considered to be “normal” conditions). The difference in performance based on dryness or wetness leads to unpredictable and inconsistent golf shots as weather conditions change. In many cases, certain club heads within a set, such as long irons, are affected by wet conditions differently than or club heads within the same set, such as short irons or wedges. For example, in long irons, wet conditions can increase spin rate, leading to shots that travel further than intended. In short irons and wedges, wet conditions can reduce spin rate, leading to shots that do not stop where intended and are more difficult to hold greens. The tight spacing of the plurality of score lines 105 can both decrease the spin rate of long irons in wet conditions and increase the spin rate of short irons and wedges in wet conditions. The tight spacing of the plurality of score lines 105 creates a club head that performs similarly in both wet conditions and dry conditions.

EXAMPLES

XIV. Example 1: Exemplary Club Head Set with Damping System

Tables 1 and 2 display various properties and characteristics of an exemplary set of club heads according to the present invention. The set of club heads comprised a 3-iron through 9-iron, a pitching wedge (PW) and a utility wedge (UW). The short irons in the set were similar to club head 100 described above and included a rear cavity formed above the rear wall top edge and a rear wall that sits flush with the sole rear edge. The short irons in the set were similar to club head 200 described above and included a rear cavity extending over the entire rear periphery of the club head and a rear wall offset with respect to the sole rear edge. Each individual club head in the exemplary club head set comprised a damping system including a badge housed within a rear cavity and covering at least a portion of the back face upper portion and an insert housed within an insert cavity and covering at least a portion of the back face lower portion. Table 1 below illustrates various dimensions and mass properties of each individual club head within the set.

TABLE 1
					Blade	Face	Top Rail
Club	Loft	Ixx	Iyy	Izz	Length	Height	Thickness
Head	(degrees)	(g · in2)	(g · in2)	(g · in2)	(in.)	(in.)	(in.)
3	19.0	82.3	377.3	38.2	2.766	1.860	0.305
4	22.5	87.65	386.6	41.0	2.766	1.910	0.300
5	26.0	92.2	391.9	42.4	2.760	1.960	0.295
6	29.5	98.9	406.4	45.5	2.748	2.015	0.290
7	33.0	104.4	413.8	50.3	2.720	2.040	0.280
8	37.0	115.7	422.6	52.8	2.715	2.145	0.280
9	41.0	121.6	433.9	56.3	2.713	2.170	0.280
PW	45.0	133.1	455.8	65.6	2.712	2.220	0.280
UW	50.0	136.3	470.0	71.6	2.712	2.230	0.280

As illustrated in Table 1, the blade length increases between each individual club head in the set as the loft angle increases, with the exception of the pitching wedge and the utility wedge having identical blade lengths, and the 3-iron and 4-iron having identical blade lengths. The face height decreases between each individual club head in the set as the loft angle increases. Further, the club head set comprises an increased top rail thickness in the long irons (3-iron, 4-iron, 5-iron, and 6-iron) in comparison to the wedges and short irons. As discussed above, the vibrational response of the long irons is typically more difficult to control, and the sound and feel of long irons are typically less desirable than the sound and feel of short irons. Increasing the top rail thickness of the long irons creates a club head set with a consistent vibrational response and a consistent sound and feel throughout the set.

Table 2 below illustrates the relationship between the damping system coverage area and the available rear surface area, the scoring area, and the total face surface area of each individual club head in the set.

TABLE 2
		Available Rear	Damping System		Total
Club	Loft	Surface Area	Coverage Area	Scoring	face
Head	(degrees)	(in2)	(in2)	Area	area
3	19.0	3.779	3.582	3.267	3.999
4	22.5	3.797	3.595	3.332	4.154
5	26.0	3.764	3.561	3.373	4.263
6	29.5	3.757	3.551	3.426	4.395
7	33.0	3.701	3.496	3.456	4.484
8	37.0	3.741	3.529	3.540	4.679
9	41.0	3.732	3.517	3.601	4.830
PW	45.0	3.746	3.526	3.672	5.001
UW	50.0	3.713	3.490	3.737	5.170

As illustrated in Table 7, the damping system coverage area of each club head is at least 3.49 in². In the present example, the damping system coverage area of each club head is between 94% and 95% of the available rear surface area. Further, the damping system coverage area of each club head is between 78% and 90% of the scoring area. Further, the damping system coverage area of each club head is between 70% and 87% of the total face surface area. The damping system covers a significant portion of the back face. This significant coverage leads to the sound and feel benefits detailed in the foregoing examples.

XV. Example 2: Modal Analysis

The vibrational response at impact of a club head according to the present invention (hereafter the “exemplary club head”) was compared to a control club head. The exemplary club head was similar to club head 100 described above and included a damping system comprising an insert covering a lower portion of the back face and a badge covering an upper portion of the back face. The exemplary club head comprised a damping system coverage area of 3.50 in².

The control club head comprised a construction similar to the control club head, but with a different damping system. The control club head comprised an insert covering a lower portion of the back face but was devoid of a badge. The upper portion of the control club back face was uncovered. The damping system coverage area of the control club head was 1.55 in². As illustrated in FIGS. 22A and 22B, three dominant vibrations were observed in both the control club head and the exemplary club head. The exemplary club head and the control club head each exhibited a first peak 51a, 51b corresponding to impact and a second peak 52a, 52b, and third peak 53a, 53b corresponding to residual vibrations. Table 3 below illustrates the amplitude of each peak, as well as the frequency at which the peak occurred.

TABLE 3
	Peak 1	Peak 2	Peak 3
	Frequency		Frequency		Frequency
Club	(Hz)	Amplitude	(Hz)	Amplitude	(Hz)	Amplitude
Control	3228	3.95 · 106	5248	1.3 · 106	7214	6.0 · 105
Exemplary	3202	3.95 · 106	5094	7.8 · 105	7207	2.5 · 105

The first peak 51b amplitude of the exemplary club head and the first peak 51a amplitude of the control club head were identical. The exemplary club head comprised a second peak 52b amplitude damped by 40% in comparison to the second peak 52a amplitude of the control club head. The exemplary club head comprised a third peak 53b amplitude damped by 58% in comparison to the third peak 53a amplitude of the control club head. Further, the changes in frequency of the first peak 51b, the second peak 52b, and the third peak 53b of the exemplary club head in comparison to the corresponding peaks 51a, 52a, 53a of the control club head were negligible.

The damping system of the exemplary club head led to a significant damping of residual vibrations while maintaining the same amplitude of the vibrations associated with impact. Further, the exemplary club head and the control club head exhibited similar frequencies corresponding to each peak. The result is the exemplary club head exhibiting a similar pitch and sound at impact with less residual ringing and less overall vibration felt in the hands of the golfer. The sound and feel of the exemplary club head comprising a badge, an insert, and a greater damping system coverage area are improved over the control club head devoid of a badge and comprising a lesser damping system coverage area.

XVI. Example 3: Qualitative Sound and Feel Player Test

Described herein is a player test that compared two iron-type club heads having different structures. The club heads were a cavity-back style iron having a similar shape but comprised different damping systems and different damping system coverage areas. The results compared the effect of the different structures on player satisfaction with regard to the sound and feel of the club head.

The first iron-type club head (hereafter referred to as the “exemplary club head”) comprised a rear cavity, an insert cavity, a back surface, wherein the back surface comprised an upper back surface and a lower back surface, and a damping system. The upper back surface formed a wall of the rear cavity and the lower back surface formed a wall of the insert cavity. The damping system comprised an insert placed within the insert cavity and a badge was in the rear cavity. The insert covered most of the lower back surface and the badge covered most of the upper rear surface. The exemplary club head comprised a damping system coverage area of 3.50 in².

The second iron-type club head (hereafter referred to as the “control club head”) was similar to the first and comprised a rear cavity, an insert cavity, an insert, a back surface, wherein the back surface comprised an upper back surface and a lower back surface. The upper back surface formed a wall of the rear cavity, and the lower back surface formed a wall of the insert cavity. Wherein, the insert was placed within the insert cavity and the insert covered most of the lower back surface. The upper back surface was exposed. The damping system coverage area of the control club head was 1.55 in².

A player test was conducted to compare the badge and the insert performance of the exemplary club head to the insert performance of the control club head. The player test involved twenty-two players who participated in a survey for the 4-iron test and the wedge test, and twenty-one players in the 7-iron test. The players compared their experiences with the exemplary club head, and the control club head. The players tested each club head under similar conditions, where the iron-type club heads included similar shaft lengths and similar loft angles. Further, the player test was conducted on a typical surface for striking a golf ball. The test involved striking a golf ball with a full swing with the control club head and the exemplary club head.

After testing, the participants compared the two club heads based on two parameters. The parameters included feel (or “feedback”) and sound. Based on these parameters, the participants were asked to compare the feedback and sound of exemplary club head to the control club head on a scale from “Much Worse” to “Much Better.” In between these choices, there was: “Somewhat Worse”, “About the Same”, and “Somewhat Better.” “Much Worse” represented a decrease in satisfaction, “Somewhat Worse” represented a slight decrease in satisfaction, “About the Same” represented a neither an increase or decrease in satisfaction, “Somewhat Better” represented a moderate increase in satisfaction, and “Much Better” represented a substantial increase in satisfaction.

TABLE 4
Feedback
			About
	Much	Somewhat	the	Somewhat	Much	Total
	Worse	Worse	Same	Better	Better	Votes
4 iron	0	0	11	10	1	22
7 iron	0	3	12	5	1	21
Wedge	0	1	19	0	2	22

TABLE 5
Feedback
	4 iron	7 iron	Wedge
Number of Participants who Voted	11	6	2
Somewhat Better or Much Better
Number of Participants who Voted	11	12	19
About the Same
Total Number Participants	22	21	22
Percentage of Participants who Voted	50%	29%	9%
Somewhat Better or Much Better
Percentage of Participants who Voted	100%	86%	95%
About the Same or Better

Table 4 above illustrates the votes cast by the participants when comparing the exemplary club head to the control club head for feedback. Table 5 above illustrates the percentage of players who ranked the exemplary club head “About the Same”, “Somewhat Better”, or “Much Better” than the control club head for feedback. The exemplary club head was rated “About the Same”, “Somewhat Better”, or “Much Better” when compared to the control club head by 100% of the participants for the 4-iron, 86% of the participants for the 7-iron, and 95% of the participants for the Wedge. Further, the exemplary club head was rated “Somewhat Better”, or “Much Better” when compared to the control club head by 50% of the participants for the 4-iron, 29% of the participants for the 7 iron, and 9% of the participants for the Wedge.

TABLE 6
Sound
			About
	Much	Somewhat	the	Somewhat	Much	Total
	Worse	Worse	Same	Better	Better	Votes
4 iron	0	1	7	11	3	22
7 iron	0	3	8	9	1	21
Wedge	0	1	14	6	1	22

TABLE 7
Sound
	4 iron	7 iron	Wedge
Number of Participants who Voted	14	10	7
Somewhat Better or Much Better
Number of Participants who Voted	7	8	14
About the Same
Total Number Participants	22	21	22
Percentage of Participants who Voted	64%	48%	32%
Somewhat Better or Much Better
Percentage of Participants who Voted	95%	86%	95%
About the Same or Better

Table 6 above illustrates the votes cast by the participants when comparing the exemplary club head to the control club head for sound. Table 7 above illustrates the percentage of players who ranked the exemplary club head “About the Same”, “Somewhat Better”, or “Much Better” than the control club head for sound. The exemplary club head was rated “About the Same”, “Somewhat Better”, or “Much Better” when compared to the control club head by 92% of the participants for the 4-iron, 86% of the participants for the 7-iron, and 95% of the participants for the Wedge. Further, the exemplary club head was rated “Somewhat Better”, or “Much Better” when compared to the control club head by 64% of the participants for the 4-iron, 48% of the participants for the 7-iron, and 32% of the participants for the Wedge.

The test resulted in the exemplary club head outperforming the qualitative parameters of the control club head (e.g., feedback and sound). The participants in the player test felt the exemplary club head performed better than the control club head. The increased damping system coverage area in the exemplary club head provides advantages over the feedback and sound of the control club head. The exemplary club head included multiple components that each provided a function to the feedback and sound. The damping system of the exemplary club head covers both the lower back surface and the upper back surface, whereas the control club head leaves the upper back surface fully exposed. The inclusion of the badge increases the damping system coverage area and improves the feedback and sound of the exemplary club head by damping the unwanted vibration of the club head.

In particular, participants rated the 4-iron as having the greatest improvement in feedback and sound over the control club head. The improvement in the 4-iron is significant, as the vibrational response in long irons is typically difficult to control, and the sound and feel of the long irons is generally less desirable than that of the short irons. The result is a club head set wherein the sound and feel characteristics are consistent throughout the set.

XVII. Example 4: Ball Flight Performance

The ball flight characteristics of a plurality club heads according to the present invention (hereafter the “exemplary club head(s)”) were compared to a plurality of control club heads. The exemplary club heads were similar to club head 100 and/or club head 200 described above and included a damping system comprising an insert covering a lower portion of the back face and a badge covering an upper portion of the back face. The exemplary club heads comprised a damping system coverage area of approximately 3.5 in².

The control club heads comprised a construction similar to the exemplary club heads, but with a different damping system. The control club heads comprised an insert covering a lower portion of the back face but was devoid of a badge. The control club heads comprised a damping system coverage area of approximately 1.55 in². The ball flight characteristics were compared between an exemplary 4-iron, an exemplary 7-iron, and an exemplary wedge and a control 4-iron, a control 7-iron, and a control wedge. The ball speed, launch angle, and spin rate of each club head were measured. The ball flight characteristics of each club are presented in Table 8 below.

TABLE 8
	Ball Speed	Launch Angle	Spin Rate
	(mph)	(degrees)	(rpm)
4-iron	Exemplary	132.7	11.3	4309
	Control	132.6	11.1	4412.2
7-iron	Exemplary	118.5	16.3	6570.3
	Control	118.7	15.6	6639.8
Wedge	Exemplary	98.6	22.6	9024.4
	Control	98	23.4	8543.9

The exemplary club heads performed similarly to the control club heads with respect to each ball flight characteristic. With respect to the 4-iron, the exemplary club head exhibited a 0.1 mph increase (0.08% increase) in ball speed, a 0.2 degree increase (1.8% increase) in launch angle, and a 103 rpm reduction (2.3% decrease) in spin rate. With respect to the 7-iron, the exemplary club head exhibited a 0.2 mph decrease (0.17% decrease) in ball speed, a 0.7 degree increase (4.5% increase) in launch angle, and a 70 rpm reduction (1.0% decrease) in spin rate. Regarding the wedge, the exemplary club head exhibited a 0.6 mph increase (0.6% increase) in ball speed, a 0.8 degree decrease (3.4% decrease) in launch angle, and a 481 rpm increase (5.6% increase) in spin rate. In general, the differences between the ball flight characteristics of the exemplary club heads and the control club heads were negligible. Exceptions include the substantial increase in launch angle of the exemplary 7-iron over the control 7-iron, leading to an increase in carry distance and stopping power, and the substantial increase in spin rate of the exemplary wedge over the control wedge, resulting in increased stopping power.

The exemplary club heads comprise similar ball flight characteristics to the control club heads, leading to similar or slightly improved performance. Referring to the improved vibrational response exhibited in Example 2 and the qualitative improvements in sound and feel exhibited in Example 3, the inclusion of the damping system comprising a badge in combination with an insert produces a club head with improved sound and feel while retaining a high level of ball flight performance.

XVIII. Example 5: Badge Durability

Described herein is a durability test that compared two multi-material badges made from different materials. The objective of the test was to test the badge for the ability to retain adhesion to a golf club head and limit scratches, dents, and bends throughout the use of the badge.

The first badge (hereafter referred to as the “exemplary badge”) was similar to badge 170. The exemplary badge comprised an adhesive layer, a filler layer, and a rigid layer. The rigid layer was made from 17-4 stainless steel.

The second badge (hereafter referred to as the “control badge”) was similar to badge 170. The control badge comprised an adhesive layer, a filler layer, and a rigid layer. The rigid layer was made from 6061 aluminum.

A test was conducted to compare the durability of the exemplary badge and the control badge. The durability test consisted of affixing the test specimens in the appropriate orientation and then subjecting the badge to a steel shot media for a number of designated drops. Scans and photos were taken of each badge at specified intervals. The test apparatus consisted of a funnel positioned above the badge with a 36-inch guide tube. A steel shot was released and accelerated through the guide tube to impact the badge. The badge was adhered to a platform that was set at 450 relative to the path of the guide tube. The badge further was placed an inch from the end of the guide tube and secured. Once all parameters were confirmed the steel shot was released to impact the center of the badge. The process was repeated until the badge was damaged or for 30 repetitions, whichever condition was met first concluded the test. A damaged badge would mean the badge had a loss of adhesion to the platform or an excess in scratching, denting, or bending. The badge was inspected after each impact. The badge was 3D laser scanned after 0, 10, 15, 20, and 30 drops.

After testing the control badge withstood 3 repetitions before being damaged. The control badge deformed and lost adhesion to the platform. The 3 impacts caused the rigid layer to deform to such an extent that the adhesion to the platform failed and approximately 50% of the control badge lost adhesion to the platform.

Due to the control badge failing after 3 repetitions the exemplary badge underwent 3 repetitions to provide a fair comparison of durability between the exemplary badge and the control badge. The exemplary badge withstood 3 impacts and maintained adhesion to the platform. The exemplary control badge deformed 0.012 inches at the point of impact, considered an acceptable amount of deformation.

The test resulted in the exemplary badge outperforming the control badge based on durability. The control badge failed the test and deformed such that the control badge lost adhesion to the platform. If the control were to have been attached to a club head the badge would have detached from the club head. The exemplary badge maintained adhesion to the platform and deformed only slightly. The exemplary badge will maintain adhesion and limit scratches, dents, and bends throughout the use of the badge.

XIX. Example 6: Comparison in Performance in Wet Conditions and Dry Conditions

The consistency of the performance in wet and dry conditions of an exemplary club head was compared to the consistency of the performance in wet and dry conditions of a control club head. The exemplary club head was a wedge-type club head of a similar construction to club head 100 and comprised a damping system including a badge covering an upper portion of the back face and an insert covering a lower portion of the back face. The exemplary club head comprised a spacing distance between a plurality of score lines, wherein the exemplary club head spacing distance was 0.104 inch.

The control club head comprised a construction similar to the exemplary club head, but devoid of a badge. The control club head further comprised a spacing distance between the plurality of score lines, wherein the control club head spacing distance was 0.140 inch.

The ball speed, launch angle, spin rate, and carry distance of each club head was measured both in dry conditions and wet conditions. The difference in performance of each club head between the dry conditions and the wet conditions was evaluated. Tables 9-12 below display the results of the comparison.

TABLE 9
Ball Speed Comparison
	Control	Exemplary
Dry Ball Speed (mph)	102.4	102.6
Wet Ball Speed (mph)	100.7	101.7
Change in Ball Speed (mph)	−1.7	−0.9

Table 9 above exhibits the ball speed of the control club head and the exemplary club head, each measured in both wet and dry conditions. The control club head exhibited a decrease in ball speed of 1.7 mph (1.6% decrease). The exemplary club head exhibited a decrease in ball speed of only 0.9 mph (0.9% decrease).

TABLE 10
Launch Angle Comparison
	Control	Exemplary
Dry Launch Angle (Degrees)	21.3	20.7
Wet Launch Angle (Degrees)	24.5	21.1
Change in Launch Angle (Degrees)	3.2	0.4

Table 10 above exhibits the launch angle of the control club head and the exemplary club head, each measured in both wet and dry conditions. The control club head exhibited an increase in launch angle of 3.2 degrees (15% increase). The exemplary club head exhibited an increase in launch angle of only 0.4 degrees (1.9% increase).

TABLE 11
Spin Rate Comparison
	Control	Exemplary
Dry Spin Rate (rpm)	9068.1	9321.2
Wet Spin Rate (rpm)	6902.9	9143.7
Change in Spin Rate (rpm)	−2165.2	−177.5

Table 11 above exhibits the spin rate of the control club head and the exemplary club head, each measured in both wet and dry conditions. The control club head exhibited a decrease in spin rate of 2165.2 rpm (23.9% decrease). The exemplary club head exhibited a decrease in spin rate of only 177.5 rpm (1.9% decrease).

TABLE 12
Carry Distance Comparison
	Control	Exemplary
Dry Carry Distance (yds)	132.2	132.1
Wet Carry Distance (yds)	134.2	130.8
Change in Carry Distance (yds)	2.0	−1.3

Table 12 above exhibits the carry distance of the control club head and the exemplary club head, each measured in both wet and dry conditions. The control club head exhibited an increase in carry distance of 2.0 yards (1.5% increase). The exemplary club head exhibited a decrease in carry distance of only 1.3 yards (1.0% decrease).

The exemplary club head exhibited significantly more consistent performance between dry and wet conditions in comparison to the performance of the control club head. The exemplary club head exhibited slightly reduced variability in wet and dry performance with respect to ball speed (0.8 mph less variability) and carry distance (0.7 yards less variability). Further, the exemplary club head exhibited significantly reduced variability in wet and dry performance with respect to launch angle (2.8 degrees less variability) and spin rate (1988 rpm less variability). The tighter spacing of the score lines of the exemplary club head resulted in more consistent performance in dry and wet conditions. The result of the tighter spacing of the score lines is a club head whose performance is more predictable in all weather conditions.

XX. Example 7: Performance of Club Head with Segmented Badge and Fixed Weight

Described herein is a player test that compared two iron-type club heads having different structures. The player test compared cavity-back style irons having similar body shapes but comprising different damping and weighting systems. The different damping and weighting systems produced differences in mass properties (i.e., CG and MOI characteristics) and performance characteristics, described below. The test compared the effect of the different structures on player satisfaction regarding the club head performance. Players provided feedback on notable metrics pertaining to club head performance, including ball speed, ball flight, launch angle, and spin. Players also considered the club head responsiveness (or “feel”) to be encompassed by performance. In general, golfers tend to correlate good club head performance with increased ball speed, straight ball flight, a soft feel, and limited off-center spin.

The first iron-type club head (hereafter referred to as the “exemplary club head”) comprised a rear cavity, an insert cavity, a back surface, wherein the back surface comprised an upper back surface and a lower back surface, a fixed weight on the sole, and a damping system. The upper back surface formed a wall of the rear cavity, and the lower back surface formed a wall of the insert cavity. The damping system comprised an insert placed within the insert cavity and a segmented badge occupying the rear cavity. The badge was provided with a plurality of individual sections. The badge sections define a plurality of gaps therebetween, configured to increase badge flexibility. The insert covered most of the lower back surface and the badge covered most of the upper rear surface.

The second iron-type club head (hereafter referred to as the “control club head”) differs from the exemplary club head. Specifically, the control club head was devoid of a segmented badge and a fixed weight in the sole. However, like the exemplary club head, the control club head comprised a rear cavity, an insert cavity, an insert, and a back surface, wherein the back surface comprised an upper back surface and a lower back surface. Further, the upper back surface formed a wall of the rear cavity, and the lower back surface formed a wall of the insert cavity. The insert was placed within the insert cavity and the insert covered most of the lower back surface. A unitary badge, dissimilar from the segmented badge of the exemplary embodiment, was positioned within the rear cavity, covering the majority of the upper back surface.

TABLE 13
Mass Properties Comparison
Club #	Mass (g)	CGx	CGy	CGz	Ixx	Iyy
Control Club	241.5	0.062	0.551	0.410	87.7	386.6
Head (4i)
Exemplary	244.8	0.007	0.553	0.413	90.1	408.3
Club Head (4i)
Control Club	261.5	0.062	0.532	0.520	104.5	413.9
Head (7i)
Exemplary	264	0.013	0.501	0.515	104.9	417.1
Club Head (7i)

As shown in Table 13, the combination of the segmented badge and fixed weight of the exemplary club head improves mass distribution compared to the control club head. Specifically, the exemplary 4-iron comprises a greater moment of inertia (MOI) about the x-axis and y-axis when compared to the control 4-iron. Similarly, the exemplary 4-iron comprises a greater MOI about the x-axis and y-axis when compared to the control 7-iron, as well as having a lower center of gravity, described by the CG_X distance. Increased MOI and a lower CG correlate to increased forgiveness. A lower club head CG also corresponds to improved launch characteristics.

A player test was conducted to compare the segmented badge, insert, and fixed weight performance of the exemplary club head to the unitary badge and insert performance of the control club head. The player test involved twenty players who participated in a survey for the 7-iron test, and twenty-one players in the 4-iron test. During the tests, each player would hit a representative number of golf shots with each of the control and exemplary clubs. The players tested each club head under similar conditions, with a typical ball-striking surface, and wherein the iron-type club heads included similar shaft lengths and lofts. Thereafter, the players rated their experiences with the exemplary club head and the control club head.

After testing, the participants compared the two club heads based on perceived performance, analyzed by responsiveness, launch characteristics, and ball speed. As such, participants were asked to compare the performance of the exemplary club head to the control club head on a scale from “Moderately Less Desirable” to “Moderately More Desirable.” In between these choices, there was: “Slightly Less Desirable”, “No Difference”, and “Slightly More Desirable.” “Moderately Less Desirable” represented a decrease in satisfaction relative to the control club head, “Slightly Less Desirable” represented a slight decrease in satisfaction relative to the control club head, “No Difference” represented similar satisfaction between the exemplary club head and the control club head, “Slightly More Desirable” represented a moderate increase in satisfaction relative to the control club head, and “Moderately More Desirable” represented a substantial increase in satisfaction relative to the control club head.

TABLE 14
Qualitative Performance Feedback
Feedback
	Moderately	Slightly		Slightly	Moderately
	Less	Less	No	More	More	Total
	Desirable	Desirable	Difference	Desirable	Desirable	Votes
4 iron	0	4	11	5	1	21
7 iron	0	3	10	7	0	20

TABLE 15
Qualitative Performance Feedback
Feedback
	4 iron	7 iron
Number of Participants who Voted Slightly More Desirable or	6	7
Moderately More Desirable
Number of Participants who Voted No Difference	11	10
Total Number Participants	21	20
Percentage of Participants who Voted Slightly More Desirable or	29%	35%
Moderately More Desirable
Percentage of Participants who Voted No Difference or Better	81%	85%

Tables 14 and 15 above exhibit participant responses comparing the exemplary club head to the control club head for feedback. Tables 14 and 15 above illustrate the percentage of players who ranked the exemplary club head “No Difference”, “Slightly More Desirable”, or “Moderately More Desirable” than the control club head for feedback. The exemplary club head was rated “No Difference”, “Slightly More Desirable”, or “Moderately More Desirable” when compared to the control club head by 81% of the participants for the 4-iron, and 85% of the participants for the 7-iron. Further, the exemplary club head was rated “Slightly More Desirable”, or “Moderately More Desirable” when compared to the control club head by 29% of the participants for the 4-iron, and 35% of the participants for the 7-iron.

The test resulted in the exemplary club head outperforming the qualitative parameters of the control club head (e.g., performance). The participants in the player test felt the exemplary club head performed better than the control club head. The segmented badge and sole weight provide advantages over the performance of the control club head. The exemplary club head included several components that each provided a function to the performance. The segmented badge of the exemplary club head increased badge flexibility compared to the control club head, leading to an increase in performance characteristics such as ball speed and launch angle. The exemplary club sole weight further drove the CG down, increasing spin and improving forgiveness compared to the control club head.

The player test compared the ball flight characteristics between the exemplary club head and the control club head. Specifically, the ball flight characteristics were compared between an exemplary 4-iron and a control 4-iron and between an exemplary 7-iron and a control 7-iron. The ball speed, launch angle, and spin rate of each club head were measured. The ball flight characteristics of each club are presented in Table 16 below.

TABLE 16
Ball Flight Characteristics
		Ball	Launch	Spin	Carry	Max
		Speed	Angle	Rate	Distance	Height
		(mph)	(degrees)	(rpm)	(yds)	(yds)
4-iron	Exemplary	135.0	11.7	4661	204.0	27.4
	Control	134.9	11.7	4561	203.8	27.1
7-iron	Exemplary	123.1	16.8	7071	171.9	32.8
	Control	122.8	16.7	6836	172.5	32.1

The exemplary club heads performed similarly to the control club heads with respect to each ball flight characteristic. With respect to the 4-iron, the exemplary club head exhibited a 0.1 mph increase (0.07% increase) in ball speed, similar launch angle, and a 100-rpm increase (2.1% increase) in spin rate. With respect to the 7-iron, the exemplary club head exhibited a 0.3 mph increase (0.24% increase) in ball speed, a 0.1-degree increase (0.6% increase) in launch angle, and a 235-rpm increase (3.3% increase) in spin rate. In general, the differences between the ball flight characteristics of the exemplary club heads and the control club heads were negligible. Exceptions include the increase in spin rate and ball speed of the exemplary 4-iron over the control 4-iron, leading to an increase in carry distance and stopping power.

The exemplary club heads comprise similar ball flight characteristics to the control club heads, leading to similar or slightly improved performance. Referring to the aforementioned improvements in performance and the quantitative improvements in launch, the combination of the segmented badge and sole weight produces a club head with improved performance and launch characteristics.

XXI. Example 8: Performance of Club Head with Lightweight Badge and Pronounced Toe Mass

Described herein is an additional player test, similar to the one described in Example 7, which evaluates both qualitative and quantitative improvements for a golf club head featuring a lightweight badge and a pronounced toe mass. In particular, this player test compared two iron-type club heads having different structures. The player test compared cavity-back style irons having similar body shapes, but comprising different damping and weighting systems. The different damping and weighting systems produced differences in mass properties (i.e., CG and MOI characteristics) and performance characteristics, described below. The test further compared the effect of the different structures on player satisfaction regarding the club head responsiveness (or “feel”).

The first iron-type club head (hereafter referred to as the “exemplary club head”) comprised similar features of the first iron-type club head described in Example 7. Specifically, this exemplary club head comprised a rear cavity, an insert cavity, a back surface, wherein the back surface comprised an upper back surface and a lower back surface, and a damping system. The upper back surface formed a wall of the rear cavity, and the lower back surface formed a wall of the insert cavity. In contrast to the exemplary club head described in Example 7, the present exemplary club head comprised a damping system including a lightweight ABS badge, as described above. The lightweight badge was comprised of a single rigid layer formed of an acrylonitrile butadiene styrene (ABS) plastic material and an adhesive layer. Further, the lightweight badge comprised an overall width of 1.072 inches and an overall length of 3.139 inches.

Additionally, the exemplary club head comprised a pronounced toe mass located generally toeward of the insert cavity and extending laterally, as described above and illustrated in FIG. 34. The pronounced toe mass increased the mass in the toe region, defined as the total mass located toeward of the groove lines, compared to the control club head. Likewise, the heel region mass is defined as the total mass located on the heel side of the groove lines. For the exemplary club head, the toe region had a mass of 70.8 grams and the heel region had a mass of 68.7 grams. Alternatively, for the control club head, the toe region had a mass of 65.82 grams and the heel region had a mass of 75.7 grams. Comparatively, the toe region mass was 2.1 grams (or 3.01%) heavier than the heel region mass in the exemplary club head, whereas in the control club head, the toe region mass was 9.88 grams (or 13.96%) lighter than the heel region mass. A lower percentage difference in mass between the heel and toe regions indicated a more balanced distribution in mass across the two regions. As such, the data indicated that the exemplary club head featured a better heel-to-toe mass distribution compared to the control club head. As discussed in further detail below, this distribution of mass, achieved through the inclusion of the lightweight badge and the pronounced toe mass, aligned the club head CG with the impact axis, thereby improving club head sound and feel.

The second iron-type club head (hereafter referred to as the “control club head”) differed from the exemplary club head and was identical to the control club head described in Example 7. Specifically, the control club head was devoid of a pronounced toe mass, as illustrated in FIG. 3. However, like the exemplary club head, the control club head comprised a rear cavity, an insert cavity, an insert, and a back surface, wherein the back surface comprised an upper back surface and a lower back surface. Further, the upper back surface formed a wall of the rear cavity, and the lower back surface formed a wall of the insert cavity. The insert was placed within the insert cavity and the insert covered most of the lower back surface. A badge was positioned within the rear cavity, covering the majority of the upper back surface. The control club head badge was a three-piece badge comprising a rigid layer made of a steel alloy, a filler layer, and an adhesive layer. Further, the control club head badge comprised an overall width of 1.044 inches and an overall length of 2.978 inches. The lightweight badge of the exemplary club head comprised a thinner and lighter construction than the control club head badge, as illustrated in Table 18 below. Specifically, the exemplary club head ABS badge comprised a mass of 4.38 grams, while the control club head steel alloy badge comprised a mass of 13.31 grams. Moreover, a larger portion of the badge mass was located above the impact axis for the control club head than the exemplary club head. Consequently, the lightweight badge of the exemplary club head comprised a lower MOI than the control club head badge.

TABLE 17
Club Head Mass Properties Comparison
	Mass	Ixx	Iyy	CGIX	CGIY
Club#	(g)	(g · in2)	(g · in2)	(in.)	(in.)
Control Club Head (7i)	261.5	104.5	413.8	0.06	0.03
Exemplary Club Head (7i)	261.5	103.6	422.4	0.03	0.01

TABLE 18
Badge Mass Properties Comparison
		Maximum	Badge Mass
		Badge	Above		Rigid Layer
	Badge Mass	Thickness	Impact Axis	Badge MOI	Density
Club#	(g)	(in.)	(g)	(g · cm2)	g/cm3
Control Club Head	13.31	0.37	10.72	12.40	7.85
(7i)
Exemplary Club	4.38	0.16	3.93	5.47	1.0
Head (7i)

As shown in Table 17, the combination of the lightweight badge and the pronounced toe mass of the exemplary club head improved mass distribution compared to the control club head. Specifically, the exemplary club head comprised a greater MOI about the y-axis when compared to the control club head. Table 17 further illustrates the CG_IX and CG_IY values for the exemplary and control club heads. As discussed above, CG_IX defines the distance between the club head CG and the impact axis in the horizontal direction. The CG_IY defines the distance between the club head CG and the impact axis in the vertical loft direction. The exemplary club head displayed an improvement in CG_IX and CG_IY distances compared to the control club head. Particularly, the exemplary club head exhibited a decreased CG_IX of 0.03 inches (or 50% decrease) and a decreased CG_IY of 0.02 inches (or 66.67% decrease) compared to the control club head. As previously mentioned, the pronounced toe mass increased perimeter weighting and counterbalanced the mass of the hosel, thereby increasing MOI. Likewise, the lightweight badge lowered club head CG. Increased MOI and a lowered CG correlate with an overall increase in forgiveness. A lower club head CG also corresponded to improved launch characteristics (i.e., ball speed). Moreover, aligning the club head CG with the impact axis reduced club head vibrations and rotation about the CG at impact, thereby improving sound and feel, imparting less undesirable sidespin, and leading to a straighter ball flight.

A player test was conducted to compare the performance of the exemplary club head, featuring the lightweight badge and pronounced toe mass, with that of the control club head, which included the metallic badge and was devoid of the pronounced toe mass. The player test involved twenty players who were surveyed about playability and feel afterward. During the test, each player would hit a representative number of golf shots with each of the control and exemplary clubs. The players tested each club head under similar conditions, with a typical ball-striking surface, and wherein the iron-type club heads included similar shaft lengths and lofts. Thereafter, the players rated their experiences with the exemplary club head and the control club head.

After testing, the participants compared the two club heads based on perceived performance, analyzed by responsiveness. As such, participants were asked to compare the performance of the exemplary club head to the control club head on a scale from “Moderately Less Desirable” to “Moderately More Desirable.” In between these choices, there was: “Slightly Less Desirable”, “No Difference”, and “Slightly More Desirable.” “Moderately Less Desirable” represented a decrease in satisfaction relative to the control club head. “Slightly Less Desirable” represented a slight decrease in satisfaction relative to the control club head. “No Difference” represented similar satisfaction between the exemplary club head and the control club head. “Slightly More Desirable” represented a moderate increase in satisfaction relative to the control club head. “Moderately More Desirable” represented a substantial increase in satisfaction relative to the control club head.

TABLE 19
Qualitative Performance Feedback
Feedback
	Moderately	Slightly		Slightly	Moderately
	Less	Less	No	More	More	Total
	Desirable	Desirable	Difference	Desirable	Desirable	Votes
Exemplary	1	2	11	5	1	20
Club Head
(4i)

TABLE 20
Qualitative Performance Feedback
FEEDBACK
Number of Participants who Voted Slightly More Desirable or 6
Moderately More Desirable
Number of Participants who Voted No Difference 11
Total Number Participants        20
Percentage of Participants who Voted Slightly More Desirable or 30%
Moderately More Desirable
Percentage of Participants who Voted No Difference or Better 85%

Tables 19 and 20 above exhibit participant responses comparing the exemplary club head to the control club head for feedback. Tables 19 and 20 above illustrate the percentage of players who ranked the exemplary club head “No Difference”, “Slightly More Desirable”, or “Moderately More Desirable” than the control club head for feedback. The exemplary club head was rated “No Difference”, “Slightly More Desirable”, or “Moderately More Desirable” when compared to the control club head by 85% of the participants for the 4-iron. Further, the exemplary club head was rated “Slightly More Desirable”, or “Moderately More Desirable” when compared to the control club head by 30% of the participants for the 4-iron.

The test resulted in the exemplary club head outperforming the qualitative parameters of the control club head (e.g., sound and feel). The participants in the player test felt the exemplary club head performed better than the control club head. The lightweight badge and pronounced toe mass provide advantages over the performance of the control club head. The lightweight badge of the exemplary club head increases discretionary mass thereby lowering the club head CG towards the impact axis, increasing perimeter weighting and improving club head forgiveness. Further, the pronounced toe mass counterbalances the mass of the hosel, thereby moving club head CG closer to the toe and the impact axis. This mass distribution increases ball speed and responsiveness at the impact point.

The player test further compared the dispersion area (or stat area) between the exemplary club head and the control club head. Specifically, a player performance test was conducted to capture club head performance data under regular conditions of the clubs described above. The blind test consisted of 20 golfers hitting 10 shots with a 7-iron club head of the exemplary and control club heads. The test specifically examined the precision and accuracy of each club head by measuring and recording the dispersion area of the finishing positions of each shot for each club head's sample set. A smaller dispersion area represents a more precise and forgiving club head. The results of the first player performance test are presented in Table 21 below.

TABLE 21
Player Test Dispersion Comparison
			Average	Average
			Dispersion	Dispersion
		Average	Area Difference	Percentage
		Dispersion	Over Control	Decrease Over
		Area (yd2)	(yd2)	Control
7-iron	Exemplary	862	98	10.21%
	Control	960	N/A	N/A

The exemplary club head exhibited a significant decrease in dispersion area relative to the first control club head. The dispersion area of the exemplary club head was 10.21% less than the first control club head. The results of the player performance test illustrate the improved performance of the exemplary club heads over the first control club heads. The exemplary club head was significantly more precise than the first control club head. This increased precision can be attributed to the improved CG and MOI characteristics achieved by the inclusion of the lightweight badge and pronounced toe mass. Particularly, the lightweight badge distributes mass to the perimeter, thereby improving forgiveness, and the pronounced toe mass positions the club head CG near the impact axis, thereby reducing club head rotation at impact.

In addition to performance results obtained through player testing, robotic testing was used to measure specific ball flight characteristics between the exemplary and control club heads. Specifically, the tested club heads were attached to a robotic swing device designed to precisely swing the golf club along a measurable and repeatable plane. The incorporation of a robotic swing device allows particular strike locations on the club head to be analyzed and compared.

Ball speeds were compared between an exemplary 7-iron and a control 7-iron. During these tests, 10 shots were taken at each impact location and were averaged to properly represent the data. Table 22 below compares these average ball speeds at various impact locations on the exemplary and control club heads.

TABLE 22
Ball Speed Comparison at Specific Strike Face Locations
Ball Speed at Specific Strike Face Locations
		(mph)
		Face Center	0.3″ Below Face Center
7-iron	Exemplary	119.00	116.77
	Control	118.70	115.28

Table 22 illustrates the average ball speeds at specific strike face locations for the exemplary and control club heads. During testing, the average club head speed at impact was measured at 90.29 mph with a standard deviation of 0.17. As shown above, the ball speed at face center and 0.30 inch below face center was higher for the exemplary club head than for the control club head. Specifically, the exemplary club head exhibited a 0.3 mph increase (0.25% increase) in ball speed at the face center and a 1.49 mph increase (1.29% increase) in ball speed at 0.30 inch below face center when compared to the control club head. The combination of the lightweight badge and the pronounced toe mass allocates mass downward which lowers club head CG. As previously mentioned, ball strikes at lower regions on the club head are common and generally lead to poor ball speeds and high spin. Therefore, the downward redistribution of club head mass improves ball speed at strike locations lower on the strike face.

XXII. Example 9: Durability of Lightweight Badge

Described herein is a durability analysis of the exemplary club head of Example 8. Specifically, this test examined the abrasion and dent resistance of the lightweight badge utilized in the exemplary club head. As previously mentioned, the lightweight badge is similar to of the lightweight badges described herein and comprises a single rigid layer formed of an ABS plastic material and is attached to the club head via a VHB tape. Additionally, the lightweight badge comprised three distinct finishes at three areas on the exterior surface of the badge. The first region was positioned nearest the sole and comprised a pearl chrome plated finish. The second region was positioned between the first and third regions and comprised a pearl chrome plated finish with a matte clear coat. The third region was positioned nearest the top rail and comprised a carbon fiber inlay and a matte finish. Furthermore, a protective clear coat or surface treatment consisting of acrylic and urethane primers was added to the lightweight badge across all three finishes. As described above, the surface coating provides increased durability without affecting the aesthetic appearance of the badge.

The first durability test measured abrasion resistance of the lightweight badge. This test utilized the Century Design Inc. CD-8900B Paint Abrasion Tester apparatus to subject the lightweight badge to an abrasion cycle under a normal load weight, using a tool ball as an abrader. Specifically, the Century Design Inc. CD-8900B Paint Abrasion Tester is a precision instrument designed to evaluate the abrasion resistance of coated materials. This device replicates real-world wear by subjecting test samples to controlled mechanical abrasion under standardized conditions, ensuring consistent and reliable results. The apparatus operates by moving an abrasive medium—in this case, a ball tool-over the test surface at a set speed, pressure, and cycle count. To set up the CD-8900B, the test sample is securely mounted on the apparatus, and the desired testing parameters, including abrasion medium, load, and stroke length, are configured according to the testing protocol.

During this abrasion test, the CD-8900B was configured for 10 cycles at a 500 g load with a 1.5-inch stroke length. The durability of all three regions of the lightweight badge was assessed using this method. Specifically, three testers independently evaluated the visible damage in each region and assigned a score on a scale of 1 to 5. A score of 5 indicated no visible wear, while a score of 1 signified severe wear. Furthermore, a score of 3 indicates abrasions or scratches that begin to penetrate the clear coat, creating the look of a deep scar or lesion on the badge surface. The scores from all three testers were then averaged and analyzed. A lower average score indicated low abrasion resistance, whereas a higher average score reflected high abrasion resistance.

TABLE 23
Abrasion Grading Results
	Region 1	Region 2	Region 3
Tester #	Damage Grade
1	4	4	5
2	4	4	5
3	4	4	5
Average	4.0	4.0	5.0

Table 23 illustrates the average abrasion scores assigned by each tester across all three badge regions. On average, the first and second regions received an abrasion score of 4, while the third region scored 5. These tests demonstrate that all three regions exhibit high resistance to abrasion, with the matte carbon fiber finish of the third region being particularly resistant. Generally, abrasion scores greater than 3.5 are considered passing grades, as these grades define surface-level abrasions that do not penetrate the clear coat. Accordingly, the ABS material used in the badge exhibited ample abrasion resistance while maintaining a relatively lightweight and thin construction.

The second durability test analyzed the dent resistance of the lightweight (ABS) badge by determining the amount of kinetic energy required to cause a lasting deformation, or dent, on its surface. The second durability test further compared the dent resistance of the lightweight (ABS) badge to that of the control club head badge described in Example 8. As previously mentioned, the control club head badge in Example 8 consisted of a three-piece design, including a rigid layer made of a steel alloy, a filler layer, and an adhesive layer. For this test, the exterior surface of the rigid steel alloy layer was directly evaluated for dent resistance.

The dent resistance test utilized the relationship between kinetic and potential energy of a pendulum system to mathematically calculate the kinetic energy of a striking device upon impact. Specifically, this test comprised a striking device attached to a pendulum, which was positioned at an angle and released to strike the sampled badges. The striking device featured a sphere with the same diameter as a golf ball (1.68 inches). The test began with the striking device being released from a low angle. Gradually, the angle was increased until the striking device created a dent in the badge. At this point, the angle was recorded, and the corresponding kinetic energy was calculated. During testing, it was observed that the dents were difficult to detect visually, consistent with the results from the abrasion testing described earlier. As a result, physical examination of the badge was necessary between trials to confirm that denting had occurred.

The exemplary club head badge and the control club head badge were tested across ten individual trials. During these trials, the average kinetic energy required to create dents in the badges was calculated and recorded. The results showed that the average kinetic energy required to create a dent in the exemplary club head ABS badge was 4.63 ft-lb, compared to 0.79 ft-lb for the control club head steel alloy badge. Therefore, the exemplary club head ABS badge required 3.84 ft-lb more kinetic energy (a 486% increase) to exhibit a dent compared to the steel alloy badge of the control club head. As stated above, ABS plastics exhibit a high level of dent resistance by absorbing energy through deformation without sustaining permanent deformation. Moreover, the exemplary club head ABS badge demonstrated significantly superior dent resistance while also providing mass distribution properties that lowered the club head's center of gravity (CG) and aligned it with the impact axis, as previously described.

Clauses

Clause 1. An iron-type golf club head comprising a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point; a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity; an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface; a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm3, a badge mass less than 5.0 grams, and a badge MOI less than 7.5 g·cm2 about the impact axis; and wherein the center of gravity is located within 0.025 inch of the impact axis in a vertical loft direction.

Clause 2. The iron-type golf club head of clause 1, further comprising a toe mass extending between the toe inner surface and an exterior surface of the toe, the toe mass comprising a toe mass upper surface extending between the rear wall top edge and the lower portion of the back face and increasing in height towards the exterior surface of the toe.

Clause 3. The iron-type golf club head of clause 2, wherein the rear wall top edge comprises a toe segment angle between 15° and 75° relative to the ground plane.

Clause 4. The iron-type golf club head of clause 3, wherein the insert cavity is offset toward the heel.

Clause 5. The iron-type golf club head of clause 4, wherein the insert cavity further comprises an insert cavity length L_C measured between the heel inner surface and the toe inner surface and an insert cavity center point located equidistant between the heel inner surface and the toe inner surface, wherein the insert cavity center point is heelward of the impact point.

Clause 6. The iron-type golf club head of clause 5, wherein the insert cavity length L_C is between 1.5 and 2.5 inches.

Clause 7. The iron-type golf club head of clause 1, further defining an impact cylinder extending perpendicular to the strike face, centered about the impact point, and having an impact cylinder radius of 0.5 inch, wherein greater than 25% of the badge mass is located within the impact cylinder.

Clause 8. The iron-type golf club head of clause 2, further comprising a toe section mass located toeward of a scoring area toe boundary and a heel section mass located heelward of a scoring area heel boundary, wherein a difference between the toe section mass and the heel section mass is less than 5.0 grams.

Clause 9. An iron-type golf club head comprising a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point; a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity; an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface; a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm³, a badge mass less than 7.5 grams, wherein less than 3.0 grams of the badge mass is located above the impact axis, and a badge MOI less than 7.5 g·cm² about the impact axis; and wherein the center of gravity is located within 0.025 inch of the impact axis in a vertical loft direction.

Clause 10. The iron-type golf club head of clause 9, wherein the badge comprises a maximum badge thickness less than 0.25 inch.

Clause 11. The iron-type golf club head of clause 9, wherein the rigid layer comprises a non-metallic material.

Clause 12. The iron-type golf club head of clause 11, wherein the rigid layer comprises ABS, PLA, polycarbonate, polyvinyl chloride, nylon, polypropylene, high impact polystyrene, acetal, high-density polyethylene, acrylic, reinforced polyamide, polycarbonate blends, or a fiber-reinforced resin.

Clause 13. The iron-type golf club head of clause 9, wherein the rigid layer is coupled directly to the adhesive layer

Clause 14. An iron-type golf club head comprising a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point; a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity; an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface; a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm³ and a badge mass less than 5 grams, a toe mass extending between the toe inner surface and an exterior surface of the toe, the toe mass comprising a toe mass upper surface extending between the rear wall top edge and the lower portion of the back face and increasing in height towards the exterior surface of the toe; wherein the center of gravity is located: within 0.025 inch of the impact axis in a vertical loft direction; and within 0.050 inch of the impact axis in a horizontal direction.

Clause 15. The iron-type golf club head of clause 14, wherein the rear wall top edge defines a toe segment that extends upwards from a remainder of the rear wall top edge at the toe mass.

Clause 16. The iron-type golf club head of clause 15, further comprising a rear wall ratio between 1.5 and 3.0 defined as a maximum rear wall height within the toe segment divided by a maximum rear wall height within the remainder of the rear wall top edge.

Clause 17. The iron-type golf club head of clause 15, wherein the toe segment defines a toe segment angle 15° and 75° relative to the ground plane.

Clause 18. The iron-type golf club head of clause 9, further comprising a toe section mass and a toe section volume each located toeward of a scoring area toe boundary and a heel section mass and a heel section volume each located heelward of a scoring area heel boundary, wherein a difference between the toe section mass and the heel section mass is less than 5 grams.

Clause 19. The iron-type golf club head of clause 18, wherein the heel section mass and the toe section mass are each greater than 25% of a total club head mass and the heel section volume and the toe section volume are each less than 25% of a total club head volume.

Clause 20. The iron-type golf club head of clause 18, wherein a percentage difference between the heel section mass and the toe section mass is less than 10%.

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

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

Claims

1. An iron-type golf club head comprising: a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point;a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity;an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface;a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm3, a badge mass less than 5.0 grams, and a badge MOI less than 7.5 g·cm2 about the impact axis; andwherein the center of gravity is located within 0.025 inch of the impact axis in a vertical loft direction.

2. The iron-type golf club head of claim 1, further comprising a toe mass extending between the toe inner surface and an exterior surface of the toe, the toe mass comprising a toe mass upper surface extending between the rear wall top edge and the lower portion of the back face and increasing in height towards the exterior surface of the toe.

3. The iron-type golf club head of claim 2, wherein the rear wall top edge comprises a toe segment angle between 15° and 75° relative to the ground plane.

4. The iron-type golf club head of claim 3, wherein the insert cavity is offset toward the heel.

5. The iron-type golf club head of claim 4, wherein the insert cavity further comprises an insert cavity length LC measured between the heel inner surface and the toe inner surface and an insert cavity center point located equidistant between the heel inner surface and the toe inner surface, wherein the insert cavity center point is heelward of the impact point.

6. The iron-type golf club head of claim 5, wherein the insert cavity length LC is between 1.5 and 2.5 inches.

7. The iron-type golf club head of claim 1, further defining an impact cylinder extending perpendicular to the strike face, centered about the impact point, and having an impact cylinder radius of 0.5 inch, wherein greater than 25% of the badge mass is located within the impact cylinder.

8. The iron-type golf club head of claim 2, further comprising a toe section mass located toeward of a scoring area toe boundary and a heel section mass located heelward of a scoring area heel boundary, wherein a difference between the toe section mass and the heel section mass is less than 5.0 grams.

9. An iron-type golf club head comprising: a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point;a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity;an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface;a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm3, a badge mass less than 7.5 grams, wherein less than 3.0 grams of the badge mass is located above the impact axis, and a badge MOI less than 7.5 g·cm2 about the impact axis; andwherein the center of gravity is located within 0.025 inch of the impact axis in a vertical loft direction.

10. The iron-type golf club head of claim 9, wherein the badge comprises a maximum badge thickness less than 0.25 inch.

11. The iron-type golf club head of claim 9, wherein the rigid layer comprises a non-metallic material.

12. The iron-type golf club head of claim 11, wherein the rigid layer comprises ABS, PLA, polycarbonate, polyvinyl chloride, nylon, polypropylene, high impact polystyrene, acetal, high-density polyethylene, acrylic, reinforced polyamide, polycarbonate blends, or a fiber-reinforced resin.

13. The iron-type golf club head of claim 9, wherein the rigid layer is coupled directly to the adhesive layer.

14. An iron-type golf club head comprising: a strike face comprising an impact point and an impact axis extending perpendicular to the strike face through the impact point;a back face opposite the strike face, a heel, a toe opposite the heel, a top rail, a sole opposite the top rail, a ground plane tangent to the sole at an address position, a rear wall extending upward from the sole at least partially towards the top rail, the rear wall comprising a rear wall top edge, and a center of gravity;an insert cavity formed by at least an inner surface of the rear wall, a lower portion of the back face, a heel inner surface, and a toe inner surface;a damping system comprising an insert disposed within the insert cavity and a badge attached to an upper portion of the back face, the damping system defining a damping system coverage area greater than 85% of an available surface area of the back face; the badge comprising an adhesive layer, a rigid layer with a rigid layer density less than 3.0 g/cm3 and a badge mass less than 5 grams,a toe mass extending between the toe inner surface and an exterior surface of the toe, the toe mass comprising a toe mass upper surface extending between the rear wall top edge and the lower portion of the back face and increasing in height towards the exterior surface of the toe;wherein the center of gravity is located: within 0.025 inch of the impact axis in a vertical loft direction; andwithin 0.050 inch of the impact axis in a horizontal direction.

15. The iron-type golf club head of claim 14, wherein the rear wall top edge defines a toe segment that extends upwards from a remainder of the rear wall top edge at the toe mass.

16. The iron-type golf club head of claim 15, further comprising a rear wall ratio between 1.5 and 3.0 defined as a maximum rear wall height within the toe segment divided by a maximum rear wall height within the remainder of the rear wall top edge.

17. The iron-type golf club head of claim 15, wherein the toe segment defines a toe segment angle 15° and 75° relative to the ground plane.

18. The iron-type golf club head of claim 9, further comprising a toe section mass and a toe section volume each located toeward of a scoring area toe boundary and a heel section mass and a heel section volume each located heelward of a scoring area heel boundary, wherein a difference between the toe section mass and the heel section mass is less than 5 grams.

19. The iron-type golf club head of claim 18, wherein the heel section mass and the toe section mass are each greater than 25% of a total club head mass and the heel section volume and the toe section volume are each less than 25% of a total club head volume.

20. The iron-type golf club head of claim 18, wherein a percentage difference between the heel section mass and the toe section mass is less than 10%.