GOLF CLUB HEADS AND METHODS TO MANUFACTURE GOLF CLUB HEADS

The present disclosure may be subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the present disclosure and its related documents, as they appear in the Patent and Trademark Office patent files or records, but otherwise reserves all applicable copyrights.

FIELD

The present disclosure generally relates to sports equipment, and more particularly, to golf club heads and methods to manufacture golf club heads.

BACKGROUND

In golf, various factors may affect the distance and direction that a golf ball may travel. In particular, the center of gravity (CG) and/or the moment of inertia (MOI) of a golf club head may affect the launch angle, the spin rate, and the direction of the golf ball at impact. Such factors may vary significantly based the type of golf swing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top perspective view of an example golf club head according to an embodiment of the apparatus, methods, and articles of manufacture described herein.

FIG. 2 illustrates a bottom perspective view of the golf club head of FIG. 1.

FIG. 3 illustrates a front view of the golf club head of FIG. 1.

FIG. 4 illustrates a rear view of the golf club head of FIG. 1.

FIG. 5 illustrates a top view of the golf club head of FIG. 1.

FIG. 6 illustrates a bottom view of the golf club head of FIG. 1.

FIG. 7 illustrates a heel side view of the golf club head of FIG. 1.

FIG. 8 illustrates a toe side view of the golf club head of FIG. 1.

FIG. 9 illustrates a cross-sectional view of the golf club head of FIG. 1 taken along section 9-9 of FIG. 5.

FIG. 10 illustrates a cross-sectional view of the golf club head of FIG. 1 taken along section 10-10 of FIG. 8.

FIG. 11 illustrates an exploded toe side view of the golf club head of FIG. 1.

FIG. 12 illustrates an exploded rear view of the golf club head of FIG. 1.

FIG. 13 illustrates an exploded rear perspective view of the golf club head of FIG. 1.

FIG. 14 illustrates a front and top perspective view of an example golf club according to an embodiment of the apparatus, methods, and articles of manufacture described herein.

FIG. 15 illustrates a bottom perspective view of the golf club head of FIG. 14

FIG. 16 illustrates a cross sectional view of the golf club head of FIG. 14 taken at lines 16-16 of FIG. 14.

FIG. 17 illustrates a cross sectional view of the golf club head of FIG. 14 taken at lines 17-17 of FIG. 14.

FIG. 18 illustrates an enlarged view of region 18 of the golf club head of FIG. 16.

FIGS. 19, 20, 21, 22, 23, 24, 25, 26, 27, and 28 illustrate rear views of different example face portions of an example golf club head according to an embodiment of the apparatus, methods, and articles of manufacture described herein.

FIG. 29 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 29-29 of FIG. 28.

FIG. 30 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 30-30 of FIG. 28.

FIG. 31 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 31-31 of FIG. 28.

FIG. 32 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 32-32 of FIG. 28.

FIG. 33 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 33-33 of FIG. 28.

FIG. 34 illustrates schematic cross section view of an example of the face portion of FIG. 28 taken at lines 34-34 of FIG. 28.

FIG. 35 illustrates a golf club including a golf club head according to any of the embodiments of the apparatuses, methods, and articles of manufacture described herein

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 present disclosure. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure.

DESCRIPTION

The following U.S. patents and patent Publications, which are collectively referred to herein as “the incorporated by reference applications,” are incorporated by reference herein in their entirety: U.S. Pat. Nos. 9,199,140; 9,352,197; 9,399,158; 9,550,096; 9,555,295; 9,630,070; 9,636,554; 9,662,547; 9,669,270; 9,782,643; 9,795,842; 9,795,843; 9,802,087; 9,814,945; 9,821,200; 9,821,201; 9,833,667; 9,861,867; 9,895,582; 9,895,583; 9,914,029; 9,981,160; 9,987,526; 9,999,814; 10,010,770; 10,052,532; 10,099,093; 10,143,899; 10,195,101; 10,213,659; 10,252,123; 10,293,220; 10,293,221; 10,335,645; 10,376,754; 10,384,102; 10,413,787; 10,420,989; 10,532,257; 10,583,336; 10,617,918; 10,653,928; 10,695,623; 10,695,624; 10,722,764; 10,722,765; 10,821,334; 10,843,051; 10,898,766; 10,926,142; 10,960,274; 10,967,231; 10,981,037; 11,000,742; 11,103,755; and 11,117,028; and U.S. Printed Publication Nos. 20210121747; 20210128996; 20210197039; and 20210197040.

In general, golf club heads and methods to manufacture golf club heads are described herein. The apparatus, methods, and articles of manufacture described herein are not limited in this regard. In the example of FIGS. 1-13, a golf club head 100 may include a body portion 110 with a top portion 130, a crown portion 135, a bottom portion 140, a toe portion 150, a heel portion 160, a front portion 170, and a rear portion 180. The bottom portion 140 may include a skirt portion 190 defined as a side portion of the golf club head 100 between the top portion 130 and the bottom portion 140 excluding the front portion 170 and extending across a periphery of the golf club head 100 from the toe portion 150, around the rear portion 180, and to the heel portion 160. Alternatively, the golf club head 100 may not include the skirt portion 190. The front portion 170 may include a face portion 275 to engage a golf ball. The face portion 275 may be integral to the body portion 110 or may be a separate face portion that is coupled (e.g., welded) to the front portion 170 to enclose an opening in the front portion 170. The body portion 110 may also include a hosel portion configured to receive a shaft portion (not shown). The hosel portion may be similar in many respects to any of the hosel portions described herein. The hosel portion may include an interchangeable hosel sleeve 126 and a fastener 127. Alternatively, the body portion 110 may include a bore instead of the hosel portion. The body portion 110 may be made partially or entirely of an aluminum-based material, a magnesium-type material, a steel-based material, a titanium-based material, any combination thereof, or any other suitable material. In another example the body portion 110 may be made partially or entirely of a non-metal material such as a ceramic material, a composite material, any combination thereof, or any other suitable material. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may have a club head volume greater than or equal to 300 cubic centimeters (cm³or cc). In one example, the golf club head 100 may be about 460 cc. Alternatively, the golf club head 100 may have a club head volume less than or equal to 300 cc. In particular, the golf club head 100 may have a club head volume between 100 cc and 200 cc. The club head volume of the golf club head 100 may be determined by using the weighted water displacement method (i.e., Archimedes Principle). For example, procedures defined by golf standard organizations and/or governing bodies such as the United States Golf Association (USGA) and/or the Royal and Ancient Golf Club of St. Andrews (R&A) may be used for measuring the club head volume of the golf club head 100. Although FIG. 1 may depict a particular type of club head (e.g., a driver-type club head), the apparatus, methods, and articles of manufacture described herein may be applicable to other types of club head (e.g., a fairway wood-type club head, a hybrid-type club head, an iron-type club head, a putter-type club head, etc.). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a forward portion 131 extending a distance 134 between the front portion 170 and the crown portion 135, as shown in FIG. 8. In one example, the forward portion 131 may extend a distance 134 of at least 8 mm in a front-to-rear direction, resulting in the crown portion 135 being positioned at least 8 mm rearward of the face portion 275. In another example, the forward portion 131 may extend a distance 134 of at least 12 mm in a front-to-rear direction. In another example, the forward portion 131 may extend a distance 134 of at least 16 mm in a front-to-rear direction. In yet another example, the forward portion 131 may extend a distance 134 of at least 20 mm in a front-to-rear direction. In still another example, the forward portion 131 may extend a distance 134 of between and including 12 mm and 20 mm in a front-to-rear direction. While the above examples may describe particular distances, the apparatus, methods, and articles of manufacture described herein may include a forward portion extending a distance less than 12 mm in a front-to-rear direction. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The forward portion 131 may enhance structural integrity of the golf club head 100 and resist rearward deflection of the front portion 170 during impact with a golf ball. The forward portion 131 may transfer an impact force to the crown portion 135 during an impact with a golf ball. The forward portion 131 may distribute an impact force along a surface of the crown portion that abuts a junction 132 formed between the crown portion 135 and the forward portion 131 of the top portion 130. The forward portion 131 may be an integral portion of the body portion 110. In examples where the body portion 110 is formed through a metal (e.g. titanium) casting process, the forward portion 131 may be formed as an integral portion of the body portion during the casting process. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The crown portion 135 may be a separate piece that may be attached to the top portion 130. The crown portion 135 may enclose an opening 1201 in the top portion 130. The crown portion 135 may include a heel-side perimeter 1131, a front perimeter 1132, a rear perimeter 1151, and a toe-side perimeter 1133. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As illustrated in FIGS. 12 and 13, for example, the top portion 130 of the golf club head 100 may include an opening 1201 prior to installation of the crown portion 135. The crown portion 135 may be constructed from one or more materials, and those materials may be the same or different from the material of the body portion 110. In one example, the crown portion 135 may be at least partially constructed from a composite material such as a fiber-based composite material. The crown portion 135 may be attached to a shoulder portion 1204 of the top portion 130. The shoulder portion 1204 may extend along an entire perimeter of the opening 1201 in the top portion 130 or a portion of the opening in the top portion 130. The shoulder portion 1204 may support the crown portion 135. The shoulder portion 1204 may provide a surface suitable for joining (e.g. adhering) the crown portion 135 to the top portion. In one example, the shoulder portion 1204 may extend a distance 1233 of at least 2 mm inward toward the opening 1201 in the top portion 130. In another example, the shoulder portion 1204 may extend a distance 1233 of at least 6 mm. In yet another example, the shoulder portion 1204 may extend a distance 1233 of at least 8 mm. In still another example, the shoulder portion 1204 may extend a distance 1233 of between and including 2 mm and 8 mm. While the above examples may describe particular distances, the apparatus, methods, and articles of manufacture described herein may include a shoulder portion 1204 that extends a distance 1233 less than 2 mm inward toward the opening in the top portion 130. The shoulder portion 1204 may be a continuous portion encircling the opening 1201 in the top portion 130. Alternately, the shoulder portion 1204 may include one or more discrete shoulder portions arranged to support the crown portion 135. In another example, the shoulder portion 1204 may include a plurality of tabs arranged to support the crown portion 135. In still another example, the shoulder portion 1204 may be omitted, and the crown portion 135 may be adhered to an outer surface of the top portion 130 or to an inner surface of the top portion 130. In yet another example, the shoulder portion 1204 may be omitted, and the crown portion 135 may include a protrusion extending from a bottom surface of the crown portion 135 that provides an interference fit with a perimeter edge of the opening 1201 in the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the crown portion 135 may have a thickness of less than 1.0 mm. In another example, the crown portion 135 may have a thickness of less than 0.75 mm. In yet another example, the crown portion 135 may have a thickness of less than or equal to 0.65 mm. The crown portion 135 may be made of a composite material. While the above examples may describe particular thicknesses, the apparatus, methods, and articles of manufacture described herein may have a thickness greater than or equal to 1.0 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the crown portion 135 may form at least 45% of an exterior surface area of the top portion 130. In another example, the crown portion 135 may form at least 55% of an exterior surface area of the top portion 130. In yet another example, the crown portion 135 may form at least 65% of an exterior surface area of the top portion 130. While the above examples may describe particular percentages, the crown portion 135 may form less than 45% of the exterior surface area of the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

A top stiffening portion 136 may enhance stiffness of the top portion 130. The top stiffening portion 136 may compensate for the presence of one or more relatively less stiff, thin, or lightweight regions elsewhere in the top portion 130 or crown portion 135. The top stiffening portion 136 may enhance overall stiffness of the golf club head 100. The top stiffening portion 136 may limit rearward deflection of the face portion 275 and/or forward portion 131 toward the rear portion 180 in response to the face portion 275 impacting a golf ball. The top stiffening portion 136 may resist physical compression of the crown portion 135 in a front-to-rear direction in response to the face portion 275 impacting a golf ball, which may reduce risk of cracking or delaminating of the crown portion 135 in examples where the crown portion 135 is constructed of two or more layers of composite material. The top stiffening portion 136 may be a raised portion of the top portion 130. The top stiffening portion 136 may be part of a contoured portion of the top portion 130. The top stiffening portion 136 may serve as a visual alignment aid for a golfer aligning a golf shot. The top stiffening portion 136 may improve acoustic response of the golf club head 100 in response to the face portion 275 impacting a golf ball. The top stiffening portion 136 may have a thickness greater than another region of the top portion 130 or the crown portion 135. The top stiffening portion 136 may have a thickness greater than an average thickness of the crown portion 135. The top stiffening portion 136 may be integral to the top portion 130. The top stiffening portion 136 may be one or more separate portions adhered or joined to the top portion 130 to provide structural reinforcement. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As mentioned above, the top portion 130 may include one or more top stiffening portions. In one example, the top stiffening portion 136 may include a first top stiffening portion 137, a second top stiffening portion 138, and a third top stiffening portion 139, as shown in FIG. 1. The first top stiffening portion 137 may be located adjacent to the forward portion 131 of the top portion 130. The first top stiffening portion 137 may have a thickness greater than an average thickness of the crown portion 135. In one example, the first top stiffening portion 137 may have a thickness of greater than 2 mm. In another example, the first top stiffening portion 137 may have a thickness of greater than or equal to 2.1 mm. In another example, the first top stiffening portion 137 may have a thickness of greater than or equal to 2.2 mm. In still another example, the first top stiffening portion 137 may have a thickness of greater than or equal to 2.4 mm. While the above examples may describe particular thickness, the apparatus, methods, and articles of manufacture described herein may include the first top stiffening portion 137 with a thickness of less than or equal to 2 mm. In one example, the first top stiffening portion 137 may have a length of at least 1.25 cm in a heel-to-toe direction. In another example, the first top stiffening portion 137 may have a length of at least 2 cm in a heel-to-toe direction. In yet another example, the first top stiffening portion 137 may have a length of at least 3 cm in a heel-to-toe direction. In still yet another example, the first top stiffening portion 137 may have a length of at least 4 cm in a heel-to-toe direction. In another example, the first top stiffening portion 137 may have a length of between and including 4 and 4.5 cm in a heel-to-toe direction. While the above examples may describe particular lengths, the apparatus, methods, and articles of manufacture describe herein may include the first top stiffening portion 137 having a length of less than 3 cm. The first top stiffening portion 137 may reduce aerodynamic drag of the golf club head 100. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The second top stiffening portion 138 may extend from the first top stiffening portion 137 toward the rear portion 180. The second top stiffening portion 138 may extend from the first top stiffening portion 137 toward the rear portion 180 and toward the toe portion 150. The second top stiffening portion 138 may extend from a toe-side end of the first top stiffening portion 137 to a rear perimeter of the crown portion 135. The second top stiffening portion 138 may extend from the first top stiffening portion 137 toward a weight port region on the bottom portion 140. The second top stiffening portion 138 may extend from the first top stiffening portion 137 toward a weight port region on the bottom portion 140, where the weight port region is closer to the toe portion 150 than other weight port regions on the bottom portion. The second top stiffening portion 138 may taper in width in a front-to-rear direction. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The second top stiffening portion 138 may serve as a support structure between the forward portion 131 and the rear portion 180. The second top stiffening portion 138 may oppose rearward deflection of the forward portion 131 in response to the face portion 275 impacting a golf ball. The second top stiffening portion 138 may have a thickness greater than an average thickness of the crown portion 135. The second top stiffening portion 138 may have a thickness of greater than 2 mm. The second top stiffening portion 138 may have a thickness of greater than or equal to 2.1 mm. The second top stiffening portion 138 may have a thickness of greater than or equal to 2.2 mm. While the above examples may describe particular thicknesses, the apparatus, methods, and articles of manufacture described herein may include the second top stiffening portion 138 with a thickness of less than or equal to 2 mm. In one example, the second top stiffening portion 138 may have a length of at least 2 cm. In another example, the second top stiffening portion 138 may have a length of at least 4 cm. While the above examples may describe particular lengths, the apparatus, methods, and articles of manufacture describe herein may include a second top stiffening portion 138 having a length less than 2 cm. The second top stiffening portion 138 may reduce aerodynamic drag of the golf club head. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The third top stiffening portion 139 may extend from the first top stiffening portion 137 toward the rear portion 180. The third top stiffening portion 139 may extend from the first top stiffening portion 137 toward the rear portion 180 and toward the heel portion 160. The third top stiffening portion 139 may extend from a heel-side end of the first top stiffening portion 137 to a rear perimeter of the crown portion 135. The third top stiffening portion 139 may extend from the first top stiffening portion 137 toward a weight port region on the bottom portion 140. The third top stiffening portion 139 may extend from the first top stiffening portion 137 toward a weight port region on the bottom portion 140, where the weight port region is closer to the heel portion 160 than other weight port regions on the bottom portion. The third top stiffening portion 139 may taper in width in a front-to-rear direction. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The third top stiffening portion 139 may serve as a support structure between the forward portion 131 and the rear portion 180. The third top stiffening portion 139 may oppose rearward deflection of the forward portion 131 in response to the face portion 275 impacting a golf ball. The third top stiffening portion 139 may have a thickness greater than an average thickness of the crown portion 135. The third top stiffening portion 139 may have a thickness of greater than 2 mm. The third top stiffening portion 139 may have a thickness of greater than or equal to 2.1 mm. The third top stiffening portion 139 may have a thickness of greater than or equal to 2.2 mm. While the above examples may describe particular thicknesses, the apparatus, methods, and articles of manufacture described herein may include the third top stiffening portion 139 with a thickness of less than or equal to 2 mm. The third top stiffening portion 139 may have a length of at least 2 cm. The third top stiffening portion 139 may have a length of at least 4 cm. The third top stiffening portion 139 may reduce aerodynamic drag of the golf club head. While the above example may describe a particular number of top stiffening portions, the apparatus, methods, and articles of manufacture described herein may include more or fewer top stiffening portions. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a central top portion 101, a toe-side top portion 102, and a heel-side top portion 103. The central top portion 101 may be a raised central top portion 101. The raised central top portion 101 may be located between the heel-side top portion 103 and the toe-side top portion 102. The raised central top portion 101 may have a maximum height greater than a maximum height of the toe-side top portion 102, as shown in FIG. 8. The raised central top portion 101 may have a maximum height greater than a maximum height of the heel-side top portion 103, as shown in FIG. 7. The raised central top portion 101 may serve as a visual alignment aid. The raised central top portion 101 may improve aerodynamic performance of the golf club head 100. The raised central top portion 101 may stiffen the top portion 130 and reduce deflection (e.g. bulging) of the top portion 130 in response to the face portion 275 impacting a golf ball. Reducing bulging of the top portion 130 may be desirable to reduce shear stress on a joint (e.g. an adhesive bond) between the crown portion 135 and the shoulder portion 1204 of the opening 1201 in the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The central top portion 101 may include a thin portion. The toe-side top portion 102 may include a thin portion. The heel-side top portion 103 may include a thin portion. Thin portions may be desirable to reduce overall mass of the top portion 130, which may lower the CG of the golf club head 100. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a plurality of contoured surfaces. The plurality of contoured surfaces may generate turbulent flow across the top portion 130 of the golf club head 100 during a golf swing. The plurality of contoured surfaces may reduce aerodynamic drag of the golf club head 100. The plurality of contoured surfaces may enhance rigidity of the golf club head 100. The plurality of contoured surfaces may enhance structural integrity of the golf club head 100. The apparatus, methods, and articles of manufacture described herein are not limited in this regard

An outer surface 515 of the central top portion 101 may be elevated above an outer surface 516 of the toe-side top portion 102. The outer surface 515 area of the central top portion 101 may be elevated above an outer surface 517 of the heel-side top portion 103. The apparatus, methods, and articles of manufacture described herein are not limited in this regard. The apparatus, methods, and articles of manufacture described herein are not limited in this regard

The top portion 130 may include a first contoured transition region 501 located between the central top portion 101 and the toe-side top portion 102. The crown portion 135 may include a second contoured transition region 502 located between the central top portion 101 and the heel-side top portion 103. The location of the first contoured transition region 501 may coincide with the location of the second top stiffening portion 138. The location of the second contoured transition region 502 may coincide with the location of the third top stiffening portion 139. Together, the central top portion 101, toe-side top portion 102, heel-side top portion 103, first contoured transition region 501, and second contoured transition region 502 may form a multi-level top portion 130. Together, the central top portion 101, toe-side top portion 102, heel-side top portion 103, first contoured transition region 501, and second contoured transition region 502 may form a multi-thickness top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

FIG. 9 depicts a cross-sectional toe side view of the example golf club head of FIG. 1 taken at section line 9-9 of FIG. 5. The outer surface 515 of the central top portion 101 may be elevated above an outer surface 517 of the heel-side top portion 103. In one example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 517 of the heel-side top portion 103 by a height of greater than or equal to 0.5 mm. In another example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 517 of the heel-side top portion 103 by a height of greater than or equal to 1.0 mm. In yet another example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 517 of the heel-side top portion 103 by a height of greater than or equal to 2.0 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The outer surface 515 of the central top portion 101 may be elevated above an outer surface 516 of the toe-side top portion 102. In one example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 516 of the toe-side top portion 102 by a height of greater than or equal to 0.5 mm. In another example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 516 of the toe-side top portion 102 by a height of greater than or equal to 1.0 mm. In yet another example, the outer surface 515 of the central top portion 101 may be elevated above an outer surface 516 of the toe-side top portion 102 by a height of greater than or equal to 2.0 mm. While the above examples may describe particular heights, the apparatus, methods, and articles of manufacture described herein may include outer surfaces with a difference in height of less than 0.5 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As shown in FIG. 7, the outer surface 517 of the heel-side top portion 103 may be recessed below the forward portion 131 proximate to the junction 132. Likewise, as shown in FIG. 8, the outer surface 516 of the toe-side top portion 102 may be recessed below the forward portion 131 proximate the junction 132. In one example, the outer surface 517 of the heel-side top portion 103 may be recessed below the forward portion 131 proximate to the junction 132 by a distance of greater than or equal to 0.5 mm. In another example, the outer surface 517 of the heel-side top portion 103 may be recessed below the forward portion 131 proximate to the junction 132 by a distance of greater than or equal to 1.0 mm. In yet another example, the outer surface 516 of the toe-side top portion 102 may be recessed below the forward portion 131 proximate the junction 132 by a distance of greater than or equal to 0.5 mm. The outer surface 516 of the toe-side top portion 102 may be recessed below the forward portion 131 proximate the junction 132 by a distance of greater than or equal to 1.0 mm. While the above examples may describe particular distances, the apparatus, methods, and articles of manufacture described herein may include outer surfaces recessed by distances of less than 0.5 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The central top portion 101 may be bounded by the first contoured transition region 501, the second contoured transition region 502, a rear perimeter 1151, and a front perimeter 1132, as shown in FIGS. 5 and 12. The central top portion 101 may be bounded by the first contoured transition region 501, the second contoured transition region 502, a rear body perimeter 111, and a front perimeter 1132, as shown in FIG. 5. The central top portion 101 may be bounded by the first top stiffening portion 137, the second top stiffening portion 138, the third top stiffening portion 139, and the rear perimeter 1151, as shown in FIG. 5. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

A front region of the central top portion 101 may have a symmetrical shape relative to a central vertical plane 593 that intersects the geometric center (e.g., at or proximate to a “sweet spot” of the golf club head 100) on the face portion 275 and is normal to a front vertical plane. A front portion of the central top portion 101 may have a nonsymmetrical shape relative to the central vertical plane 593 that intersects the geometric center on the face portion 275 and is normal to the front vertical plane. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the second top stiffening portion 138 and third top stiffening portion 139 may diverge in a front-to-rear direction, as shown in FIG. 5. The central top portion 101 may have an irregular polygon-like shape (e.g., a quadrilateral-like shape). The distance between the second and third top stiffening portions 138 and 139 at or proximate to the front portion 170 may be less than the distance between the second and third top stiffening portions 138 and 139 at or proximate to the rear portion 180. In another example, the second top stiffening portion 138 and third top stiffening portion 139 may converge in a front-to-rear direction. A distance between the second and third top stiffening portions 138 and 139 at or proximate to the front portion 170 may be greater than a distance between the second and third top stiffening portions 138 and 139 at or proximate to the rear portion 180. In yet another example, the second top stiffening portion 138 and third top stiffening portion 139 may converge and then diverge in a front-to-rear direction. In another example, the second top stiffening portion 138 and third top stiffening portion 139 may diverge and then converge in a front-to-rear direction. In still another example, the second top stiffening portion 138 and third top stiffening portion 139 may be substantially parallel in a front-to-rear direction. The distance between the second stiffening portion 138 and third top stiffening portion 139 at or proximate to the front portion 170 may be equal or substantially the same as the distance between the second and third top stiffening portions 138 and 139 at or proximate to the rear portion 180. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIG. 1, the central top portion 101 may be raised relative to the toe-side top portion 102 and the heel-side top portion 103, resulting in a raised central top portion 101. Variations in relative heights of the central top portion 101, toe-side top portion 102, and heel-side top portion 103 may improve aerodynamic performance by reducing a drag coefficient associated with the golf club head 100. Variations in relative heights of the central top portion 101, toe-side top portion 102, and heel-side top portion 103 may provide a visual alignment aid. Variations in relative heights of the central top portion 101, toe-side top portion 102, and heel-side top portion 103, together with contoured transition regions (501, 502) with integral ribs, may enhance structural integrity of the top portion 130. In another example, the central top portion 101 may be depressed relative to the toe-side top portion 102 and the heel-side top portion 103. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The total surface area of the top portion 130 may include surface areas of the central top portion 101, toe-side top portion 102, heel-side top portion 103, first contoured transition region 501, second contoured transition region 502, and the forward portion 131. In one example, the surface area of the central top portion 101 may be less than or equal to 40% of the total surface area of the top portion 130. In another example, the surface area of the central top portion 101 may be at least 10% of the total surface area of the top portion 130. In another example, the surface area of the central top portion 101 may be at least 20% of the total surface area of the top portion 130. In yet another example, the surface area of the central top portion 101 may be at least 30% of the total surface area of the top portion 130. In still yet another example, the surface area of the central top portion 101 may be at least 40% of the total surface area of the top portion 130. In still yet another example, the surface area of the central top portion 101 may be at least 50% of the surface area of the top portion 130. In another example, the surface area of the central top portion 101 may be at least 60% of the total surface area of the top portion 130. In still yet another example, the surface area of the central top portion 101 may be at least 70% of the total surface area of the top portion 130. In still yet another example, the surface area of the central top portion 101 may be at least 80% of the total surface area of the top portion 130. In still yet another example, the surface area of the central top portion 101 may be at least 90% of the total surface area of the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The toe-side top portion 102 may be bounded by the first contoured transition region 501, a toe-side body perimeter 112, and the forward portion 131. In one example, the surface area of the toe-side top portion 102 may be at least 5% of the total surface area of the top portion 130. In another example, the surface area of the toe-side top portion 102 may be at least 10% of the total surface area of the crown portion 135. In yet another example, the surface area of the toe-side top portion 102 may be at least 15% of the total surface area of the top portion 130. In still yet another example, the surface area of the toe-side top portion 102 may be at least 20% of the surface area of the top portion 130. In still yet another example, the surface area of the toe-side top portion 102 may be at least 25% of the total surface area of the top portion 130. In still yet another example, the surface area of the toe-side top portion 102 may be at least 30% of the total surface area of the top portion 130. In still yet another example, the surface area of the toe-side top portion 102 may be at least 35% of the total surface area of the top portion 130. In still yet another example, the surface area of the toe-side top portion 102 may be at least 40% of the total surface area of the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The heel-side top portion 103 may be bounded by the second contoured transition region 502, a heel-side body perimeter 113, and the forward portion 131. In one example, the surface area of the heel-side top portion 103 may be at least 5% of the total surface area of the top portion 130. In another example, the surface area of the heel-side top portion 103 may be at least 10% of the total surface area of the top portion 130. In yet another example, the surface area of the heel-side top portion 103 may be at least 15% of the total surface area of the top portion 130. In still yet another example, the surface area of the heel-side top portion 103 may be at least 20% of the total surface area of the top portion 130. In still yet another example, the surface area of the heel-side top portion 103 may be at least 25% of the total surface area of the top portion 130. In still yet another example, the surface area of the heel-side top portion 103 may be at least 30% of the total surface area of the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the outer surface 515 area of the central top portion 101 may be greater than or equal to 40% of a total outer surface area of the top portion 130, the outer surface 516 area of the toe-side top portion 102 may be less than or equal to 30% of the total outer surface area of the top portion 130, and the outer surface 517 area of the heel-side top portion 103 be less than or equal to 15% of the total outer surface area of the top portion 130. In another example, the outer surface area 515 of the central top portion 101 may be greater than or equal to 50% of a total outer surface area of the top portion 130, the outer surface area of the toe-side top portion 102 may be greater than or equal to 15% of the total outer surface area of the top portion 130, and the outer surface area of the heel-side top portion 103 be greater than or equal to 5% of the total outer surface area of the top portion 130. In another example, the outer surface area 515 of the central top portion 101 may be greater than or equal to 30% of a total outer surface area of the top portion 130, the outer surface area of the toe-side top portion 102 may be greater than or equal to 10% of the total outer surface area of the top portion 130, and the outer surface area of the heel-side top portion 103 be greater than or equal to 5% of the total outer surface area of the top portion 130. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

FIG. 5 depicts a top view of the example golf club head 100 of FIG. 1 with a golf ball 550 proximate to the face portion 275. The golf ball 550 may be in contact with and aligned with a geometric center 276 of the face portion 275. The golf ball 550 may have a diameter of about 1.68 inches. A central vertical plane 593 bisects the golf ball 550 and the golf club head 100. A toe-side bounding plane 591 bounds a toe-side of the golf club head 100. A heel-side bounding plane 595 bounds a heel-side of the golf club head 100. A toe-side dividing plane 592 divides the toe-side of the golf club head and bounds a toe-side of the golf ball 550. A heel-side dividing plane 594 divides the heel-side of the golf club head and bounds a heel-side of the golf ball 550. The top portion 130 may include a perimeter that includes a toe-side perimeter, heel-side perimeter, front perimeter, and rear perimeter. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 of the golf club head 100 may include a plurality of integral ribs. The integral ribs may form the top stiffening portion 136. The integral ribs (e.g., generally shown as 537, 538, and 539) may provide embedded structural supports within the top portion 130. Each integral rib may be located in a top stiffening region adjacent to one or more thin portions. The top portion 130 may have contoured transition regions (e.g., generally shown as 501 and 502) between the thin portions and the thicker top stiffening portions where the integral ribs reside. Contoured transition regions may prevent or mitigate unwanted stress concentrations within the top portion 130 by avoiding distinct edges between thin portions and adjacent thicker portions (e.g., such as 137, 138, or 139). Stress concentrations may be undesirable as they may result in cracking or delaminating of layers of the top portion 130 during use of the golf club head 100. For example, in an alternative embodiment having non-integral ribs attached to either an inner or outer surface of the top portion 130, a distinct edge may exist at a junction formed between a non-integral rib and a surface of the top portion 130, and that edge may introduce an unwanted stress concentration. After numerous ball strikes, presence of the stress concentration may result in cracking of the top portion 130 proximate to the non-integral rib. This physical deterioration of the top portion 130 may negatively impact performance of the golf club head 100. For instance, as the top portion 130 physically deteriorates, shot-to-shot variability may increase. Shot-to-shot variability may be unacceptable to an individual who requires consistent performance from the golf club head 100. Physical deterioration of the top portion 130 may also negatively affect appearance of the golf club head 100. For the sake of long-term durability, consistency, and appearance, it is therefore desirable to have a top portion 130 with contoured transition regions (501, 502) between the thin portions and the thicker portions containing integral ribs. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a toe-side integral rib 538. The toe-side integral rib 538 may extend from the front perimeter 1132 of the crown portion 135 to the rear perimeter 1151 of the crown portion. The toe-side integral rib 538 may extend rearward from the forward portion 131. The toe-side integral rib 538 may extend rearward from a starting location between the central vertical plane 593 and the toe-side dividing plane 592 and terminate at an ending location between the toe-side bounding plane 591 and the toe-side dividing plane 592. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the toe-side integral rib 538 may have a maximum thickness between and including 1.0 mm and 2.0 mm. In another example, the toe-side integral rib 538 may have a maximum thickness greater than or equal to 1.0 mm. In another example, the toe-side integral rib 538 may have a maximum thickness greater than or equal to 2.0 mm. In another example, the toe-side integral rib 538 may have a maximum thickness greater than or equal to 2.1 mm. In yet another example, the toe-side integral rib 538 may have a maximum thickness greater than or equal to 2.2 mm. In yet another example, the toe-side integral rib 538 may have a maximum thickness greater than or equal to 2.4 mm. While the above examples may describe particular thicknesses, the apparatus, methods, and article of manufacture described herein may include the toe-side integral rib 538 with a maximum thickness of less than 2 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a heel-side integral rib 539. The heel-side integral rib 539 may extend from a front perimeter 1132 of the crown portion 135 to a rear perimeter 1151 of the crown portion. The heel-side integral rib 539 may extend rearward from the forward portion 131. The heel-side integral rib 539 may extend rearward from a starting location between the central vertical plane 593 and the heel-side dividing plane 594 and terminate at an ending location between the heel-side bounding plane 595 and the heel-side dividing plane 594. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the heel-side integral rib 539 may have a maximum thickness between and including 1.0 mm and 2.0 mm. In another example, the heel-side integral rib 539 may have a maximum thickness greater than or equal to 1.0 mm. In another example, the heel-side integral rib 539 may have a maximum thickness greater than or equal to 2.0 mm. In another example, the heel-side integral rib 539 may have a maximum thickness greater than or equal to 2.1 mm. In yet another example, the heel-side integral rib 539 may have a maximum thickness greater than or equal to 2.4 mm. While the above examples may describe particular thicknesses, the apparatus, methods, and article of manufacture described herein may include the heel-side integral rib 539 with a maximum thickness of less than 2 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The top portion 130 may include a central integral rib 537. The central integral rib 537 may extend along the front perimeter 1132 of the crown portion 135. The central integral rib 537 may extend from the toe-side integral rib 538 to the heel-side integral rib 539. The central integral rib 537 may extend from a forward-most end of the toe-side integral rib 538 to a forward-most end of the heel-side integral rib 539. The central integral rib 537 may extend a distance of at least 3 centimeters beside the junction 132 formed between the front perimeter 1132 of the crown portion 135 and the forward portion 131 of the top portion 130. The central integral rib 537 may be located between the toe-side dividing plane 592 and the heel-side dividing plane 594. The central integral rib 537 and the face portion 275 may have parallel curves. In one example, the central integral rib 537 may have a maximum thickness greater than or equal to 2.0 mm. In another example, the central integral rib 537 may have a maximum thickness greater than or equal to 2.1 mm. In yet another example, the central integral rib 537 may have a maximum thickness greater than or equal to 2.4 mm. While the above examples may describe particular thicknesses, the apparatus, methods, and article of manufacture described herein may include the central integral rib 537 with a maximum thickness of less than 2 mm. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The integral ribs (e.g., generally shown as 537, 538, and 539) may enhance the flexural strength of the top portion 130. The integral ribs may enhance the compressive strength of the top portion 130. The integral ribs may reduce outward deflection (e.g., bulging) of the top portion 130 in response to an impact force transferred from the body portion 110 to the crown portion 135 during impact with a golf ball. The integral ribs may reduce deflection of the crown portion 135 inward toward in the interior cavity of the golf club head 100 in response to a downward force applied to an outer surface of the crown portion 135. Inward deflection of the crown portion 135 may be easier to accurately measure in a test environment than outward deflection. In certain instances, resistance to inward deflection may correlate to resistance to outward deflection. Inward deflection may be measured by applying a downward force to an outer surface of the crown portion and measuring physical deflection of the crown portion with a suitable measuring device. In one example, when a downward force of 200 pound-force (lbf) is applied to the central top portion 101, the central top portion 101 may deflect less than 0.025 inch. In another example, when a downward force of 200 lbf is applied to the central top portion 101, the central top portion 101 may deflect less than 0.015 inch. In another example, when a downward force of 200 lbf is applied to the central top portion 101, the central top portion 101 may deflect less than 0.012 inch. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Certain rules or regulations imposed by the USGA or other governing bodies may limit a spring-like effect of certain designs, materials, or constructions of golf club heads. To ensure a club head 100 conforms to certain rules and regulations, it may therefore be desirable to minimize spring-like effects of certain aspects of the club head. For instance, it may be desirable to minimize a spring-like effect of the top portion 130 by reinforcing the crown portion to minimize deflection during use. The integral ribs may allow the top portion 130 to resist deflection better than a similar lightweight crown portion that lacks integral ribs. In one example, the top portion 130 with integral ribs may only deflect inward about 0.012 inch whereas a crown portion without integral ribs may deflect about 0.020 inch in response to applying a downward force of 200 lbf to the respective crown portions. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As shown in FIG. 5, the toe-side integral rib 538 and the heel-side integral rib 539 may diverge in a front-to-rear direction along the top portion 130. In another example, the toe-side integral rib 538 and heel-side integral rib 539 may converge in a front-to-rear direction along the top portion 130. In yet another example, a toe-side integral rib 538 and a heel-side integral rib 539 may converge and then diverge in a front-to-rear direction along the top portion 130. In another example, the toe-side integral rib 538 and heel-side integral rib 539 may be substantially parallel in a front-to-rear direction along the top portion 130. The toe-side rib 538 may include one or more curved portions along its length. Similarly, the heel-side rib 539 may include one or more curved portions along its length. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

An outer surface of the top portion 130 may have an anti-glare finish. An outer surface of the top portion 130 may have a medium or low gloss appearance to reduce the amount of light reflected upward at an individual's eyes when aligning the golf club head 100 with a golf ball and performing a golf shot. A relative gloss value may be determined by projecting a beam of light at a fixed intensity and angle onto the outer surface of the top portion 130 and measuring the amount of light reflected at an equal but opposite angle upward at the individual. On a measurement scale, a specular reflectance of 0 gloss units (GU) may be associated with a perfectly matte surface, and a specular reflectance of 100 GU may be associated with a highly polished black glass material. Providing a top portion 130 with a relatively low specular reflectance may be desirable to reduce distraction perceived by the individual of the golf club head 100, which may reduce mishits and thereby improve performance. In one example, an outer surface of the top portion 130 may have a specular reflectance of less than 55 GU. In another example, the outer surface of the top portion 130 may have a specular reflectance of less than 40 GU. In yet another example, the outer surface of the top portion 130 may have a specular reflectance of less than 25 GU. In still another example, the outer surface of the top portion 130 may have a specular reflectance of less than 10 GU. While the above examples may describe particular specular reflectance, the apparatus, methods, and article of manufacture may include the outer surface of the top portion 130 with a specular reflectance greater than or equal to 55 GU. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In some examples, the outer surface of the top portion 130 may include an antireflective coating 133. In one example, the antireflective coating 133 may have a specular reflectance of less than 55 GU. In another example, the antireflective coating 133 may have a specular reflectance of less than 40 GU. In yet another example, the antireflective coating 133 may have a specular reflectance of less than 25 GU. In still another example, the antireflective coating 133 may have a specular reflectance of less than 10 GU. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may include a plurality of weigh port regions. Each weight port region may include a weight port. Each weight port may include a weight. As shown in FIG. 6, a first weight port region 174 may be located closer to the rear portion 180 than the front portion 170. A second weight port region 175 may be located closer to the toe portion 150 than the heel portion 160. A third weight port region 176 may be located closer to the heel portion 160 than the toe portion 150. A fourth weight port region 177 may be located closer to the front portion 170 than the rear portion 180. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first weight port region 174 may include a first weight port 154 containing a first weight portion 164. The second weight port region 175 may include a second weight port 155 containing a second weight portion 165. The third weight port region 176 may include a third weight port 156 containing a third weight portion 166. The fourth weight port region 177 may include a fourth weight port 157 containing a fourth weight portion 167. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The set of weight portions (e.g., generally shown as weight portions 164, 165, 166, and 167) may have similar or different masses. By using weight portions having similar or different masses in each of the weight ports, the overall mass in a weight port region and/or the mass distribution in the weight port regions may be adjusted to generally optimize and/or adjust the swing weight, center of gravity, moment of inertia, and/or an overall feel of the golf club head 100 for an individual using the golf club head 100. In one example, the set of weight portions may collectively have a mass of at least 8 grams. In another example, the set of weight portions may collectively have a mass of at least 12 grams. In yet another example, the set of weight portions may collectively have a mass of between and including 8 grams and 13 grams. In still yet another example, the set of weight portions may collectively have a mass of between and including 12 grams and 16 grams. In still yet another example, the set of weight portions may collectively have a mass of between and including 15 grams and 19 grams. In still yet another example, the set of weight portions may collectively have a mass of between and including 18 grams and 22 grams. While the above examples may describe particular masses, the apparatus, methods, and articles of manufacture described herein may include the set of weight portions to have an aggregate mass of less than 8 grams or an aggregate mass of greater than 19 grams. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The bottom portion 140 of the golf club head 100 may have in inner surface 142 and an outer surface 145. The golf club head 100 may include one or more raised portions protruding outward from the outer surface 145. Each raised portion may include a weight port region. Each weight port region may include a weight port. Each weight port may include a weight portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may include a central protrusion 147 extending from the outer surface 145 of the bottom portion 140. The central protrusion 147 may extend from the rear portion 180 toward the front portion 170, as shown in FIG. 2. The central vertical plane 593 may pass through the central protrusion 147. The central vertical plane 593 may bisect the central protrusion 147. The central protrusion 147 may be located between the toe-side dividing plane 592 and the heel-side dividing plane 594, as shown in FIG. 6. The central protrusion 147 may include the first weight port region 174. The central vertical plane 593 may pass through the first weight port 154 and the first weight portion 164. The central vertical plane 593 may bisect the first weight port 154 and the first weight portion 164. The central protrusion 147 may include the fourth weight port region 177. The central vertical plane 593 may pass through the fourth weight port 157 and the fourth weight portion 167. The central vertical plane 593 may bisect the fourth weight port 157 and the fourth weight portion 167. The central protrusion 147 may allow placement of weight portions (e.g. 164, 167) a greater distance from a center point of the golf club head 100 to increase perimeter weighting and MOI without increasing club head volume. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may include a toe-side protrusion 148 extending from the outer surface 145 of the bottom portion 140. The toe-side protrusion 148 may be located between the toe-side dividing plane 592 and the toe-side bounding plane 591. The toe-side protrusion 148 may be located closer to the rear portion 180 than the front portion 170. The toe-side protrusion 148 may include the second weight port region 175. The toe-side protrusion 148 may allow placement of the weight portion 165 a greater distance from the center point of the golf club head 100 to increase perimeter weighting and MOI without increasing club head volume. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may include a heel-side protrusion 149 extending from the outer surface 145 of the bottom portion 140. The heel-side protrusion 149 may be located between the heel-side dividing plane 594 and the heel-side bounding plane 595. The heel-side protrusion 149 may be located closer to the rear portion 180 than the front portion 170. The heel-side protrusion 149 may include the third weight port region 176. The heel-side protrusion 149 may allow placement of the weight portion 166 a greater distance from the center point of the golf club head 100 to increase perimeter weighting and MOI without increasing club head volume. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 100 may include an insert 1350. The insert 1350 may be a vibration-dampening insert. The insert 1350 may be a sound-enhancing insert that attenuates certain frequencies. The insert 1350 may include a filler material. As shown in FIG. 9, the insert 1350 may be located on the inner surface 142 of the bottom portion 140 of the golf club head 100. The insert 1350 may be adjacent to one or more of the weight port regions. The insert 1350 may surround one or more of the weight ports. The insert 1350 may abut one or more of the weight port regions. The insert 1350 may abut the third weight port region 176. The insert 1350 may be closer to the heel portion 160 than the toe portion 150. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The insert 1350 may be located between the central vertical plane 593 and the heel-side bounding plane 595. The insert 1350 may be located between the heel-side dividing plane 594 and the heel-side bounding plane 595. The insert 1350 may be located between the central protrusion 147 and the heel-side bounding plane 595. The insert 1350 may be located between the heel-side integral rib 539 and the inner surface 142 of the bottom portion 140. The insert 1350 may extend from a front side of the third weight port 156 to a rear side of the third weight port, as shown in FIG. 10. The insert 1350 may surround or partially surround the third weight port 156. The insert 1350 may include a plurality of hexagonal recesses. The hexagonal recesses may define a honeycomb pattern. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The filler material may be an elastic polymer or elastomer material (e.g., a viscoelastic urethane polymer material such as Sorbothane® material manufactured by Sorbothane, Inc., Kent, Ohio), a thermoplastic elastomer material (TPE), a thermoplastic polyurethane material (TPU), and/or other suitable types of materials to absorb shock, isolate vibration, and/or dampen noise. In another example, the filler material may be a high density ethylene copolymer ionomer, a fatty acid modified ethylene copolymer ionomer, a highly amorphous ethylene copolymer ionomer, an ionomer of ethylene acid acrylate terpolymer, an ethylene copolymer comprising a magnesium ionomer, an injection moldable ethylene copolymer that may be used in conventional injection molding equipment to create various shapes, an ethylene copolymer that can be used in conventional extrusion equipment to create various shapes, and/or an ethylene copolymer having high compression and low resilience similar to thermoset polybutadiene rubbers. For example, the ethylene copolymer may include any of the ethylene copolymers associated with DuPont™ High-Performance Resin (HPF) family of materials (e.g., DuPont™ HPF AD1172, DuPont™ HPF AD1035, DuPont® HPF 1000 and DuPont™ HPF 2000), which are manufactured by E.I. du Pont de Nemours and Company of Wilmington, Delaware. The DuPont™ HPF family of ethylene copolymers are injection moldable and may be used with conventional injection molding equipment and molds, provide low compression, and provide high resilience. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In the example of FIGS. 14-17, a golf club head 1400 may include a body portion 1410 with a top portion 1430, a crown portion 1435, a bottom portion 1440, a toe portion 1450, a heel portion 1460, a front portion 1470, and a rear portion 1480. The bottom portion 1440 may include a skirt portion 1490 defined as a side portion of the golf club head 1400 between the top portion 1430 and the bottom portion 1440 excluding the front portion 1470 and extending across a periphery of the golf club head 1400 from the toe portion 1450, around the rear portion 1480, and to the heel portion 1460. Alternatively, the golf club head 1400 may not include the skirt portion 1490. The front portion 1470 may include a face portion 1510 to engage a golf ball. The face portion 1510 may be integral to the body portion 1410 or may be partially or fully a separate piece that is coupled (e.g., welded) to the front portion 1470 to enclose an interior cavity 1412 of the body portion 1410. The body portion 1410 may also include a hosel portion 1465 configured to receive a shaft portion (not shown). The hosel portion 1465 may be similar in many respects to any of the hosel portions described herein. The hosel portion may include an interchangeable hosel sleeve (not shown) and a fastener 1427. Alternatively, the body portion 1410 may include a bore instead of the hosel portion 1465. The body portion 1410 may be made partially or entirely from any of the materials described herein for the golf club head 100 and may be similar in many respects to the golf club head 100. The golf club head 1400 may be similar in many respects to any of the golf club heads described herein or in any of the incorporated by reference applications. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The crown portion 1435 may define a separate crown portion insert that may be attached to the top portion 1430. The crown portion insert may enclose an opening (shown for example in FIG. 12) in the top portion 1430. The configuration of the top portion 1430 may be similar in many respects to the top portion 130 of the golf club head 100. The configuration of the opening in the top portion 1430 and the crown portion 1435 may be similar in many respects to the openings and crown portions of any of the golf club heads described herein or in any of the incorporated by reference applications. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club head 1400 may include a plurality of weigh port regions with each weight portion region having one or more weight ports and weight portions. As shown in FIG. 15, the golf club head 1400 may include a first weight port region 1674 at or proximate to the rear portion 1480 with a first weight port 1654 containing a first weight portion 1664, a second weight port region 1676 at or proximate to the front portion 1470 with a second weight port 1656 containing a second weight portion 1666, and third weight port region 1677 at or proximate to the heel portion 1460 with a third weight port 1657 containing a third weight portion 1667. In another example, the configuration and number of the weight port regions, weight ports, and weight portions may be similar in many respects to the same parts, respectively, of the golf club head 100 (i.e., four weight port regions, weight ports, and weight portions). In yet other examples, the configuration of the weight ports and weight portions may be similar in many respects to the weight ports and weight portions of any of the golf club heads described herein or in any of the incorporated by reference applications. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The configuration of the bottom portion 1440, the structural configuration of the interior cavity 1412, and the configuration of any one or more inserts in the interior cavity 1412 of the golf club head 1400 may be similar in many respects to similar parts, respectively, of the golf club head 100. Further, the configuration of any one or more inserts in the interior cavity may be similar in many respects to any of the one or more inserts described herein or in any of the incorporated by reference applications. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The face portion 1510 may include a front surface 1520 having a plurality of grooves 1521 and a rear surface 1530. The front surface 1520 and the grooves 1521 may be configured to strike a golf ball. In one example, as shown in FIGS. 14-18, the face portion 1510 may include an outer face portion 1515 that may be integral with the body portion 1410 and surround a face opening 1517 in the face portion. A face insert portion 1550 may be attached to the outer face portion 1515 to close the face opening 1517 and enclose the interior cavity 1412. The face opening 1517 may include a perimeter edge 1522 and the face insert portion 1550 may include a perimeter edge 1552. A gap (not shown) may exist between the perimeter edge 1552 of the face insert portion 1550 and the perimeter edge 1522 of the face opening 1517. In one example, the gap may be a V-shaped gap to enhance weld penetration. During manufacturing, the gap may be entirely or partially filled with weld material during a welding process in which the face insert portion 1550 is joined to the outer face portion 1515. A sanding or polishing process may follow by which excess weld material is removed to produce a smooth surface across the front portion 1470 of the golf club head 1400 and any excess weld material from the rear surface 1530 of the face portion 1510. While the above example may describe the body portion 1410 and the face insert portion 1550 as separate components of the golf club head 1400, the apparatus, methods, and articles of manufacture described herein may include golf club heads with the face portion being an integral part of the body portion (i.e., not separate components). In another example, the outer face portion 1515 and the face insert portion 1550 may be a one-piece part. Accordingly, the face portion 1510 may be attached to the front portion 1470 as described herein or in any of the incorporated by reference applications to enclose the interior cavity 1412. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIGS. 16-18, the face insert portion 1550 may include a first portion 1720 having a first thickness 1722 (T₁), a second portion 1730 having a second thickness 1732 (T₂), and a third portion 1740 having a third thickness 1742 (T₃). The second portion 1730 may also be referred to herein as a first transition portion 1730, which may define a transition in thickness between the first portion 1720 and the third portion 1740. In one example, as shown in FIG. 18, the first thickness 1722 may be greater than the third thickness 1742 (T₁>T₃). The second thickness 1732 may vary between the first thickness 1722 and the third thickness 1742. In other words, the second portion 1730 may be a transition portion 1730 that provides a transition in the thickness of the face insert portion 1550 between the first portion 1720 and the third portion 1740. The face portion 1510 may further include a fourth portion 1750 having a fourth thickness 1752 (T₄) and a fifth portion 1760 having a fifth thickness 1762 (T₅). The fifth portion 1750 may be defined by the outer face portion 1515. As described herein, the face insert portion 1550 may have a greater thickness than the outer face portion 1515. Accordingly, the third thickness 1742 may be greater than the fifth thickness 1762 (i.e., the thickness of the outer face portion 1515). The fourth thickness 1752 may vary between the third thickness 1742 and the fifth thickness 1762. In other words, the fourth portion 1750 may be a second transition portion 1750 that provides a transition in thickness between face insert portion 1550 and the outer face portion 1515. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first transition portion 1730 may surround the first portion 1720 at an inner perimeter 1724. Accordingly, at the inner perimeter 1724, which may define a boundary between the first portion 1720 and the transition portion 1730, the first thickness 1722 and the second thickness 1732 may be the same or slightly vary due to manufacturing tolerances. From the inner perimeter 1724, the second thickness 1732 may decrease up to an outer perimeter 1734, which may define a boundary between the transition portion 1730 and the third portion 1740. Accordingly, at the outer perimeter 1734, the second thickness 1732 and the third thickness 1742 may be the same or slightly vary due to manufacturing tolerances. In one example, as shown in FIGS. 16-18, the decrease in the second thickness 1732 from the inner perimeter 1724 to the outer perimeter 1734 may have a shallow or slight s-shaped path or profile. In other examples, some of which may be described herein, the decrease in the second thickness 1732 from the inner perimeter 1724 to the outer perimeter 1734 may have any path or profile. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the first thickness 1722 may be greater than or equal to 0.1 inch (2.54 millimeters) and less than or equal to 0.2 inch (5.08 mm). In another example, the first thickness 1722 may be greater than or equal to 0.12 inch (3.05 millimeters) and less than or equal to 0.19 inch (4.83 mm). In yet another example, the first thickness 1722 may be greater than or equal to 0.13 inch (3.3 millimeters) and less than or equal to 0.16 inch (4.06 mm). As described herein, the first thickness 1722 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400 without compromising the structural integrity of the face portion 1510. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the third thickness 1742 may be greater than or equal to 0.09 inch (2.29 millimeters) and less than or equal to 0.16 inch (4.06 mm). In another example, the third thickness 1742 may be greater than or equal to 0.1 inch (2.54 millimeters) and less than or equal to 0.15 inch (3.81 mm). In yet another example, the third thickness 1742 may be greater than or equal to 0.12 inch (3.05 millimeters) and less than or equal to 0.14 inch (3.56 mm). As described herein, the third thickness 1742 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400 without compromising the structural integrity of the face portion 1510. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the fifth thickness 1762 may be greater than or equal to 0.06 inch (1.52 millimeters) and less than or equal to 0.12 inch (3.05 mm). In another example, the fifth thickness 1762 may be greater than or equal to 0.08 inch (2.03 millimeters) and less than or equal to 0.11 inch (2.79 mm). In yet another example, the fifth thickness 1762 may be greater than or equal to 0.09 inch (2.29 millimeters) and less than or equal to 0.10 inch (2.54 mm). As described herein, the fifth thickness 1762 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400 without compromising the structural integrity of the face portion 1510. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the variation in the second thickness 1732 may be linear (an example shown in FIG. 29) between the inner perimeter 1724 and the outer perimeter 1734. Alternatively, the variation in the second thickness 1732 may be nonlinear between the inner perimeter 1724 and the outer perimeter 1734. For example, as shown in FIG. 18, the variation in the second thickness 1732 may be follow a slightly curved s-shaped path (another example shown in FIG. 34). In other words, the second thickness 1732 may follow a slight concave path to curve downward from the first thickness 1722 and then follow a slight convex path to level with the third thickness 1742. The variation in the second thickness 1732 (e.g., various examples shown in FIGS. 29-34) may follow a concave path, a convex path, a compound curve, a stepwise shape, or any linear or nonlinear shape. The variation in the fourth thickness 1752 may also follow a linear path, concave path, a convex path, a compound curvature, a stepwise shape, or any nonlinear shape. For example, as shown in FIG. 18, the variation in the fourth thickness 1752 may follow a linear path from the third thickness 1742 to the fifth thickness 1762. The variation in the second thickness 1732 and/or the variation in the fourth thickness 1752 may also depend on the method of manufacturing the rear surface 1530 of the face portion 1510. For example, for a face insert portion 1550 that is manufactured by milling or machining, the variation in the second thickness 1732 may depend on the shape and movement patterns of the tip of the machining tool used to manufacture the transition portion 1730. In another example, the variation in the second thickness 1732 may not be similar at different locations on the transition portion 1730. For example, the variation in the second thickness 1732 and/or the fourth thickness 1752 may be linear at one portion and curved (e.g., convex or concave) at another portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As shown in FIGS. 16-18, any variation in the thickness of the face portion 1510 may be defined by variations in the height 1531 of the rear surface 1530 of the face portion 1510 (i.e., the distance by which the rear surface 1530 projects into the interior cavity 1412 of the golf club head 1400 from the front surface 1520), whereas the front surface 1520 of the face portion 1510, which is configured to strike a golf ball, has a generally smooth or uniform surface profile except for the plurality of grooves 1521. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first portion 1720 may be located at a center region of the face portion 1510 or at a sweet spot region of the face portion 1510. The sweet spot region may be a region of the face portion 1510 that may provide optimum performance characteristics for the golf club head 1400 when striking a golf ball. The sweet spot region may also represent a region of the face portion 1510 that may have a higher probability of ball strikes than other locations on the face portion 1510. The first portion 1720 may be partially or fully within the sweet spot region, overlap the sweet spot region, and/or envelope the sweet spot region. The shape, size, and/or thickness of the first portion 1720, the second portion 1730, and/or the third portion 1740 may be determined and/or optimized to provide the golf club head 1400 with certain performance characteristics such as a particular range of characteristic time (CT) values, a particular range of coefficient of restitution (COR) values, and/or dampened vibration and sound without compromising the structural integrity of the face portion 1510. The first portion 1720 may have any shape. In one example, as shown in FIG. 17, the first portion 1720 may have a slightly curved or rounded trapezoidal shape that may expand in width (i.e., the dimension between the top portion 1430 and the bottom portion 1440) in a direction toward toe portion 1450. As shown in FIG. 17, the slightly rounded trapezoidal shape of the first portion 1720 may also be slightly rotated or tilted upward to generally correspond with the configuration of the face portion 1510 and/or the configuration of the sweet spot. As described further herein, the first portion 1720 may have any shape and size to provide the golf club head 1400 with certain performance characteristics. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIG. 17, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape with the inner perimeter 1724 being centered with and nested in the outer perimeter 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter 1734. The third portion 1740 may surround the transition portion 1730 and extend from the outer perimeter 1734 to the perimeter edge 1552 of the face insert portion 1550. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, an area of the first portion 1720 may be greater than or equal to 0.7 inch²(451.61 mm²) and less than or equal to 1.6 inch²(1032.26 mm²). In another example, an area of the first portion 1720 may be greater than or equal to 0.88 inch²(567.74 mm²) and less than or equal to 1.42 inch²(916.13 mm²). In yet another example, an area of the first portion 1720 may be greater than or equal to 1.06 inch²(683.87 mm²) and less than or equal to 1.24 inch²(800.00 mm²). The area of the first portion 1720 relative to the face insert portion 1550 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400. In one example, the area of the first portion 1720 may be greater than or equal to 25% of the area of the face insert portion 1550 and less than or equal to 40% of the area of the face insert portion 1550. In another example, the area of the first portion 1720 may be greater than or equal to 28% of the area of the face insert portion 1550 and less than or equal to 37% of the area of the face insert portion 1550. In yet another example, the area of the first portion 1720 may be greater than or equal to 31% of the area of the face insert portion 1550 and less than or equal to 34% of the area of the face insert portion 1550. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, an area of the second portion 1730 may be greater than or equal to 1.0 inch²(645.16 mm²) and less than or equal to 2.3 inch²(1483.87 mm²). In another example, an area of the second portion 1730 may be greater than or equal to 1.26 inch²(812.90 mm²) and less than or equal to 2.04 inch²(1316.13 mm²). In yet another example, an area of the second portion 1730 may be greater than or equal to 1.52 inch²(980.64 mm²) and less than or equal to 1.78 inch²(1148.38 mm²). The area of the second portion 1730 relative to the face insert portion 1550 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400. In one example, the area of the second portion 1730 may be greater than or equal to 35% of the area of the face insert portion 1550 and less than or equal to 55% of the area of the face insert portion 1550. In another example, the area of the second portion 1730 may be greater than or equal to 38% of the area of the face insert portion 1550 and less than or equal to 52% of the area of the face insert portion 1550. In yet another example, the area of the second portion 1730 may be greater than or equal to 41% of the area of the face insert portion 1550 and less than or equal to 49% of the area of the face insert portion 1550. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, an area of the third portion 1740 may be greater than or equal to 0.5 inch²(322.58 mm²) and less than or equal to 1.1 inch²(709.68 mm²). In another example, an area of the third portion 1740 may be greater than or equal to 0.62 inch²(400.00 mm²) and less than or equal to 0.98 inch²(632.26 mm²). In yet another example, an area of the third portion 1740 may be greater than or equal to 0.74 inch²(477.42 mm²) and less than or equal to 0.86 inch²(554.84 mm²). The area of the third portion 1740 relative to the face insert portion 1550 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400. In one example, the area of the third portion 1740 may be greater than or equal to 15% of the area of the face insert portion 1550 and less than or equal to 30% of the area of the face insert portion 1550. In another example, the area of the third portion 1740 may be greater than or equal to 18% of the area of the face insert portion 1550 and less than or equal to 27% of the area of the face insert portion 1550. In yet another example, the area of the third portion 1740 may be greater than or equal to 21% of the area of the face insert portion 1550 and less than or equal to 24% of the area of the face insert portion 1550. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, an area of the fourth portion 1750 may be greater than or equal to 0.5 inch²(322.58 mm²) and less than or equal to 0.9 inch²(580.64 mm²). In another example, an area of the fourth portion 1750 may be greater than or equal to 0.58 inch²(374.19 mm²) and less than or equal to 0.82 inch²(529.03 mm²). In yet another example, an area of the fourth portion 1750 may be greater than or equal to 0.66 inch²(425.81 mm²) and less than or equal to 0.74 inch²(477.42 mm²). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, an area of the fifth portion 1760 may be greater than or equal to 1.9 inch²(1225.80 mm²) and less than or equal to 3.3 inch²(2129.03 mm²). In another example, an area of the fifth portion 1760 may be greater than or equal to 2.18 inch²(1406.45 mm²) and less than or equal to 3.02 inch²(1948.38 mm²). In yet another example, an area of the fifth portion 1760 may be greater than or equal to 2.46 inch²(1587.09 mm²) and less than or equal to 2.74 inch²(1767.74 mm²). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The area of the face insert portion 1550 relative to the area of face portion 1510 may be determined to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400 without compromising the structural integrity of the golf club head 1400. In one example, the area of the face insert portion 1550 may be greater than or equal to 40% of the area of the face portion 1510 and less than or equal to 60% of the area of the face portion 1510. In another example, the area of the face insert portion 1550 may be greater than or equal to 45% of the area of the face portion 1510 and less than or equal to 55% of the area of the face portion 1510. In yet another example, the area of the face insert portion 1550 may be greater than or equal to 48% of the area of the face portion 1510 and less than or equal to 53% of the area of the face portion 1510. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first portion 1720, the second portion 1730, and/or the third portion 1740 may have any shape to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400. In one example, as shown in FIGS. 19 and 20, the first portion 1720 and the transition portion 1730 may have a rectangular shape having rounded corners. In one example, as shown in FIGS. 19 and 20, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape and the inner perimeter 1724 is centered and nested in the outer perimeter 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. In FIG. 20, the shape of the first portion 1720 and the transition portion 1730 may be elongated and slightly tilted upward relative to the shape and orientation of the first portion 1720 and the transition portion 1730, respectively, that are shown in FIG. 19. Accordingly, the first portion 1720 and the transition portion 1730 shown in the example of FIG. 20 have larger areas than the corresponding parts, respectively, that are shown in FIG. 19. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIGS. 21 and 22, the first portion 1720 and the transition portion 1730 may have an elliptical shape. In one example, as shown in FIGS. 21 and 22, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape and the inner perimeter 1724 is centered and nested in the outer perimeter portion 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter portion 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. In FIG. 22, the elliptical shape of the first portion 1720 and the transition portion 1730 may be elongated and slightly tilted upward relative to the corresponding shapes, respectively, that are shown in FIG. 21. Accordingly, the first portion 1720 and the transition portion 1730 shown in the example of FIG. 22 have larger areas than the corresponding parts, respectively, that are shown in FIG. 21. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIG. 23, the first portion 1720 and the transition portion 1730 may have a rhombus-like shape having rounded corners. In one example, as shown in FIG. 23, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape and the inner perimeter 1724 is centered and nested in the outer perimeter 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in FIG. 24, the first portion 1720 and/or the transition portion 1730 may have a circular shape. In one example, as shown in FIG. 24, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape and the inner perimeter 1724 is concentric with the outer perimeter 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As shown in the examples of FIGS. 16 and 19-24, the first portion 1720 and the transition portion 1730 may have any geometric shape. However, the first portion 1720 and the transition portion 1730 may have any simple or complex geometric and/or non-geometric shapes. For example, the first portion 1720 and the transition portion 1730 may have shapes that may be constructed from a combination of simple geometric shapes. In one example, as shown in FIG. 25, the first portion 1720 and the transition portion 1730 may have a four-lobed shape that may be constructed from a combination of two transversely intersecting elliptical shapes (shown in dashed lines). In the example of FIG. 25, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter 1734 have generally the same shape and the inner perimeter 1724 is concentric with the outer perimeter 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. In another example, as shown in FIG. 26, the first portion 1720 and the transition portion 1730 may have a geometric shape that may be similar to a figure eight shape and constructed from a combination of two intersecting circular shapes (shown in dashed lines). In the example of FIG. 26, the transition portion 1730 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter portion 1734 have generally the same shape and the inner perimeter 1724 is concentric with the outer perimeter portion 1734. In another example (not shown), the transition portion width 1738 may vary at one of more locations in the transition portion 1730. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As shown in the examples of FIGS. 16 and 19-26, the transition portion 1740 may have a constant transition portion width 1738 such that the inner perimeter 1724 and the outer perimeter portion 1734 have generally the same shape and the inner perimeter 1724 is concentric with the outer perimeter 1734. In other words, the inner perimeter 1724 may be generally parallel with the outer perimeter 1734. However, the inner perimeter 1724 and the outer perimeter 1734 may have any shape that may result in a variable transition portion width 1738 on the face portion 1510. In one example, as shown in FIG. 27, the inner perimeter 1724 may have an elliptical shape and the outer perimeter 1734 may have a trapezoidal shape. In another example, as shown in FIG. 28, the inner perimeter 1724 may have a circular shape and the outer perimeter 1734 has an elliptical shape. Accordingly, in the examples of FIGS. 27 and 28, the transition portion width 1738 may vary at different locations on the face portion 1510. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The transition portion thickness 1732 may also vary in profile between the inner perimeter 1724 and the outer perimeter 1734 for any of the configurations of the face insert portion 1550 described herein. For example, with reference to FIGS. 28-30, the transition portion thickness 1732 in region 2910, which has a relatively large transition portion width 1738, may have a linear profile having a smaller slope than a linear profile of the variation in the transition portion thickness 1732 in region 2920, which has a relatively small transition portion width 1738. In other words, the variation in transition portion thickness 1732 is more gradual in region 2910 than the variation in transition portion thickness 1732 in region 2920. In another example, and with reference to FIGS. 28, 31, and 32, the transition portion 1730 may have a convex thickness profile. Accordingly, the transition portion thickness 1732 in region 2910, which has a relatively large transition portion width 1738, may have a smaller (i.e., shallower) curvature than a curvature of the variation in the transition portion thickness 1732 in region 2920, which has a small transition portion width 1738. In yet another example, as illustrated in FIGS. 28, 33, and 34, the transition portion 1730 may have an s-shaped curvature. Accordingly, the transition portion thickness 1732 in region 2910, which has a relatively large transition portion width 1738, may have a slight and elongated s-shaped curvature, whereas the transition portion thickness 1732 in region 2920, which has a small transition portion width 1738, may have a relatively sharp and shortened s-shaped curvature. Accordingly, the variation in transition portion thickness 1732 may be more gradual in region 2910 than the variation in the transition portion thickness 1732 in region 2920. Thus, in one example, the rate of change in the transition portion thickness 1732 between the inner perimeter 1724 and the outer perimeter portion 1734 at any location on the transition portion 1730 may depend on the magnitude of the transition portion width 1738 and the profile of the variation of the transition portion thickness 1732 (i.e., linear, curved, etc.). In other examples of the face portion 1510, the transition portion thickness 1732 may vary in any manner (not shown) at any location in the transition portion 1730 to provide certain performance characteristics for the golf club head 1400. The transition portion thickness 1752 may also be configured to have any profile shape as described herein. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example (not shown), the outer face portion 1515 and the face insert portion 1550 may be made from the same material. Referring to FIGS. 14-18, for example, the outer face portion 1515 may be made from titanium or titanium alloy, whereas the face insert portion 1550 may be made from steel. In another example (not shown), the outer face portion 1515 may be made from a composite material, whereas the face insert portion 1550 may be made from one or more metals or metal alloys. In yet another example, the face insert portion 1550 may be made from two or more different materials. For example, the first portion 1720 may be made from steel and the third portion 1740 may be made from titanium or a titanium alloy. The outer face portion 1515 and the face insert portion 1550 may be made from one or more materials to provide certain performance characteristics or optimum performance characteristics for the golf club head 1400. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Any of the golf club heads described herein may be part of a golf club. In one example, as shown in FIG. 35, a golf club 3500, which may include any of the golf club heads described herein, may include a shaft 3512 extending from golf club head 3510. The shaft 3512 may have a first end 3514 or first end portion 3514 (a first end portion 3514 of the shaft is shown in FIG. 35) attached to a hosel 3526 of the golf club head 3510 and a second end 3516 or a second end portion 3516 (a second end portion 3516 of the shaft is shown in FIG. 35) opposite the first end 3514. The golf club 3500 may include a grip 3530 at or proximate to the second end 3516 of the shaft 3512. The shaft 3512 may be formed from metal material, composite material, or any other suitable material or combination of materials. The grip 3530 may be formed from rubber material, polymer material, or any other suitable material or combination of materials. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The apparatus, methods, and articles of manufacture described herein may include one or more club identifiers (e.g., a serial number, a matrix barcode, a brand name, a model, a club number, a loft angle, a character, etc.). For example, the golf club head may include a visual indicator such as a club number to identify the type of golf club. In one example, the club number may correspond to the loft angle of the golf club head (e.g., 3, 4, 5, 6, 7, 8, or 9). In one example, a 7-iron type golf club head may be marked with “7”. In another example, the golf club head may include the loft angle. For example, a 54-degree wedge type golf club head may be marked “54.” In yet another example, a 10.5-degree driver type golf club head may be marked “10.5.” The club identifier may be a trademark to identify a brand or a model of the golf club head. The club identifier may be another type of visual indicator such as a product number or a serial number to identify the golf club head 100 as authentic equipment, to track inventory, or to distinguish the golf club head from fake or counterfeit products. Alternatively, the club identifier may be a digital signature or a machine-readable optical representation of information or data about the golf club head (e.g., numeric character(s), alphanumeric character(s), byte(s), a one-dimensional barcode such as a Universal Product Code (UPC), a two-dimensional barcode such as a Quick Response (QR) code, etc.). The club identifier may be placed at various locations on the golf club head (e.g., the hosel portion, the face portion, the sole portion, etc.) using various methods (e.g., laser etched, stamped, cast, or molded onto the golf club head). For example, the club identifier may be a serial number laser etched onto the hosel portion of the golf club head. Instead of being an integral part of the golf club head, the club identifier may be a separate component coupled to the golf club head (e.g., a label adhered via an adhesive or an epoxy).

Any of the apparatus, methods, or articles of manufacture described herein may include one or more visual identifiers such as alphanumeric characters, colors, images, symbols, logos, and/or geometric shapes. For example, one or more visual identifiers may be manufactured with one or more portions of a golf club such as the golf club head (e.g., casted or molded with the golf club head), painted on the golf club head, etched on the golf club (e.g., laser etching), embossed on the golf club head, machined onto the golf club head, attached as a separate badge or a sticker on the golf club head (e.g., adhesive, welding, brazing, mechanical lock(s), any combination thereof, etc.), or any combination thereof. The visual identifier may be made from the same material as the golf club head or a different material than the golf club head (e.g., a plastic badge attached to the golf club head with an adhesive). Further, the visual identifier may be associated with manufacturing and/or brand information of the golf club head, the type of golf club head, one or more physical characteristics of the golf club head, or any combination thereof. In particular, a visual identifier may include a brand identifier associated with a manufacturer of the golf club (e.g., trademark, trade name, logo, etc.) or other information regarding the manufacturer. In addition or alternatively, the visual identifier may include a location (e.g., country of origin), a date of manufacture of the golf club or golf club head, or both.

The visual identifier may include a serial number of the golf club or golf club head, which may be used to check the authenticity to determine whether or not the golf club or golf club head is a counterfeit product. The serial number may also include other information about the golf club that may be encoded with alphanumeric characters (e.g., country of origin, date of manufacture of the golf club, or both). In another example, the visual identifier may include the category or type of the golf club head (e.g., 5-iron, 7-iron, pitching wedge, etc.). In yet another example, the visual identifier may indicate one or more physical characteristics of the golf club head, such as one or more materials of manufacture (e.g., visual identifier of “Titanium” indicating the use of titanium in the golf club head), loft angle, face portion characteristics, mass portion characteristics (e.g., visual identifier of “Tungsten” indicating the use of tungsten mass portions in the golf club head), interior cavity and filler material characteristics (e.g., one or more abbreviations, phrases, or words indicating that the interior cavity is filled with a polymer material), any other information that may visually indicate any physical or play characteristic of the golf club head, or any combination thereof. Further, one or more visual identifiers may provide an ornamental design or contribute to the appearance of the golf club or the golf club head.

The terms “and” and “or” may have both conjunctive and disjunctive meanings. The terms “a” and “an” are defined as one or more unless this disclosure indicates otherwise. The term “coupled,” and any variation thereof, refers to directly or indirectly connecting two or more elements chemically, mechanically, and/or otherwise. The phrase “removably connected” is defined such that two elements that are “removably connected” may be separated from each other without breaking or destroying the utility of either element.

The term “substantially” when used to describe a characteristic, parameter, property, or value of an element may represent deviations or variations that do not diminish the characteristic, parameter, property, or value that the element may be intended to provide. Deviations or variations in a characteristic, parameter, property, or value of an element may be based on, for example, tolerances, measurement errors, measurement accuracy limitations and other factors. The term “proximate” is synonymous with terms such as “adjacent,” “close,” “immediate,” “nearby,” “neighboring,” etc., and such terms may be used interchangeably as appearing in this disclosure.

The apparatus, methods, and articles of manufacture described herein may be implemented in a variety of embodiments, and the foregoing description of some of these embodiments does not necessarily represent a complete description of all possible embodiments. Instead, the description of the drawings, and the drawings themselves, disclose at least one embodiment, and may disclosure alternative embodiments.

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

Further, while the above examples may be described with respect to golf clubs, the apparatus, methods and articles of manufacture described herein may be applicable to other suitable types of sports equipment such as a fishing pole, a hockey stick, a ski pole, a tennis racket, etc.

Although certain example apparatus, methods, and articles of manufacture have been described herein, the scope of coverage of this disclosure is not limited thereto. On the contrary, this disclosure covers all apparatus, methods, and articles of articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.

Number	Date	Country
63117182	Nov 2020	US
62662112	Apr 2018	US
62734176	Sep 2018	US
62734922	Sep 2018	US
62740355	Oct 2018	US
62745113	Oct 2018	US
62751456	Oct 2018	US
62772669	Nov 2018	US
62621948	Jan 2018	US
62655437	Apr 2018	US
62444671	Jan 2017	US
62445878	Jan 2017	US
62530734	Jul 2017	US
62624294	Jan 2018	US
62850292	May 2019	US
62676860	May 2018	US
62786371	Dec 2018	US
62820728	Mar 2019	US
62816418	Mar 2019	US
62837592	Apr 2019	US
62816418	Mar 2019	US
62957757	Jan 2020	US
62837592	Apr 2019	US
62873773	Jul 2019	US
62897015	Sep 2019	US
62837592	Apr 2019	US
62873773	Jul 2019	US
62897015	Sep 2019	US
62820728	Mar 2019	US
62816418	Mar 2019	US
62957757	Jan 2020	US
62963430	Jan 2020	US
63057252	Jul 2020	US
63010036	Apr 2020	US

	Number	Date	Country
Parent	17528436	Nov 2021	US
Child	18229744		US
Parent	16889524	Jun 2020	US
Child	17389659		US
Parent	16419639	May 2019	US
Child	16889524		US
Parent	16234169	Dec 2018	US
Child	16419639		US
Parent	16205583	Nov 2018	US
Child	16234169		US
Parent	15724035	Oct 2017	US
Child	15981094		US
Parent	15440968	Feb 2017	US
Child	15724035		US
Parent	16030403	Jul 2018	US
Child	16533352		US
Parent	16930716	Jul 2020	US
Child	17400516		US
Parent	16422661	May 2019	US
Child	16930716		US
Parent	16813453	Mar 2020	US
Child	17198906		US
Parent	16807591	Mar 2020	US
Child	17198770		US
Parent	17225414	Apr 2021	US
Child	17407025		US

	Number	Date	Country
Parent	17389659	Jul 2021	US
Child	17528436		US
Parent	15981094	May 2018	US
Child	16419639		US
Parent	16533352	Aug 2019	US
Child	16889524		US
Parent	17400516	Aug 2021	US
Child	17528436		US
Parent	17198906	Mar 2021	US
Child	17528436		US
Parent	17198770	Mar 2021	US
Child	17528436		US
Parent	17149954	Jan 2021	US
Child	17528436		US
Parent	17407025	Aug 2021	US
Child	17528436		US

GOLF CLUB HEADS AND METHODS TO MANUFACTURE GOLF CLUB HEADS

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Abstract

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CROSS REFERENCE

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