MULTI-PIECE GOLF CLUB HEAD

FIELD

This disclosure relates generally to golf clubs, and more particularly to a golf club head having discreet regions of specific mass relationships, including a lightweight forward portion, to achieve specific mass properties and performance.

BACKGROUND

In the early history of golf, golf club heads were made primarily of a single material, such as wood. Subsequently, golf club heads progressed away from a construction made primarily from wood to one made primarily of metal. Initial golf club heads made of metal were made of steel alloys. Overtime, golf club heads started to be made of titanium alloys. Some, but not all, golf club head manufacturers have transitioned away from use of a single material to a multi-material and multi-piece construction. The use of multiple pieces and the use of multiple materials can provide various manufacturing, mass distribution, and performance advantages. The multiple pieces of a multi-piece golf club head can be joined together in a variety of ways, such as adhesive bonding, welding, and brazing.

Often, the strength of the connection between joined pieces of a multi-piece golf club head affects the durability of the golf club head and thus the performance of the golf club head over time. A weak joint tends to accelerate degradation of the connection as the golf club head is used to impact golf balls. Degradation in a bond between bonded pieces can lead to a diminution of the performance of the golf club head, such as via a reduction in stiffness and lack of proper load transfer, at best, and complete failure of the golf club head, at worst. Typically, the strike face of a driver-type golf club head undergoes several thousand collisions with a golf ball through its life-cycle. Each collision imparts a force onto the strike face in the range of 10,000 g to 20,000 g, where g is equal to the force per unit mass due to gravity. Repeated impacts, at such high forces, tends to cause degradation of the joints, connections, and bonds forming the golf club head. Accordingly, a strong initial and durable joint, connection, and/or bond between the pieces of a golf club head is desired.

Because welding generally provides a stronger initial bond and can exhibit a higher durability compared to other bonding techniques, the pieces of many conventional multi-piece golf club heads utilize materials, such as compatible metals, that are conducive to welding. However, many metals used to construct multi-piece golf club heads have a higher density than non-metallic materials. Therefore, the mass available to for distribution around such golf club heads (otherwise known as discretionary mass), which can be utilized for promote the performance of golf club heads, can be limited. For this reason, providing a multi-piece golf club head, which has strong and durable bonds between the pieces of the golf club head and promotes an increase in discretionary mass, can be difficult.

SUMMARY

The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the shortcomings of golf club heads with a multi-piece construction, that have not yet been fully solved. Accordingly, the subject matter of the present application has been developed to provide a golf club head that overcomes at least some of the shortcomings of conventional golf club heads described herein.

The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular embodiment or implementation. In other examples, additional features and advantages may be recognized in certain embodiments and/or implementations that may not be present in all embodiments or implementations. Further, in some examples, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the subject matter and are not therefore to be considered to be limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:

FIG. 1 is a schematic, perspective view of a golf club head, according to one or more examples of the present disclosure;

FIG. 2 is a schematic, perspective view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 3 is a schematic, side elevation view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 4 is another schematic, side elevation view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 5 is a schematic, front view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 6 is a schematic, rear view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 7 is a schematic, top plan view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 8 is a schematic, bottom plan view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 9A is a schematic, cross-sectional, side elevation view of the golf club head of FIG. 1, taken along the line 9-9 of FIG. 5, according to one or more examples of the present disclosure;

FIG. 9B is a schematic, cross-sectional, side elevation view of a detail of the golf club head of FIG. 9A, according to one or more examples of the present disclosure;

FIG. 10 is a schematic, exploded, perspective view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 11 is another schematic, exploded, perspective view of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 12 is a schematic, top plan view of a body of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 13 is a schematic, bottom plan view of the body of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 14 is a schematic, exploded, perspective view of the body of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 15 is another schematic, exploded, perspective view of the body of the golf club head of FIG. 1, according to one or more examples of the present disclosure;

FIG. 16 is a schematic, perspective view of another golf club head, according to one or more examples of the present disclosure;

FIG. 17 is a schematic, cross-sectional, side elevation view of the golf club head of FIG. 16, taken along the line 16-16 of FIG. 16, according to one or more examples of the present disclosure;

FIG. 18 is a schematic, exploded, perspective view of another golf club head, according to one or more examples of the present disclosure;

FIG. 19 is a schematic, exploded, perspective view of yet another golf club head, according to one or more examples of the present disclosure;

FIG. 20 is a schematic, exploded, perspective view of the golf club head of FIG. 19, according to one or more examples of the present disclosure;

FIG. 21 is a schematic, front elevation view of a ring of the golf club head of FIG. 19, according to one or more examples of the present disclosure;

FIG. 22 is a schematic, rear view of a face portion of a golf club head, according to one or more examples of the present disclosure;

FIG. 23 is a schematic, rear view of a face portion of a golf club head, according to one or more examples of the present disclosure;

FIG. 24 is a schematic, perspective view of the face portion of FIG. 56, according to one or more examples of the present disclosure;

FIG. 25 is a schematic, rear view of a face portion of a golf club head, according to one or more examples of the present disclosure;

FIG. 26 is a schematic, front elevation view of a strike plate of a golf club head, according to one or more examples of the present disclosure;

FIG. 27 is a schematic, bottom view of a strike plate of a golf club head, according to one or more examples of the present disclosure;

FIG. 28A is a schematic, bottom sectional view of a heel portion of a strike plate of a golf club head, according to one or more examples of the present disclosure;

FIG. 28B a schematic, bottom sectional view of a toe portion of a strike plate of a golf club head, according to one or more examples of the present disclosure;

FIG. 29 is a schematic, sectional view of a polymer layer of a strike plate of a golf club head, according to one or more examples of the present disclosure;

FIG. 30 is a schematic, sectional, bottom plan view of a golf club head, taken along a line similar to the line 30-30 of FIG. 9B, according to one or more examples of the present disclosure;

FIG. 31 is a schematic, sectional, side elevation view of a forward portion and a crown portion of the golf club head of FIG. 30, taken along the line 31-31 of FIG. 30, according to one or more examples of the present disclosure;

FIG. 32 is a schematic, sectional, side elevation view of a forward portion and a crown portion of the golf club head of FIG. 30, taken along the line 32-32 of FIG. 30, according to one or more examples of the present disclosure;

FIG. 33 is a schematic, side elevation view of a first part of a golf club head being laser ablated by a first laser, according to one or more examples of the present disclosure;

FIG. 34 is a schematic, side elevation view of a second part of a golf club head being laser ablated by a second laser, according to one or more examples of the present disclosure;

FIG. 35 is a schematic, side elevation view of a first part, of a golf club head, bonded to a second part, of the golf club head, according to one or more examples of the present disclosure;

FIG. 36 is a schematic, perspective view of an ablation pattern, of peaks and valleys, of an ablated surface of a part of a golf club head, according to one or more examples of the present disclosure;

FIG. 37 is a schematic, side elevation view of an ablation pattern, of peaks and valleys, of an ablated surface of a part of a golf club head, according to one or more examples of the present disclosure;

FIG. 38 is a schematic, perspective view of a strike plate of a golf club head being laser ablated by a laser, according to one or more examples of the present disclosure;

FIG. 39 is a schematic, perspective view of a body of a golf club head being laser ablated by a laser, according to one or more examples of the present disclosure;

FIG. 40 is a schematic, perspective, exploded view of a strike plate and a body of a golf club head, according to one or more examples of the present disclosure;

FIG. 41 is a schematic, perspective, exploded view of a strike plate and a body of a golf club head, according to one or more examples of the present disclosure;

FIG. 42 is a schematic flow diagram of a method of making a golf club head, according to one or more examples of the present disclosure;

FIG. 43 is a schematic flow diagram of a method of making a golf club head, according to one or more examples of the present disclosure;

FIG. 44 is a schematic, side elevation view of a first part, of a golf club head, bonded to a second part, of the golf club head, according to one or more examples of the present disclosure;

FIG. 45 is a schematic, top plan view of an ablation pattern on a part of a golf club head, according to one or more examples of the present disclosure;

FIG. 46 is a schematic, top plan view of an ablation pattern on a part of a golf club head, according to one or more examples of the present disclosure;

FIG. 47 is a schematic, perspective view of a sheet, including bonding tape, according to one or more examples of the present disclosure;

FIG. 48 is a schematic, side elevation, sectional view of a bonding tape package, according to one or more examples of the present disclosure;

FIG. 49 is a schematic, perspective view of a tape-retention fixture, according to one or more examples of the present disclosure;

FIG. 50 is a schematic, perspective view of a tape-retention fixture, according to one or more examples of the present disclosure;

FIG. 51 is a schematic, perspective view of a tape-retention fixture, according to one or more examples of the present disclosure;

FIG. 52 is a schematic, perspective view of a tape-retention fixture, according to one or more examples of the present disclosure;

FIG. 53 is a schematic, perspective view of a crown insert of a golf club head, according to one or more examples of the present disclosure;

FIG. 54 is a schematic, perspective view of a sole insert of a golf club head, according to one or more examples of the present disclosure;

FIG. 55 is a schematic, top plan view of a golf club head that includes a crown insert, according to one or more examples of the present disclosure;

FIG. 56 is a schematic, bottom plan view of a golf club head that includes a sole insert, according to one or more examples of the present disclosure;

FIG. 57A is a schematic, side elevation, sectional view of a crown insert temporarily bonded, via bonding tape, to a body of a golf club head, according to one or more examples of the present disclosure;

FIG. 57B is a schematic, side elevation, sectional view of a crown insert temporarily bonded, via bonding tape, to a body of a golf club head, according to one or more examples of the present disclosure;

FIG. 58 is a schematic, perspective view of a vacuum bag, in a non-collapsed state, enclosing a golf club head, according to one or more examples of the present disclosure;

FIG. 59 is a schematic, perspective view of a vacuum bag, in a collapsed state, enclosing a golf club head, according to one or more examples of the present disclosure;

FIG. 60 is a schematic, perspective view of a vacuum bag, in a non-collapsed state, enclosing a golf club head, according to one or more examples of the present disclosure;

FIG. 61 is a schematic, perspective view of a vacuum bag, in a collapsed state, enclosing a golf club head, according to one or more examples of the present disclosure;

FIG. 62 is a schematic, side elevation, sectional view of an oven, according to one or more examples of the present disclosure;

FIG. 63 is a schematic, exploded, perspective view of a fairway-metal type golf club head, according to one or more examples of the present disclosure;

FIG. 64 is a schematic, exploded, perspective view of an iron-type golf club head, according to one or more examples of the present disclosure;

FIG. 65 is a schematic, perspective view of a golf club head, according to one or more examples of the present disclosure;

FIG. 66A is a schematic, sectional, side elevation view of a golf club head, according to one or more examples of the present disclosure;

FIG. 66B is a schematic, sectional, close-up, side elevation view of the golf club head of FIG. 66A, according to one or more examples of the present disclosure;

FIG. 67 is a schematic, sectional, side elevation view of a golf club head, according to one or more examples of the present disclosure;

FIG. 68 is a schematic, front elevation view of a golf club head, according to one or more examples of the present disclosure; and

FIG. 69 is a schematic, front elevation view of a golf club head, according to one or more examples of the present disclosure.

FIG. 70A is a toe side view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 70B is a face side view of the golf club head of FIG. 70A.

FIG. 70C is a perspective view of the golf club head of FIG. 70A.

FIG. 70D is a top view of the golf club head of FIG. 70A.

FIG. 71 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 72 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 73 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 74 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 75 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 76 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 77A is a front view of the apparatus used for measuring a Sight Adjusted Perceived Face Angle in accordance with the current disclosure.

FIG. 77B is a close up view of the arrangement of the laser and cameras in the apparatus used for measuring a Sight Adjusted Perceived Face Angle in accordance with the current disclosure.

FIG. 77C is a side view of a golf club head fixture in an 69apparatus used for measuring a Sight Adjusted Perceived Face Angle in accordance with the current disclosure.

FIG. 78 is a graph of the Sight Adjusted Perceived Face Angle vs. the Dispersion in Ball Flight for four clubs having the alignment features in accordance with the current disclosure.

FIG. 79A is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 79B is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 80 is a reference to the CIELAB color system.

FIG. 81 is a side elevation view from a toe side of a golf club head in accord with one embodiment of the current disclosure.

FIG. 82 is a side elevation view from a heel side of a golf club head in accord with one embodiment of the current disclosure, with sole and crown inserts removed.

FIG. 83A is a top view of a golf club head in accord with one embodiment of the current disclosure, with a crown insert removed.

FIG. 83B is atop cross-sectional view of a front portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 84 is a bottom perspective view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 85 is a bottom perspective view of a golf club head in accord with one embodiment of the current disclosure, with two sole inserts removed.

FIG. 86 is an exploded perspective view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 87 is a bottom perspective view from a heel side of a golf club head in accord with one embodiment of the current disclosure.

FIG. 88 is a perspective view from a toe side of a golf club head in accord with one embodiment of the current disclosure, providing elevation markers on the golf club head at various heights relative to a ground plane.

FIG. 89 is a flowchart of a method in accordance with one or more of the present embodiments.

FIG. 90 is a top view of a golf club head in accord with one embodiment of the current disclosure having tooled alignment feature.

FIG. 91 is a perspective view of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed.

FIG. 92 is a perspective view of a golf club head in accord with one embodiment of the current disclosure, with a face insert installed.

FIG. 93 is a flowchart of a method in accordance with one or more of the present embodiments.

FIG. 94 is a section view of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed.

FIG. 95A is a section view of an upper lip of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed.

FIG. 95B is a section view of a lower lip of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed.

FIG. 96 is a top view of a golf club head in accord with one embodiment of the current disclosure.

FIG. 97 is a perspective view from a toe side of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed.

FIG. 98 is a perspective view from heel side of a golf club head in accord with one embodiment of the current disclosure.

FIG. 99 is a perspective view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 100 is a perspective view from the rear portion of a golf club head in accord with one embodiment of the current disclosure, without a crown insert installed.

FIG. 101 is a view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 102 is a view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 103 is a view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 104 is a view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 105 is a view of a portion of a golf club head in accord with one embodiment of the current disclosure.

FIG. 106 is a perspective view from a toe side of two golf club heads, one golf club head in accord with one embodiment of the current disclosure and one golf club head in accord with a prior art club head.

FIG. 107 is a is a front elevation view of a face insert.

FIG. 108 is a is a bottom perspective view of a face insert.

FIG. 109A is a section view of a heel portion of a face insert.

FIG. 109B is a section view of a toe portion of a face insert.

FIG. 110 is a section view of a polymer layer of a face insert.

FIG. 111 is a front view of the club head.

FIG. 112 is toe-side view of a front portion of the club head.

FIG. 113 is a toe-side view of the entire club head.

FIG. 114 is a heel-side view of the club head.

FIG. 115 is a rear view of the club head.

FIG. 116 is a bottom view of the club head.

FIG. 117 shows the hosel region of the club head from the heel side.

FIG. 118 shows the hosel region of the club head from the front.

FIG. 119 is a cross-section view showing a toe portion of the club head from the heel side.

FIG. 120 is a cross-section view showing a heel portion of the club head from the toe side.

FIG. 121 is a top view of the club head.

FIG. 122 is a top view of the club head with the crown panel removed.

FIG. 123 is a heel-side view of the club head with the crown and sole panels removed.

FIG. 124 is a toe-side view of the club head with the crown and sole panels removed.

FIG. 125 is a rear view of the club head with the crown and sole panels removed.

FIG. 126 is a front view of the club head with the crown panel removed.

FIG. 127 is a cross-sectional view of an upper-front portion of the club head.

FIG. 128 is a cross-section view of an upper-front portion of the body of the club head.

FIG. 129 shows a toe-side portion of the club head with the crown panel removed.

FIG. 130 shows a heel-side portion of the club head with the crown panel removed.

FIG. 131 shows an upper-front-toe portion of the body of the club head.

FIG. 132 shows a front-heel portion of the body of the club head.

FIG. 133 shows an upper-front-toe portion of the body of the club head.

FIG. 134 shows a front-heel portion of the body of the club head.

FIG. 135A is a cross-sectional view of an upper-front portion of the club head.

FIG. 135B is an enlarged cross-sectional view of an upper-front portion of the club head.

FIG. 136 is a cross-sectional view of an upper-front portion of the club head.

FIG. 137 is a partial front view of the club head with the crown panel.

FIG. 138 is a partial front view of the club head with the crown panel removed.

FIG. 139 is a partial perspective view of the club head with the crown panel removed.

FIG. 140 is a partial perspective view of the club head with the crown panel removed.

FIG. 141 is a cross-sectional view of the club head.

FIG. 142 is a front view of the club head.

FIG. 143 is a front view of the club head.

FIG. 144 is a front view of the club head.

FIG. 145 is a front view of the club head.

FIG. 146 is a perspective view of the club head.

FIG. 147 is a perspective view of the club head with the sole insert removed.

FIG. 148 is atop view of the club head with the crown and face plate removed.

FIG. 149 is a front view of the club head with the crown and face plate removed.

FIG. 150 is a front view of the club head with the crown and face plate removed.

FIG. 151 is a front view of the club head with the crown removed.

FIG. 152 is a front view of the club head with the crown removed.

FIG. 153 is a cross-sectional view of the club head.

FIG. 154 is a partial cross-sectional view of the club head.

FIG. 155 is a front view of the club head.

FIG. 156 is a partial cross-sectional view of the club head.

FIG. 157 is a partial cross-sectional view of the club head.

FIG. 158 is a perspective view of the crown.

FIG. 159 is an exploded perspective view of an embodiment of the club head.

FIG. 160 is atop view of the club head.

FIG. 161 is a toe side view of the club head.

FIG. 162 is a heel side view of the club head.

FIG. 163 is a bottom view of the club head.

FIG. 164 is a partial top view of the club head.

FIG. 165 is a face view of the club head.

FIG. 166 is a rear view of the club head.

FIG. 167 is a partial top view of the club head.

FIG. 168 is a cross-sectional view of the club head.

FIG. 169 is a cross-sectional view of the club head.

FIG. 170 is a partial face view of the club head.

FIG. 171 is a cross-sectional view of the club head.

FIG. 172 is a partial face view of the club head.

FIG. 173 is a cross-sectional view of the club head.

FIG. 174 is a perspective cross-sectional view of the club head.

FIG. 175 is a perspective cross-sectional view of the club head.

FIG. 176 is a toe side view of the club head.

FIG. 177 is atop view of the club head.

FIG. 178 is a heel side view of the club head.

FIG. 179 is a bottom view of the club head.

FIG. 180 is a partial top view of the club head.

FIG. 181 is a front view of the club head.

FIG. 182 is a rear view of the club head.

FIG. 183 is a partial top view of the club head.

FIG. 184 is a cross-sectional view of the club head.

FIG. 185 is a cross-sectional view of the club head.

FIG. 186 is a partial toe side view of the club head.

FIG. 187 is a partial top view of the club head.

FIG. 188 is a partial heel side view of the club head.

FIG. 189 is a partial bottom view of the club head.

FIG. 190 is an exploded view of the club head.

FIG. 191 is an exploded view of the club head.

FIG. 192 is a perspective view of the club head.

FIG. 193 is a perspective view of the club head.

FIG. 194 is a perspective view of the club head.

FIG. 195 is a perspective view of the club head.

FIG. 196 is a front view of the club head.

FIG. 197 is a rear view of the club head.

FIG. 198 is a heel side view of the club head.

FIG. 199 is a toe side view of the club head.

FIG. 200 is a top view of the club head.

FIG. 201 is a bottom view of the club head.

FIG. 202 is a cross-sectional view of the club head.

FIG. 203 is a cross-sectional view of the club head.

FIG. 204 is a perspective view of the club head.

FIG. 205 is a perspective view of the club head.

FIG. 206 is a perspective view of the club head.

FIG. 207 is a perspective view of the club head.

FIG. 208 is a front view of the club head.

FIG. 209 is a rear view of the club head.

FIG. 210 is a heel side view of the club head.

FIG. 211 is a toe side view of the club head.

FIG. 212 is atop view of the club head.

FIG. 213 is a bottom view of the club head.

FIG. 214 is a cross-sectional view of the club head.

FIG. 215 is a cross-sectional view of the club head. FIG. 306 is a front elevation view of a golf club head in accordance with the embodiments of the current disclosure.

FIG. 216 is an illustration of the central region of a golf club head in accordance with the embodiments of the current disclosure.

FIG. 217 is an illustration of a plot of coefficient of restitution (COR) values for locations on the striking face of a golf club head in accordance with one or more embodiments of the current disclosure.

FIG. 218 is an illustration of another plot of coefficient of restitution (COR) values for locations on the striking face of a golf club head in accordance with one or more embodiments of the current disclosure.

FIG. 219 is an illustration of another plot of coefficient of restitution (COR) values for locations on the striking face of a golf club head in accordance with one or more embodiments of the current disclosure.

FIG. 220 is a top view of the club head.

FIG. 221 is a heel side view of the club head.

FIG. 222 is a front elevation view of the club head.

FIG. 223 is a top view of the club head.

FIG. 224 is a cross-sectional view of the club head.

DETAILED DESCRIPTION

For purposes of this description, certain aspects, advantages, and novel features of the embodiments of this disclosure are described herein. The described methods, systems, and apparatus should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed methods, systems, and apparatus are not limited to any specific aspect, feature, or combination thereof, nor do the disclosed methods, systems, and apparatus require that any one or more specific advantages be present, or problems be solved.

Features, properties, characteristics, materials, values, ranges, or groups described in conjunction with a particular aspect, embodiment or example of the disclosure are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The disclosure is not restricted to the details of any foregoing embodiments. The disclosure extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods, systems, and apparatus can be used in conjunction with other systems, methods, and apparatus.

As used herein, the terms “a,” “an,” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element. As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C,” or “A, B, and C.” As used herein, the term “coupled” generally means physically coupled or linked and does not exclude the presence of intermediate elements between the coupled items absent specific contrary language. The inventive features include all novel and non-obvious features disclosed herein both alone and in novel and non-obvious combinations with other elements. As used herein, the phrase “and/or” means “and”, “or” and both “and” and “or”. As used herein, the singular forms “a,” “an,” and “the” refer to one or more than one, unless the context clearly dictates otherwise. As used herein, the term “includes” means “comprises.” Any use of terminology such as “at least one of A and B” shall be interpreted to mean “at least one of A or B,” and is not meant to exclude having both A and B, unless noted otherwise.

Directions and other relative references (e.g., inner, outer, upper, lower, etc.) may be used to facilitate discussion of the drawings and principles herein, but are not intended to be limiting. For example, certain terms may be used such as “inside,” “outside,”, “top,” “down,” “interior,” “exterior,” and the like. Such terms are used, where applicable, to provide some clarity of description when dealing with relative relationships, particularly with respect to the illustrated embodiments. Such terms are not, however, intended to imply absolute relationships, positions, and/or orientations unless explicitly used within the claims. For example, with respect to an object, an “upper” part can become a “lower” part simply by turning the object over. Nevertheless, it is still the same part and the object remains the same. As used herein, “and/or” means “and” or “or,” as well as “and” and “or.”

The following describes examples of golf club heads in the context of a driver-type golf club head having a multi-piece construction, but the principles, methods and designs described may be applicable, in whole or in part, to fairway wood golf club heads, utility golf club heads (also known as hybrid golf club heads), iron-type golf club heads, putter-type golf club heads, and the like, because such golf club heads can also be made to have a multi-piece construction.

In some examples disclosed herein, the golf club head has a strike face formed of a non-metallic material, such as a fiber-reinforced polymeric material. A breakdown of the adhesive joint formed between a body of the golf club head and a non-metallic strike plate can cause characteristic time (CT) creep. USGA regulations require the CT of a golf club head to remain within the regulated limit regardless of the number of impacts the golf club head has with a golf ball. The CT of conventional driver-type golf club heads tends to increase after multiple impacts with a golf ball. The increase of CT due to impacts with a golf ball is known as CT creep. In certain examples disclosed herein, the golf club heads are configured to strengthen the adhesive joint formed between the body of the golf club heads and the non-metallic strike plate, such as by optimizing the surface structure of the golf club head for stronger adhesive bonds.

U.S. Patent Application Publication No. 2014/0302946 A1 ('946 App), published Oct. 9, 2014, which is incorporated herein by reference in its entirety, describes a “reference position” similar to the address position used to measure the various parameters discussed throughout this application. The address or reference position is based on the procedures described in the United States Golf Association and R&A Rules Limited, “Procedure for Measuring the Club Head Size of Wood Clubs,” Revision 1.0.0, (Nov. 21, 2003). Unless otherwise indicated, all parameters are specified with the club head in the reference position.

FIGS. 3, 4, 5, and 9A are examples that show a golf club head 100 in the address or reference position. The golf club head 100 is in the address or reference position when a hosel axis 191 of the golf club head 100 is at a lie angle θ of 60-degrees relative to a ground plane 181 (see, e.g., FIG. 5) and a strike face 145 of the golf club head 100 is square relative to an imaginary target line 101 (see, e.g., FIG. 7). As shown in FIGS. 3, 4, 5, and 9A, positioning the golf club head 100 in the address or reference position lends itself to using a club head origin coordinate system 185, centered at a geometric center (e.g., center face 183) of the strike face 145, for making various measurements. With the golf club head in the address or reference position, using the USGA methodology, various parameters described throughout this application including head height, club head center of gravity (CG) location, and moments of inertia (MOI), can be measured relative to the club head origin coordinate system 185 or relative to another reference or references.

For further details or clarity, the reader is advised to refer to the measurement methods described in the '946 App and the USGA procedure. Notably, however, the origin and axes associated with the club head origin coordinate system 185 used in this application may not necessarily be aligned or oriented in the same manner as those described in the '946 App or the USGA procedure. Further details are provided below on locating the club head origin coordinate system 185.

In some examples, the golf club heads described herein include driver-type golf club heads, which can be identified, at least partially, as golf club heads with strike faces that have a total surface area of at least 3,500 mm{circumflex over ( )}2, preferably at least 3,800 mm{circumflex over ( )}2, and even more preferably at least 3,900 mm{circumflex over ( )}2(e.g., between 3,500 mm²and 5,000 mm²in one example, less than 5,000 mm²in various examples, and between 3,700 mm²and 4,300 mm²in another example). In some examples, such as when the strike face is defined by a non-metal material, the total surface area of the strike face is no more than 4,300 mm²and no less than 3,300 mm². The total surface area of the strike face is the outermost area of the striking face, which can be the outermost area of a face insert in some examples. In certain examples, the total surface area of the strike face is the surface area of the surface of the striking face that is bounded on its periphery by all points where the face transitions from a substantially uniform bulge radius (i.e., face heel-to-toe radius of curvature) and a substantially uniform roll radius (i.e., face crown-to-sole radius of curvature) to the body of the golf club head. In certain examples, the strike face of the golf club head disclosed herein is defined in the same manner as in one or more of U.S. Patent Application Publication No. 2020/0139208, filed Oct. 22, 2019, U.S. Pat. No. 8,801,541, issued Aug. 12, 2014, and U.S. Pat. No. 8,012,039, issued Sep. 6, 2011, all of which are incorporated herein by reference in their entirety. In yet some examples, the strike face has a uniform bulge radius and a uniform roll radius, except for portions that have a higher lofted toe and a lower lofted heel, such as described in U.S. patent application Ser. No. 17/006,561, filed Aug. 28, 2020, U.S. Pat. No. 9,814,944, issued Nov. 14, 2017, U.S. Pat. No. 10,265,586, issued Apr. 23, 2019, and U.S. Patent Application Publication No. 2019/0076705, filed Oct. 15, 2018, which are incorporated herein by reference in their entirety.

Additionally, in certain examples, driver-type golf club heads include a center-of-gravity (CG) projection, or BP projection, explained later in detail with respect to FIGS. 310-312, which is, in one example, at most 3 mm above or below a center face of the strike face, and preferably at most 1 mm above or below the center face, as measured along a vertical axis (z-axis), or in another example, at most 5 mm below a center face of the strike face, and preferably at most 4 mm below the center face, as measured along a vertical axis (z-axis). In some examples, the CG projection is toe-ward of the geometric center of the strike face. Moreover, in some examples, driver-type golf club heads have a relatively high moment of inertia about a vertical axis (e.g., a CG z-axis passing through the CG and parallel with the z-axis of the club head origin coordinate system 185) (e.g. Izz>400 kg-mm{circumflex over ( )}2and preferably Izz>450 kg-mm{circumflex over ( )}2, and more preferably Izz>500 kg-mm{circumflex over ( )}2, but less than 590 kg-mm{circumflex over ( )}2 in certain implementations), a relatively high moment of inertia about a horizontal axis (e.g., a CG x-axis passing through the CG and parallel with the x-axis of the club head origin coordinate system 185) (e.g. Ixx>250 kg-mm{circumflex over ( )}2and preferably Ixx>300 kg-mm{circumflex over ( )}2 or 320 kg-mm{circumflex over ( )}2, and more preferably Ixx>350 kg-mm{circumflex over ( )}2, more preferably Ixx>375 kg-mm{circumflex over ( )}2, more preferably Ixx>385 kg-mm{circumflex over ( )}2, more preferably Ixx>400 kg-mm{circumflex over ( )}2, more preferably Ixx>415 kg-mm{circumflex over ( )}2, more preferably Ixx>430 kg-mm{circumflex over ( )}2, more preferably Ixx>450 kg-mm{circumflex over ( )}2, but no more than 590 kg·mm²in some examples), and preferably a ratio of Ixx/Izz>0.70. More details about inertia Izz and Ixx can be found in U.S. Patent Application Publication No. 2020/0139208, Published May 7, 2020, which is incorporate herein by reference in its entirety.

According to certain examples, a summation of Ixx and Izz is greater than 780 kg-mm{circumflex over ( )}2, 800 kg-mm{circumflex over ( )}2, 820 kg-mm{circumflex over ( )}2, 825 kg-mm{circumflex over ( )}2, 850 kg-mm{circumflex over ( )}2, 860 kg-mm{circumflex over ( )}2, 875 kg-mm{circumflex over ( )}2, 900 kg-mm{circumflex over ( )}2, 925 kg- mm{circumflex over ( )}2, 950 kg-mm{circumflex over ( )}2, 975 kg-mm{circumflex over ( )}2, or 1000 kg-mm{circumflex over ( )}2, but less than 1,100 kg-mm{circumflex over ( )}2. For example, the summation of Ixx and Izz can be between 740 kg-mm{circumflex over ( )}2and 1,100 kg-mm{circumflex over ( )}2, such as around 869 kg-mm{circumflex over ( )}2. Ixx is at least 65% of Izz in some examples, even more preferably Ixx is at least 68% of Izz in some examples. In some example, a golf club head mass may range from 190 grams to 210 grams, preferably between 195 grams and 205 grams, even more preferably no more than 203 grams. The golf club head mass includes the mass of any FCT system and fastener to tighten the FCT system, but not the shaft of the golf club head or the grip of the golf club head. A maximum distance from a leading edge to a trailing edge of the club head as measured parallel to the y-axis is preferably is between 112 mm and 127 mm, preferably between 115 mm and 127 mm, even more preferably between 119 mm and 127 mm.

The larger inertia values and lower CG projection e.g. no more than 3 mm above center face can be achieved by including a forward weight and a rearward weight as discussed in more detail below. The forward weight can be a single forward weight or two or more forward weights. The forward weight can be located proximate to an imaginary vertical plane passing through the y-axis, or the forward weight can be offset to either a toe or a heel side of the imaginary vertical plane passing through the y-axis or both a toe and a heel side of the imaginary vertical plane passing through the y-axis of the golf club head. The forward weight can be separately formed and threadedly attached, welded, or bonded to the golf club head, or the forward weight can be a thickened region of the golf club head or in some cases the forwarded weight could be molded or over-molded into a forward portion of a golf club head. See below and U.S. Pat. No. 10,220,270, issued Mar. 5, 2019, which is incorporated herein by reference in its entirety, for further discussion on the various locations of forward and rearward weights. A forward weight is forward of a center of gravity of the golf club head and a rearward weight is rearward of a center of gravity of the golf club head.

In some examples, the golf club heads described herein have a delta-1 value that is no more than 25 mm, preferably between 20 mm and 25 mm. The delta-1 of the driver-type golf club head is a distance, along the y-axis of the head center face origin coordinate system 185, between the CG of the golf club head and an XZ plane, passing through the x-axis and the z-axis of the head center face origin coordinate system 185 and passing through the hosel axis 191. In certain examples, the Ixx of the golf club head is at least 335 kg·mm²and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 345 kg·mm²and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 355 kg·mm²and the delta 1 is no more than 25 mm, the Ixx of the golf club head is at least 365 kg·mm²and the delta 1 is no more than 25 mm, or the Ixx of the golf club head is at least 375 kg·mm²and the delta 1 is no more than 25 mm.

In some examples, the golf club heads described herein have a delta-1 value that is between 20 mm and 35 mm. In certain examples, the Ixx of the golf club head is at least 335 kg·mm²and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 345 kg·mm²and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 355 kg·mm²and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 365 kg·mm²and the delta 1 is between 22 mm and 32 mm, the Ixx of the golf club head is at least 375 kg·mm²and the delta 1 is between 23 mm and 32 mm, the Ixx of the golf club head is at least 385 kg·mm²and the delta 1 is between 24 mm and 32 mm, the Ixx of the golf club head is at least 395 kg·mm²and the delta 1 is between 25 mm and 32 mm, or the Ixx of the golf club head is at least 405 kg·mm²and the delta 1 is between 27 mm and 32 mm.

Referring to FIGS. 1 and 2, according to some examples, the golf club head 100 of the present disclosure includes a toe portion 114 and a heel portion 116, opposite the toe portion 114. Additionally, the golf club head 100 includes a forward portion 112 (e.g., face portion) and a rearward portion 118, opposite the forward portion 112. The golf club head 100 additionally includes a sole portion 117, at a bottom region of the golf club head 100, and a crown portion 119, opposite the sole portion 117 and at a top region of the golf club head 100. Also, the golf club head 100 includes a skirt portion 121 that defines a transition region where the golf club head 100 transitions between the crown portion 119 and the sole portion 117. Accordingly, the skirt portion 121 is located between the crown portion 119 and the sole portion 117 and extends about a periphery of the golf club head 100. Referring to FIG. 9A, the golf club head 100 further includes an interior cavity 113 that is collectively defined and enclosed by the forward portion 112, the rearward portion 118, the crown portion 119, the sole portion 117, the heel portion 116, the toe portion 114, and the skirt portion 121.

The strike face 145 extends along the forward portion 112 from the sole portion 117 to the crown portion 119, and from the toe portion 114 to the heel portion 116. Moreover, the strike face 145, and at least a portion of an interior surface 166 of the forward portion 112, opposite the strike face 145, is planar in atop-to-bottom direction. As further defined, the strike face 145 faces in the generally forward direction. In some examples, the strike face 145 is co-formed with the body 102. In such examples, a minimum thickness of the forward portion 112 at the strike face 145 is between 1.5 mm and 2.5 mm and a maximum thickness of the forward portion 112 at the strike face 145 is less than 3.7 mm. An interior surface 166 of the forward portion 112, opposite the strike face 145, is not chemically etched and has an alpha case thickness of no more than 0.30 mm, in some examples.

Referring to FIGS. 9A, 9B, and 38-41, in some examples, the golf club head 100 includes a strike plate 143 that is not co-formed with the body 102. The strike plate 143 is formed separately from the body 102 and bonded to the body 102. As shown, the strike plate 143 defines the strike face 145 of the golf club head 100. In these examples, the body 102 includes a plate opening 149 at the forward portion 112 of the golf club head 100 and a plate-opening recessed ledge 147 that extends continuously about the plate opening 149. The plate opening recessed ledge 147 is non-planar or curved in some examples. An inner periphery of the plate-opening recessed ledge 147 defines the plate opening 149. The plate-opening recessed ledge 147 is divided into at least a top plate-opening recessed ledge 147A, that extends adjacently along the crown portion 119 of the golf club head 100 in a heel-to-toe direction, and a bottom plate-opening recessed ledge 147B, that extends adjacently along the sole portion 117 of the golf club head 100 in a heel-to-toe direction. Although not shown, the plate-opening recessed ledge is further divided into toe and heel plate-opening recessed ledges. Some properties of a plate-opening recessed ledge can be found in U.S. Pat. No. 9,278,267, issued Mar. 8, 2016, which is incorporated herein by reference in its entirety.

As shown in FIG. 9B, the top plate-opening recessed ledge 147A has a width (TPLW) and a thickness (TPLT). The width TPLW is defined as the distance from the inner periphery of the ledge 147A defining the plate opening 149 to the furthest extent of the adhering surface of the ledge 147A away from the inner periphery. The thickness TPLT is defined as the thickness of the material defining the adhering surface of the ledge 147A. In some examples, a recess 190 (e.g., an internal recess) is formed in an internal surface of the body 102 and has depth that extends in a back-to-front direction such that in a sole-to-crown direction, the recess 190 is between the top plate-opening recessed ledge 147A and a top of the golf club head 100. In other words, the recess 190 overlaps the top plate-opening recessed ledge 147A in a crown-to-sole direction. Notably, rearward of the recess 190 the thickness of the crown may increase locally such that the thickness of the crown portion proximate to where the crown insert joins the club head is thicker than at the recess 190. This may be done to stiffen the overall structure of the crown joint and mitigate stress in the composite crown joint.

Referring to FIGS. 30-32, in some examples, the golf club head 100 further includes an interior mass pad 129 formed in the crown portion 119 at a location adjacent a top plate-opening recessed ledge 147A. The interior mass pad 129 is also located between and offset (e.g., spaced apart) from the heel portion 116 and the toe portion 114 of the golf club head 100. A portion of the recess 190 is formed in the interior mass pad 129 in some examples. The interior mass pad 129 extends along only a portion of a length of the top plate-opening recessed ledge 147A. The length of the top plate-opening recessed ledge 147A extends in a heel-to-toe direction. Moreover, in some examples, the top plate-opening recessed ledge 147A is non-planar or curved. According to some examples, a thickness (WT) of the crown portion at the recess 190 is thicker at the interior mass pad 129 (see, e.g., FIG. 31) than away from the interior mass pad 129 (see, e.g., FIG. 32).

In certain examples, the width TPLW of the top plate-opening recessed ledge 147A is greater than 4.5 mm (e.g., greater than 5.0 mm in some examples and greater than 5.5 mm in other examples, but less than 8.0 mm, preferably less than 7.0 mm in some examples). In some examples, a ratio of the width TPLW to a maximum height of the strike plate 143 is between 0.08 and 0.15. In the same or different examples, a ratio of the width TPLW to a maximum height of the plate opening 149 is between 0.07 and 0.15, such as 0.1, where in some examples the maximum height of the plate opening 149 is between 50-60 mm, such as 53 mm.

According to some examples, the thickness TPLT of the top plate-opening recessed ledge 147A is between a minimum value of 0.8 mm and a maximum value of 1.7 mm (e.g., between 0.9 mm and 1.6 mm in some examples and between 0.95 mm and 1.5 mm in other examples). As shown, the thickness TPLT is greater away from the inner periphery of the ledge 147A than at the inner periphery of the ledge 147A. Accordingly, the thickness TPLT varies along the width TPLW of the ledge 147A in some examples. For example, as shown, the thickness TPLT tapers or decreases in a crown-to-sole direction (e.g., toward a center of the plate opening 149). In some examples, the top ledge thickness TPLT of the top plate-opening recessed ledge 147A varies such that a maximum value of the top ledge thickness TPLT is between 30% and 60% greater than a minimum value of the top ledge thickness TPLT. In certain examples, a ratio of the thickness TPLT to a thickness of the strike plate is between 0.2 and 1.2. According to certain examples, a ratio of the width TPLW to the thickness TPLT is between 2.6 and 10.

The bottom plate-opening recessed ledge 147B has a width (BPLW) and a thickness (BPLT). The width BPLW is defined as the distance from the inner periphery of the ledge 147B defining the plate opening 149 to the furthest extent of the adhering surface of the ledge 147B away from the inner periphery. The thickness BPLT is defined as the thickness of the material defining the adhering surface of the ledge 147B.

In certain examples, the width BPLW of the bottom plate-opening recessed ledge 147B is greater than 4.5 mm (e.g., greater than 5.0 mm in some examples and greater than 5.5 mm in other examples, but less than 8.0 mm, preferably less than 7.0 mm in some examples). In some examples, a ratio of the width BPLW to a maximum height of the strike plate 143 is between 0.08 and 0.15. In the same or different examples, a ratio of the width BPLW to a maximum height of the plate opening 149 is between 0.07 and 0.15, such as 0.1, where in some examples the maximum height of the plate opening 149 is between 50-60 mm, such as 53 mm.

According to some examples, the thickness BPLT of the bottom plate-opening recessed ledge 147B is between 0.8 mm and 1.7 mm (e.g., between 0.9 mm and 1.6 mm in some examples and between 0.95 mm and 1.5 mm in other examples). As shown, the thickness BPLT is greater away from the inner periphery of the ledge 147B than at the inner periphery of the ledge 147B. Accordingly, the thickness BPLT varies along the width BPLW of the ledge 147B in some examples. For example, as shown, the thickness BPLT decreases in a sole-to-crown direction (e.g., toward a center of the plate opening 149). In some examples, the bottom ledge thickness BPLT of the bottom plate-opening recessed ledge 147B varies such that a maximum value of the bottom ledge thickness BPLT is between 30% and 60% greater than a minimum value of the bottom ledge thickness BPLT. In certain examples, a ratio of the thickness BPLT to a thickness of the strike plate is between 0.2 and 1.2. According to certain examples, a ratio of the width BPLW to the thickness BPLT is between 2.6 and 10.

As shown, the strike plate 143 is attached to the body 102 by fixing the strike plate 143 in seated engagement with at least the top plate-opening recessed ledge 147A and the bottom plate-opening recessed ledge 147B. When joined to the top plate-opening recessed ledge 147A and the bottom plate-opening recessed ledge 147B in this manner, the strike plate 143 covers or encloses the plate opening 149. Moreover, in some examples, the top plate-opening recessed ledge 147A and the strike plate 143 are sized, shaped, and positioned relative to the crown portion 119 of the golf club head 100 such that the strike plate 143 abuts the crown portion 119 when seatably engaged with the top plate-opening recessed ledge 147A. The strike plate 143, abutting the crown portion 119, defines a topline of the golf club head 100. Moreover, in some examples, the visible appearance of the strike plate 143 contrasts enough with that of the crown portion 119 of the golf club head 100 that the topline of the golf club head 100 is visibly enhanced. Because the strike plate 143 is formed separately from the body 102, the strike plate 143 can be made of a material that is different than that of the body 102. In one example, the strike plate 143 is made of a fiber-reinforced polymeric material, such as described hereafter.

Notably, the TPLW, TPLT, BPLW, and BPLT dimensions help to control the local stiffness of the club head and to ensure sufficient bonding area to bond the strike plate to the body 102. The modulus of the strike plate if formed from a fiber-reinforced polymeric material will be much different than the modulus of the body if formed from a metal material such that the stiffness or compliance of the two are different, and during impact the strike plate and the body will move at different rates due to the different moduli unless precautions are taken in the design to account for the stiffness differences. The recess 190, and the TPLW, TPLT, BPLW, and BPLT dimensions, all play a role in controlling the overall compliance and rate with which the face and body move during impact. Additionally, TPLW and BPLW contribute to ensuring sufficient bond area and face performance. Too little bond area and the bonded joint will fail, too much bond area and the face will not perform i.e. the coefficient of restitution will not be optimized, and in some examples too much bond area will result in the face peeling away from the club head due to the differences in stiffness. Thus, TPLW, TPLT, BPLW, and BPLT dimensions contribute to the overall performance of the club head and to the avoidance of bonded joint failure. In some examples, the bond area will range from 850 mm²to 1800 mm², preferably between 1,300 mm²to 1,500 mm². In some examples, a ratio of the bond area to the inner surface area of the strike plate (rear surface area of the strike plate) will range from 21% to 45%. In some examples, a total bond area of the strike plate will be less than a total bond area of the crown insert. In some examples, a ledge width TPLW and/or BPLW will be less than a ledge width of the forward crown-opening recessed ledge 168A (front-back as measured along the y-axis).

The forward portion 112 includes a sidewall 146 that defines a depth of the plate-opening recessed ledge 147 and defines a radially outer periphery of the plate-opening recessed ledge 147 away from a center of the plate opening 149. The sidewall 146 is angled (e.g., acute, obtuse, or perpendicular) relative to the plate-opening recessed ledge 147. In some examples, the angle defined between the sidewall 146 and the plate-opening recessed ledge 147 is between 70° and 120°. In certain examples, the angle defined between the sidewall 146 and the plate-opening recessed ledge 147 is greater than 90°. The body 102 further includes a transition portion between the plate-opening recessed ledge 147 and the sidewall 146. In some examples, the transition portion defines a radiused surface, which couples together the surfaces of the plate-opening recessed ledge 147 and the sidewall 146.

Referring to FIGS. 9A, 9B, and 31, bonding tape 174 adhesively bonds the strike plate 143 to the body 102. In some examples, the bonding tape 174 is interposed between the plate-opening recessed ledge 147 and the strike plate 143 and interposed between the sidewall 146 and the strike plate 143. For example, a strike-plate ledge strip 176A of the bonding tape 174 is between the plate-opening recessed ledge 147 and the strike plate 143, and a strike-plate sidewall strip 176B of the bonding tape 174 is interposed between the sidewall 146 and the strike plate 143. However, in other examples, the strike-plate ledge strip 176A of the bonding tape 174 is interposed between the plate-opening recessed ledge 147 and the strike plate 143, but the strike-plate sidewall strip 176B of the bonding tape 174 is not interposed between the sidewall 146 and the strike plate 143. Referring to FIG. 31, a thickness (LT) of the strike-plate ledge strip 176A between the plate-opening recessed ledge 147 and the strike plate 143 is greater than a thickness (ST) of the strike-plate sidewall strip 176B between the sidewall 146 and the strike plate 143, in some examples. According to one particular example, the thickness (LT) of the strike-plate ledge strip 176A between the plate-opening recessed ledge 147 and the strike plate 143 is between 0.25 mm and 0.45 mm, and the thickness (ST) of the strike-plate sidewall strip 176B between the sidewall 146 and the strike plate 143 is between 0.15 mm and 0.25 mm. The thickness of the bonding tape 174 of a fully formed golf club head 100 (e.g., after the bonding tape 174 has been compressed and cured (i.e., thermally activated)) can be different than the thickness of the bonding tape 174 prior to fully forming the golf club head 100 (e.g., prior to the bonding tape 174 being compressed and cured). The above-presented values for the thickness of the bonding tape 174 is prior to compressing and curing the bonding tape 174.

In some examples, the strike plate may have a maximum face plate height of no more than 55 mm as measured along the z-axis through the club head origin, preferably no more than 55 mm and no less than 40 mm, even more preferably between 49 mm and 54 mm. In some instance, the strike plate formed of fiber-reinforced polymeric material may have a front surface area of no more than 4,180 mm², and preferably between 3,200 mm²and 4,180 mm², more preferably between 3,500 mm²and 4,180 mm². According to certain examples, the strike face 145 has a first bulge radius of at least 300 mm and a first roll radius of at least 250 mm. Generally, a bulge radius greater than 300 mm has a better CT creep rate and club heads with a bulge no less 300 mm bulge radius and a roll radius within 30-50 mm of the bulge radius performed well.

The golf club head 100 includes a body 102, a crown insert 108 (or crown panel) attached to the body 102 at a top of the golf club head 100, and a sole insert 110 (or sole panel) attached to the body 102 at a bottom of the golf club head 100 (see, e.g. FIGS. 10 and 11). Accordingly, the body 102 effectually provides a frame to which one or more inserts, panels, or plates are attached. The body 102 includes a cup 104 and a ring 106 (e.g., a rear ring). The ring 106 is joined to the cup 104 at a toe-side joint 112A and a heel-side joint 112B. The cup 104 defines at least part of the forward portion 112 of the golf club head 100. The ring 106 defines at least part of the rearward portion 118 of the golf club head 100. Additionally, the cup 104 defines part of the crown portion 119, the sole portion 117, the heel portion 116, the toe portion 114, and the skirt portion 121. Similarly, the ring 106 defines part of the heel portion 116, the toe portion 114, and the skirt portion 121.

The cup 104 is cup-shaped, and is often also referred to as a collar. More specifically, as shown in FIG. 14, the cup 104, including the strike face 145, is enclosed on one end by the strike face 145, enclosed on four sides (e.g., by the crown portion 119, the sole portion 117, the toe portion 114, and the heel portion 116), which extend substantially transversely from the strike face 145, and open on an end opposite the strike face 145. Accordingly, the cup 104, when coupled with the strike face 145, resembles a cup or a cup-like unit.

The ring 106 is not circumferentially closed or does not form a continuous annular or circular shape. Instead, the ring 106 is circumferentially open and defines a substantially semi-circular shape. Thus, as defined herein, the ring 106 is termed a ring because it has a ring-like, semi-circular shape, and, when joined to the cup 104, forms a circumferentially closed or annular shape with the cup 104.

The cup 104 is formed separately from the ring 106 and the ring 106 is subsequently joined to the cup 104. Accordingly, the body 102 has at least a two-piece construction where the cup 104 defines one piece of the body 102 and the ring 106 define another piece of the body 102. Accordingly, a seam is defined at each of the toe-side joint 112A and the heel-side joint 112B where the cup 104 and the ring 106 are adjoined. The cup 104 and the ring 106 are separately formed using any of various manufacturing techniques. In one example, the cup 104 and the ring 106 are formed using a casting process. Because the cup 104 and the ring 106 are formed separately, the cup 104 and the ring 106 can be made of different materials. For example, the cup 104 can be made of a first material and the ring 106 can be made of a second material where the second material is different than the first material.

Referring to FIGS. 14 and 15, the cup 104 includes a toe ring-engagement surface 150A and a heel ring-engagement surface 150B. Similarly, the ring 106 includes a toe cup-engagement surface 152A and a heel cup-engagement surface 152B. The toe-side joint 112A is formed by abutting and securing together the toe ring-engagement surface 150A of the cup 104 and the toe cup-engagement surface 152A of the ring 106 and abutting and securing together the heel ring-engagement surface 150B of the cup 104 and the heel cup-engagement surface 152B of the ring 106. The engagement surfaces are secured together via any suitable securing techniques, such as welding, brazing, adhesives, mechanical fasteners, and the like. In the illustrated example, as shown in FIGS. 9A, 14, and 15, the engagement surfaces are bonded together via the bonding tape 174.

To help strengthen and stiffen the toe-side joint 112A and the heel-side joint 112B, complementary mating elements can be incorporated into or coupled to the engagement surfaces. In the illustrated example, the cup 104 includes a toe projection 154A protruding from the toe ring-engagement surface 150A and a heel projection 154B protruding from the heel ring-engagement surface 150B. In contrast, in the illustrated example, the ring 106 includes a toe receptacle 156A formed in the toe cup-engagement surface 152A and a heel receptacle 156B formed in the heel cup-engagement surface 152B. The toe projection 154A mates with (e.g., is received within) the toe receptacle 156A and the heel projection 154B mates with (e.g., is received within) the heel receptacle 156B as the engagement surfaces abut each other to form the joints. Although in the illustrated example, the toe projection 154A and the heel projection 154B form part of the cup 104 and the toe receptacle and the heel receptacle 156B form part of the ring 106, in other examples, the mating elements can be reversed such that the toe projection 154A and the heel projection 154B form part of the ring 106 and the toe receptacle and the heel receptacle 156B form part of the cup 104. Additionally, different types of complementary mating elements, such as tabs and notches, can be used in addition to or in place of the projections and receptacles.

In some examples, the toe-side joint 112A and the heel-side joint 112B are located a sufficient distance from the strike face 145 to avoid potential failures due to severe impacts undergone by the golf club head 100 when striking a golf ball. For example, each one of the toe-side joint 112A and the heel-side joint 112B can be spaced at least 20 mm, at least 30 mm, at least 40 mm, at least 50 mm, at least 60 mm, and/or from 20 mm to 70 mm rearward of the center face 183 of the strike face 145, as measured along a y-axis (front-to-back direction) of the club head origin coordinate system 185. Referring to FIG. 14, according to certain examples, a first distance D1, from the strike face 145 to the heel ring-engagement surface 150B, is less than a second distance D2, from the strike face 145 to the toe ring-engagement surface 150A. In other words, in some examples, the cup 104 extends rearwardly from the strike face 145 a shorter distance at the heel portion 116 than at the toe portion 114.

Referring to FIGS. 10-13, the body 102 comprises a crown opening 162 and a sole opening 164. The crown opening 162 is located at the crown portion 119 of the golf club head 100 and when open provides access into the interior cavity 113 of the golf club head 100 from a top of the golf club head 100. In contrast, the sole opening 164 is located at the sole portion 117 of the golf club head 100 and when open provides access into the interior cavity 113 of the golf club head 100 from a bottom of the golf club head 100. Corresponding sections of the crown opening 162 and the sole opening 164 are defined by the cup 104 and the ring 106. More specifically, referring to FIGS. 10-15, a forward section 162A of the crown opening 162 and a forward section 164A of the sole opening 164 are defined by the cup 104, and a rearward section 162B of the crown opening 162 and a rearward section 164B of the sole opening 164 are defined by the ring 106. Accordingly, when the cup 104 and the ring 106 are joined together, the forward section 162A and the rearward section 162B collectively define the crown opening 162, and the forward section 164A and the rearward section 164B collectively define the sole opening 164.

The cup 104 additionally includes a forward crown-opening recessed ledge 168A and a forward sole-opening recessed ledge 170A. The ring 106 includes a rearward crown-opening recessed ledge 168B and a rearward sole-opening recessed ledge 170B. The forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B form a sole-opening recessed ledge 170 of the golf club head 100. Moreover, in some examples, the sole-opening recessed ledge 170 is non-planar or curved. The ledges are offset inwardly, toward the interior cavity 113, from the exterior surfaces of the body 102 surrounding the ledges by distances corresponding with the thicknesses of the crown insert 108 and the sole insert 110. In some examples, the offset of the ledges from the exterior surfaces of the body 102 is approximately equal to the corresponding thicknesses of the crown insert 108 and the sole insert 110, such that the inserts are flush with the corresponding surrounding exterior surfaces of the body 102 when attached to the ledges. However, in some examples, the crown insert 108 and the sole insert 110 need not be flush with (e.g., can be raised or recessed relative to) the surrounding exterior surface of the body 102 when seatably engaged with the corresponding ledges. In some examples, a thickness of the sole insert 110 is greater than a thickness of the crown insert 108. Moreover, the sole insert 110 is made up of a first quantity of stacked plies, each made of a fiber-reinforced polymeric material, and the crown insert 108 is made up of a second quantity of stacked plies, each made of a fiber-reinforced polymeric material. In some examples, the first quantity of stacked plies is greater than the second quantity of stacked plies.

When the cup 104 and the ring 106 are joined, the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B collectively define a crown-opening recessed ledge 168 of the body 102, and the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B collectively define a sole-opening recessed ledge 170 of the body 102. The inner periphery of the forward crown-opening recessed ledge 168A defines the forward section 162A of the crown opening 162 and the inner periphery of the rearward crown-opening recessed ledge 168B defines the rearward section 162B of the crown opening 162. Likewise, the inner periphery of the forward sole-opening recessed ledge 170A defines the periphery of the forward section 164A of the sole opening 164 and the inner periphery of the rearward sole-opening recessed ledge 170B defines the periphery of the rearward section 164B of the sole opening 164. Accordingly, the inner periphery of the crown-opening recessed ledge 168 defines the periphery of the crown opening 162 and the inner periphery of the sole-opening recessed ledge 170 defines the periphery of the sole opening 164.

Referring to FIG. 31, a thickness of the body 102 at the crown portion 119 decreases in a rearward-to-forward direction from a forward extent 132 of the crown-opening recessed ledge 168, and decreases in a forward-to-rearward direction from the forward extent 132 of the crown-opening recessed ledge 168. This results in a localized increase in thickness at the forward extent 132, which helps to strengthen and stiffen the joint between the body 102 and the crown insert 108.

The crown insert 108 and the sole insert 110 are formed separately from each other and separately from the body 102. Accordingly, the crown insert 108 and the sole insert 110 are attached to the body 102 as shown in FIGS. 10 and 11. In the illustrated examples, the crown insert 108 is seated on and bonded to, such as with the bonding tape 174, the crown-opening recessed ledge 168. For example, a crown-insert strip 178 of the bonding tape 174 is between the crown-opening recessed ledge 168 and the crown insert 108. Furthermore, in the illustrated examples, the sole insert 110 is seated on and bonded to, such as with the bonding tape 174, the sole-opening recessed ledge 170. For example, a sole-insert strip 180 of the bonding tape 174 is between the sole-opening recessed ledge 170 and the sole insert 110. In this manner, the crown insert 108 encloses or covers the crown opening 162 and defines, at least in part, the crown portion 119 of the golf club head 100, and the sole insert 110 encloses or covers the sole opening 164 and defines, at least in part, the sole portion 117 of the golf club head 100.

The crown insert 108 and the sole insert 110 can have any of various shapes. Referring to FIG. 4, in one example, the crown insert 108 is shaped such that a location (PCH), corresponding with the peak crown height of the golf club head 100, is rearward of a hosel 120 of the golf club head 100 and rearward of the hosel axis 191 of the hosel 120 of the golf club head 100. The peak crown height is the maximum crown height of a golf club head where the crown height at a given location along the golf club head is the distance from the ground plane 181, when the golf club head is in the address position on the ground plane, to an uppermost point on the crown portion at the given location. In some examples, the crown height of the golf club head 100 increases and then decreases in a front-to-rear direction away from the strike face 145. In certain examples, the portion or exterior surface of the crown portion that defines the peak crown height is made of the at least one first material. According to some examples, a first crown height is defined at a face-to-crown transition region in the forward crown area where the club face connects to the crown portion of the club head, a second crown height is defined at a crown-to-skirt transition region where the crown portion connects to a skirt of the golf club head near a rear end of the golf club head, and a maximum crown height is defined rearward of the first crown height and forward of the second crown height, where the maximum crown height is greater than both the first and second crown heights. In some examples, the maximum crown height occurs toeward of a geometric center of the strike face. According to certain examples, the maximum crown height is formed by a non-metal composite crown insert.

Referring to FIG. 3, a peak skirt height (shown associated with a location (PSH)) is the maximum skirt height of a golf club head, where the skirt height at a given location along the golf club head is the distance from the ground plane, when the golf club head is in the address position on the ground plane, to an uppermost point on the skirt portion at the rearwardmost point of the skirt portion on the golf club head.

According to some examples, a ratio of a peak crown height of the crown portion 119 to a peak skirt height of the skirt portion 121 ranges between about 0.45 to 0.59, preferably 0.49-0.55, and in one example the skirt height is about 34 mm and the peak crown height is about 65 mm, which results in a ratio of peak skirt height to peak crown height of about 0.52. A peak skirt height typically ranges between 28 mm and 38 mm, preferably between 31 mm and 36 mm. A peak crown height typically ranges between 60 mm and 70 mm, preferably between 62 mm and 67 mm. It is desirable to limit a difference between the peak crown height and the peak skirt height to no more than 40 mm, preferably between 27 mm and 35 mm. It is desirable for the peak skirt height to be the same as or greater than a Z-up value for the golf club head i.e. the vertical distance along a z-axis from the ground plane 181 to the center of gravity. It is desirable for the peak crown height to be two times (2×) larger than a Z-up value for the golf club head. A greater peak skirt height may help with better aerodynamics and better air flow attachment especially for faster swing speeds. Likewise, if the difference between the peak crown height and peak skirt height is too great there will be a greater likelihood of the flow separating early from the golf club head i.e. increased likelihood of turbulent flow.

The construction and material diversity of the golf club head 100 enables the golf club head 100 to have a desirable center-of-gravity (CG) location and peak crown height location. In one example, a y-axis coordinate, on the y-axis of the club head origin coordinate system 185, of the location (PCH) of the peak crown height is between about 26 mm and about 42 mm. In the same or a different example, a distance parallel to the z-axis of the club head origin coordinate system 185, from the ground plane 181, when the golf club head 100 is in the address position, of the location (PCH) of the peak crown height ranges between 60 mm and 70 mm, preferably between 62 mm and 67 mm as described above. According to some examples, a y-axis coordinate, on the y-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 ranges between 25 mm and 50 mm, preferably between 32 mm and 38 mm, more preferably between 36.5 mm and 42 mm, an x-axis coordinate, on the x-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 ranges between −10 mm and 10 mm, preferably between −6 mm and 6 mm, and more preferably between −7 mm and 7 mm, and a z-axis coordinate, on the z-axis of the head origin coordinate system 185, of the center-of-gravity (CG) of the golf club head 100 is less than 2 mm, such as ranges between −10 mm and 2 mm, preferably between −7 mm and −2 mm.

Additionally, the construction and material diversity of the golf club head 100 enables the golf club head 100 to have desirable mass distribution properties. Referring to FIGS. 3, 5, and 6, the golf club head 100 includes a rearward mass and a forward mass. The rearward mass of the golf club head 100 is defined as the mass of the golf club head 100 within an imaginary rearward box 133 having a height (HRB), parallel to a crown-to-sole direction (parallel to z-axis of golf club head origin coordinate system 185), of 35 mm, a depth (DRB), in a front-to-rear direction (parallel to y-axis of golf club head origin coordinate system 185), of 35 mm, and a width (WRB), in a toe-to-heel direction (parallel to x-axis of golf club head origin coordinate system 185), greater than a maximum width of the golf club head 100. As shown, a rear side of the imaginary rearward box 133 is coextensive with a rearmost end of the golf club head 100 and a bottom side of the imaginary rearward box 133 is coextensive with the ground plane 181 when the golf club head 100 is in the address position on the ground plane 181. The forward mass of the golf club head 100 is defined as the mass of the golf club head 100 within an imaginary forward box 135 having a height (HFB), parallel to the crown-to-sole direction, of 20 mm, a depth (DFB), in the front-to-rear direction, of 35 mm, and a width (WFB), in the toe-to-heel direction, greater than a maximum width of the golf club head 100. As shown, a forward side of the imaginary forward box 135 is coextensive with a forwardmost end of the golf club head 100 and a bottom side of the imaginary forward box 135 is coextensive with the ground plane 181 when the golf club head 100 is in the address position on the ground plane 181.

According to some examples, a first vector distance (V1) from a center-of-gravity of the rearward mass (RMCG) to a CG of the driver-type golf club head is between 49 mm and 64 mm (e.g., 55.7 mm), a second vector distance (V2) from a center-of-gravity of the forward mass (FMCG) to the CG of the driver-type golf club head is between 22 mm and 34 mm (e.g., 29.0 mm), and a third vector distance (V3) from the CG of the rearward mass (RMCG) to the CG of the forward mass (FMCG) is between 75 mm and 82 mm (e.g., 79.75 mm). In certain examples, V1 is no more than 56.3 mm. In some examples, V2 is no less than 23.7 mm, preferably no less than 25 mm, or even more preferably no less than 27 mm. Some additional values of V1 and V2 relative to Zup and CGy values for various examples of the golf club head 100 are provided in Table 1 below. As defined herein, Zup measures the center-of-gravity of the golf club head 100 relative to the ground plane 181 along a vertical axis (e.g., parallel to the z-axis of the club head origin coordinate system 185) when the golf club head 100 is in the proper address position on the ground plane 181. CGy is the coordinate of the center-of-gravity of the golf club head 100 on the y-axis of the club head origin coordinate system 185.

TABLE 1

Example
Zup
CGy
V1
V2

1
26 mm
37 mm
55.7 mm
29.0 mm

2
30 mm
37 mm
56.3 mm
31.8 mm

3
22 mm
37 mm
55.2 mm
27.3 mm

4
25 mm
32 mm
61.0 mm
23.7 mm

5
25 mm
40 mm
52.7 mm
30.76 mm

In one embodiment Zup is less than V2, and in a further embodiment Zup is at least 5% less than V2, and at least 7.5% or 10% less in additional embodiments. CGy is greater than V2 but less than 75% of V1 in another embodiment, while in another embodiment CGy is at least 10% greater than V2 but less than 70% of V1. In another embodiment CGy is at least 60% greater than Zup, Zup is no more than 50% of V1, and CGy is less than 140% of V2.

The crown insert 108 has a crown-insert outer surface that defines an outward-facing surface or exterior surface of the crown portion 119. Similarly, the sole insert 110 has a sole-insert outer surface that defines an outward-facing surface or exterior surface of the sole portion 117. As defined herein, the crown-insert outer surface and the sole-inert outer surface includes the combined outer surfaces of multiple crown inserts and multiple sole inserts, respectively, if multiple crown inserts or multiple sole inserts are used. In one example, a total surface area of the sole-insert outer surface is smaller than a total surface area of the crown-insert outer surface. According to one example, the total surface area of the crown-insert outer surface is at least 9,482 mm². In one example, the total surface area of the sole-insert outer surface is at least 8,750 mm²and the sole insert has a maximum width, parallel to a heel-to-toe direction, of at least between 80 mm and 120 mm. The total surface area of the crown-insert outer surface can range between 5,300 mm{circumflex over ( )}2 to 11,000 mm{circumflex over ( )}2, preferably between 9,200 mm{circumflex over ( )}2and 10,300 mm{circumflex over ( )}2, preferably between 5,300 mm{circumflex over ( )}2and 7,000 mm{circumflex over ( )}2. The total surface area of the sole-insert outer surface can range between 4,300 mm{circumflex over ( )}2 to 10,200 mm{circumflex over ( )}2, preferably between 7,700 mm{circumflex over ( )}2and 9,900 mm{circumflex over ( )}2, preferably between 4,300 mm{circumflex over ( )}2and 6,600 mm{circumflex over ( )}2.

Preferably the total surface area of the sole-insert outer surface is greater than the total surface area of the sole-insert outer surface in the instance when at least a portion of the sole is formed of a composite material. A ratio of total surface area of the crown-insert outer surface formed of composite material to the total surface area of the sole-insert outer surface formed of composite material may be at least 2:1 in some examples, in other instance the ratio may be between 0.95 and 1.5, more preferably between 1.03 and 1.4, even more preferably between 1.05 and 1.3. In this instance a composite material will generally have a density between about 1 g/cc and about 2 g/cc, and preferably between about 1.3 g/cc and about 1.7 g/cc.

In some embodiments, the total exposed composite surface area in square centimeters multiplied by the CGy in centimeters and the resultant divided by the volume in cubic centimeters may range from 1.22 to 2.1, preferably between 1.24 and 1.65, even more preferably between 1.49 and 2.1, and even more preferably 1.7 and 2.1.

Moreover, the total mass of the crown insert 108 is less than a total mass of the sole insert 110 in some examples. According to some examples, where the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material and the body 102 is made of a metallic material, a ratio of a total exposed surface area of the body 102 to a total exposed surface area (e.g., the surface area of the outward-facing surfaces) of the crown insert 108 and the sole insert 110 is between 0.95 and 1.25 (e.g., 1.08). The crown insert 108, whether a single piece or split into multiple pieces, has a mass of 9 grams and the sole insert 110, whether a single piece or split into multiple pieces, has a mass of 13 grams, in some examples. Moreover, in certain examples, the crown insert 108 is about 0.65 mm thick and the sole insert 110 is about 1.0 mm thick. However, in certain examples, the minimum thickness of the crown portion 119 is less than 0.6 mm. According to some examples, an areal weight of the crown portion 119 of the golf club head 100 is less than 0.35 g/cm²over more than 50% of an entire surface area of the crown portion 119 and/or at least part of the crown portion 119 is formed of a non-metal material with a density between about 1 g/cm³to about 2 g/cm³. These and other properties of the crown insert 108 and the sole insert 110 can be found in U.S. Patent Application Publication No. 2020/0121994, published Apr. 23, 2020, which is incorporated herein by reference in its entirety. In certain examples, an areal weight of the sole portion 117 is less than about 0.35 g/cm²over more than about 50% of an entire surface area of the sole portion 117. In certain examples, an areal weight of the crown insert 108 is less than an areal weight of the sole insert 110. At least 50% of the crown portion 119 has a variable thickness that changes at least 25% along at least 50% of the crown portion 119, in certain examples.

The cup 104 of the body 102 also includes the hosel 120, which defines the hosel axis 191 extending coaxially through a bore 193 of the hosel 120 (see, e.g., FIG. 14). The hosel 120 is configured to be attached to a shaft of a golf club. In some examples, the hosel 120 facilitates the inclusion of a flight control technology (FCT) system 123 between the hosel 120 and the shaft to control the positioning of the golf club head 100 relative to the shaft.

The FCT system 123 may include a fastener 125 that is accessible through a lower opening 195 formed in a sole region of the cup 104. An additional example of the FCT system 123 is shown in association with the golf club head 400 of FIGS. 19 and 20, which has a hosel 420 and a lower opening 495 to facilitate attachment of the FCT system 123 to the body 102. The FCT system 123 includes multiple movable parts that fit within the and extend from the hosel 120. The fastener 125 facilitates adjustability of the FCT system 123 system by loosening the fastener 125 and maintaining an adjustable position of the golf club head relative to the shaft by tightening the fastener 125. The lower opening 195 is open to the bore 193 of the hosel 120. To promote an increase in discretionary mass, an internal portion 127 of the hosel 120 (i.e., a portion of the hosel 120 that is within the interior cavity 113) includes a lateral opening 189 that is open to the interior cavity 113. Because of the lateral opening 189, the internal portion 127 of the hosel 120 only partially surrounds FCT components extending through the bore 193 of the hosel 120. In some examples a height of the lateral opening 189, in a direction parallel to the hosel axis 191, is between 10 mm and 15 mm, a width of the lateral opening 189, in a direction perpendicular to the hosel axis 191, is at least 1 radian, and/or a projected area of the lateral opening 189 is at least 75 mm².

Referring to FIG. 15, in some examples, the cup 104 includes the strike face 145. In other words, in some examples, the strike face 145 is co-formed (e.g., co-cast) with all other portions of the cup 104. Accordingly, in these examples, the strike face 145 is made of the same material as the rest of the cup 104. However, in other examples, similar to those associated with the golf club heads of FIGS. 9A, 9B, 17 and 18, the strike face 145 is defined by a strike plate that is formed separate from the cup 104 and separately attached to the cup 104. According to certain examples, the portion of the golf club head 100 defining the strike face 145 or the strike plate defining the strike face 145 includes variable thickness features similar to those described in more detail in U.S. patent application Ser. No. 12/006,060; and U.S. Pat. Nos. 6,997,820; 6,800,038; and 6,824,475, which are incorporated herein by reference in their entirety.

FIG. 21 illustrates an exemplary rear surface of a face portion 600 of one or more of the golf club heads disclosed herein. In FIG. 21, the rear surface is viewed from the rear with the hosel/heel to the left and the toe to the right. FIGS. 22 and 23 illustrate another exemplary face portion 700 having a variable thickness profile, and FIG. 24 illustrates yet another exemplary face portion 800 having a variable thickness profile. The variable thickness profile of the face portion 700 is formed by a cone-shaped projection, which can have a geometric center that is toeward of a geometric center of the strike face in some examples. The face portions disclosed herein can be formed as a result of a casting process and optional post-casting modifications to the face portions. Accordingly, the face portion can have a great variety of novel thickness profiles. For example, in one examples, a thickness of the forward portion, at the strike face, changes at least 25% along the strike face. By casting the face into a desired geometry, rather than forming the face plate from a flat rolled sheet of metal in a traditional process, the face can be created with greater variety of geometries and can have different material properties, such as different grain direction and chemical impurity content, which can provide advantages for a golf performance and manufacturing.

In a traditional process, the face plate is formed from a flat sheet of metal having a uniform thickness. Such a sheet of metal is typically rolled along one axis to reduce the thickness to a certain uniform thickness across the sheet. This rolling process can impart a grain direction in the sheet that creates a different material properties in the rolling axis direction compared to the direction perpendicular to the rolling direction. This variation in material properties can be undesirable and can be avoided by using the disclosed casting methods instead to create face portion.

Furthermore, because a conventional face plate starts off as a flat sheet of uniform thickness, the thickness of the whole sheet has to be at least as great as the maximum thickness of the desired end product face plate, meaning much of the starting sheet material has to be removed and wasted, increasing material cost. By contrast, in the disclosed casting methods, the face portion is initially formed much closer to the final shape and mass, and much less material has to be removed and wasted. This saves time and cost.

Still further, in a conventional process, the initial flat sheet of metal has to be bent in a special process to impart a desired bulge and roll curvature to the face plate. Such a bending process is not needed when using the disclosed casting methods.

The unique thickness profiles illustrated in FIGS. 22-25 are made possible using casting methods, such as those disclosed in U.S. Pat. No. 10,874,915 issued Dec. 29, 2020, which is incorporated by reference in its entirety, and were previously not possible to achieve using conventional processes, such as starting from a sheet of metal having a uniform thickness, mounting the sheet in a lathe or similar machine and turning the sheet to produce a variable thickness profile across the rear of the face plate. In such a turning process, the imparted thickness profile must be symmetrical about the central turning axis, which limits the thickness profile to a composition of concentric circular ring shapes each having a uniform thickness at any given radius from the center point. In contrast, no such limitations are imposed using the disclosed casting methods, and more complex face geometries can be created.

By using casting methods, large numbers of the disclosed club heads can be manufacture faster and more efficiently. For example, 50 or more heads can be cast at the same time on a single casting tree, whereas it would take much longer and require more resources to create the novel face thickness profiles on face plates using a conventional milling methods using a lathe, one at a time.

In FIG. 22, the rear face surface or interior surface of the face portion 600 includes a non-symmetrical variable thickness profile, illustrating just one example of the wide variety of variable thickness profiles made possible using the disclosed casting methods. The center 602 of the face can have a center thickness, and the face thickness can gradually increase moving radially outwardly from the center across an inner blend zone 603 to a maximum thickness ring 604, which can be circular. The face thickness can gradually decrease moving radially outwardly from the maximum thickness ring 604 across an variable blend zone 606 to a second ring 608, which can be non-circular, such as elliptical. The face thickness can gradually decrease moving radially outwardly from the second ring 608 across an outer blend zone 609 to heel and toe zones 610 of constant thicknesses (e.g., minimum thickness of the face portion) and/or to a radial perimeter zone 612 defining the extent of the face portion 600 where the face transitions to the rest of the golf club head 100.

The second ring 608 can itself have a variable thickness profile, such that the thickness of the second ring 608 varies as a function of the circumferential position around the center 602. Similarly, the variable blend zone 606 can have a thickness profile that varies as a function of the circumferential position around the center 602 and provides a transition in thickness from the maximum thickness ring 604 to the variable and less thicknesses of the second ring 608. For example, the variable blend zone 606 to a second ring 608 can be divided into eight sectors that are labeled A-H in FIG. 22, including top zone A, top-toe zone B, toe zone C, bottom-toe zone D, bottom zone E, bottom-heel zone F, heel zone G, and top-heel zone H. These eight zones can have differing angular widths as shown, or can each have the same angular width (e.g., one eighth of 360 degrees). Each of the eight zones can have its own thickness variance, each ranging from a common maximum thickness adjacent the ring 604 to a different minimum thickness at the second ring 608. For example, the second ring can be thicker in zones A and E, and thinner in zones C and G, with intermediate thicknesses in zones B, D, F, and H. In this example, the zones B, D, F, and H can vary in thickness both along a radial direction (thinning moving radially outwardly) and along a circumferential direction (thinning moving from zones A and E toward zones C and G).

One example of the face portion 600 can have the following thicknesses: 3.1 mm at center 602, 3.3 mm at ring 604, the second ring 608 can vary from 2.8 mm in zone A to 2.2 mm in zone C to 2.4 mm in zone E to 2.0 mm in zone G, and 1.8 mm in the heel and toe zones 610.

According to one example, the ring 604 can be about 8 mm away from the center 602 and the ring 608 can be about 19 mm away from the center 602. The thickness of the face portion 600 at the center 602 can be between 2.8 mm and 3.0 mm. The thickness of the face portion 600 along the ring 604 can be between 2.9 mm and 3.1 mm. The thickness of the face portion 600 along the ring 608 proximate zone A can be between 2.35 mm and 2.55 mm, proximate zone C can be between 2.3 mm and 2.5 mm, proximate zone E can be between 2.1 mm and 2.3 mm, and proximate zone G can be between 2.6 mm and 2.8 mm. The thickness of the face portion 600 at approximately 35 mm away from the center 602 can be between 1.7 mm and 1.9 mm.

According to yet another example, the thickness of the face portion 600 at the center 602 is between 2.95 mm and 3.35 mm, at about 9 mm away from the center 602 is between 3.3 mm and 3.65 mm, at about 16 mm away from the center 602 is between 2.95 mm and 3.36 mm, and at about 28 mm away from the center 602 is between 2.03 mm and 2.27 mm. The thickness of the face portion 600 greater than 28 mm away from the center 602 can be between 1.8 mm and 1.95 mm on a toe side of the face portion 600 and between 1.83 mm and 1.98 mm on a heel side of the face portion 600.

FIGS. 23 and 24 show the rear face surface of another exemplary face portion 700 that includes a non-symmetrical variable thickness profile. The center 702 of the face can have a center thickness, and the face thickness can gradually increase moving radially outwardly from the center across an inner blend zone 703 to a maximum thickness ring 704, which can be circular. The face thickness can gradually decrease moving radially outwardly from the maximum thickness ring 704 across a variable blend zone 705 to an outer zone 706 comprised of a plurality of wedge shaped sectors A-H having varying thicknesses. As best shown in FIG. 24, sectors A, C, E, and G can be relatively thicker, while sectors B, D, F, and H can be relatively thinner. An outer blend zone 708 surrounding the outer zone 706 transitions in thickness from the variable sectors down to a perimeter ring 710 having a relatively small yet constant thickness. The outer zone 706 can also include blend zones between each of the sectors A-H that gradually transition in thickness from one sector to an adjacent sector.

One example of the face portion 700 can have the following thicknesses: 3.9 mm at center 702, 4.05 mm at ring 704, 3.6 mm in zone A, 3.2 mm in zone B, 3.25 mm in zone C, 2.05 mm in zone D, 3.35 mm in zone E, 2.05 mm in zone F, 3.00 mm in zone G, 2.65 mm in zone H, and 1.9 mm at perimeter ring 710.

FIG. 25 shows the rear face of another exemplary face portion 800 that includes a non-symmetrical variable thickness profile having a targeted thickness offset toward the heel side (left side). The center 802 of the face has a center thickness, and to the toe/top/bottom the thickness gradually increases across an inner blend zone 803 to inner ring 804 having a greater thickness than at the center 802. The thickness then decreases moving radially outwardly across a second blend zone 805 to a second ring 806 having a thickness less than that of the inner ring 804. The thickness then decreases moving radially outwardly across a third blend zone 807 to a third ring 808 having a thickness less than that of the second ring 806. The thickness then decreases moving radially outwardly across a fourth blend zone 810 to a fourth ring 811 having a thickness less than that of the third ring 808. A toe end zone 812 blends across an outer blend zone 813 to an outer perimeter 814 having a relatively small thickness.

To the heel side, the thicknesses are offset by set amount (e.g., 0.15 mm) to be slightly thicker relative to their counterpart areas on the toe side. A thickening zone 820 (dashed lines) provides a transition where all thicknesses gradually step up toward the thicker offset zone 822 (dashed lines) at the heel side. In the offset zone 822, the ring 823 is thicker than the ring 806 on the heel side by a set amount (e.g., 0.15 mm), and the ring 825 is thicker that the ring 808 by the same set amount. Blend zones 824 and 826 gradually decrease in thickness moving radially outwardly, and are each thicker than their counterpart blend zones 807 and 810 on the toe side. In the thickening zone 820, the inner ring 804 gradually increases in thickness moving toward the heel.

One example of the face portion 800 can have the following thicknesses: 3.8 mm at the center 802, 4.0 mm at the inner ring 804 and thickening to 4.15 mm across the thickening zone 820, 3.5 mm at the second ring 806 and 3.65 mm at the ring 823, 2.4 mm at the third ring 808 and 2.55 mm at the ring 825, 2.0 mm at the fourth ring 811, and 1.8 mm at the outer perimeter 814.

The targeted offset thickness profile shown in FIG. 25 can help provide a desirable CT profile across the face. Thickening the heel side can help avoid having a CT spike at the heel side of the face, for example, which can help avoid having a non-conforming CT profile across the face. Such an offset thickness profile can similarly be applied to the toe side of the face, or to both the toe side and the heel side of the face to avoid CT spikes at both the heel and toe sides of the face. In other embodiments, an offset thickness profile can be applied to the upper side of the face and/or toward the bottom side of the face.

As shown in FIGS. 2, 4, 8, 9A, and 13, in some examples, the cup 104 further includes a slot 171 located in the sole portion 117 of the golf club head 100. The slot 171 is open to an exterior of the golf club head 100 and extends lengthwise from the heel portion 116 to the toe portion 114. More specifically, the slot 171 is elongate in a lengthwise direction substantially parallel to, but offset from, the strike face 145. Generally, the slot 171 is a groove or channel formed in the cup 104 at the sole portion 117 of the golf club head 100. In some implementations, the slot 171 is a through-slot, or a slot that is open to the interior cavity 113 from outside of the golf club head 100. However, in other implementations, the slot 171 is not a through-slot, but rather is closed on an interior cavity side or interior side of the slot 171. For example, the slot 171 can be defined by a portion of the side wall of the sole portion 117 of the body 102 that protrudes into the interior cavity 113 and has a concave exterior surface having any of various cross-sectional shapes, such as a substantially U-shape, V-shape, and the like.

In some examples, the slot 171 is offset from the strike face 145 by an offset distance, which is the minimum distance between a first vertical plane passing through a center of the strike face 145 and the slot at the same x-axis coordinate as the center of the strike face 145, between about 5 mm and about 50 mm, such as between about 5 mm and about 35 mm, such as between about 5 mm and about 30 mm, such as between about 5 mm and about 20 mm, or such as between about 5 mm and about 15 mm.

Although not shown, the cup 104 and/or the ring 106 may include a rearward slot, with a configuration similar to the slot 171, but oriented in a forward-to-rearward direction, as opposed to a heel-to-toe direction. The cup 104 includes a rearward slot, but no slot 171 in some examples, and both a rearward slot and the slot 171 in other examples. In one example, the rearward slot is positioned rearwardly of the slot 171. The rearward slot can act as a weight track in some implementations. Moreover, the rearward track can be offset from the strike face 145 by an offset distance, which is the minimum distance between a first vertical plane passing through the center of the strike face 145 and the rearward track at the same x-axis coordinate as the center of the strike face 145, between about 5 mm and about 50 mm, such as between about 5 mm and about 40 mm, such as between about 5 mm and about 30 mm, or such as between about 10 mm and about 30 mm.

In certain embodiments, the slot 171, as well as the rearward slot if present, has a certain slot width, which is measured as a horizontal distance between a first slot wall and a second slot wall. For the slot 171, as well as the rearward slot, the slot width may be between about 5 mm and about 20 mm, such as between about 10 mm and about 18 mm, or such as between about 12 mm and about 16 mm. According to some embodiments, a depth of the slot 171 (i.e., the vertical distance between a bottom slot wall and an imaginary plane containing the regions of the sole portion 117 adjacent opposing slot walls of the slot 171) may be between about 6 mm and about 20 mm, such as between about 8 mm and about 18 mm, or such as between about 10 mm and about 16 mm.

Additionally, the slot 171, as well as the rearward slot if present, has a certain slot length, which can be measured as the horizontal distance between a slot end wall and another slot end wall. For both the slot 171 and rearward slot, their lengths may be between about 30 mm and about 120 mm, such as between about 50 mm and about 100 mm, or such as between about 60 mm and about 90 mm. Additionally, or alternatively, the length of the slot 171 may be represented as a percentage of a total length of the strike face 145. For example, the slot 171 may be between about 30% and about 100% of the length of the strike face 145, such as between about 50% and about 90%, or such as between about 60% and about 80% mm of the length of the strike face 145.

In some examples, the slot 171 is a feature to improve and/or increase the coefficient of restitution (COR) across the strike face 145. With regards to a COR feature, the slot 171 may take on various forms such as a channel or through slot. The COR of the golf club head 100 is a measurement of the energy loss or retention between the golf club head 100 and a golf ball when the golf ball is struck by the golf club head 100. Desirably, the COR of the golf club head 100 is high to promote the efficient transfer of energy from the golf club head 100 to the ball during impact with the ball. Accordingly, the COR feature of the golf club head 100 promotes an increase in the COR of the golf club head 100. Generally, the slot 171 increases the COR of the golf club head 100 by increasing or enhancing the flexibility of the strike face 145. In some examples of the golf club heads disclosed herein, the COR is at least 0.8 for at least 25% of the strike face within the central region, as defined below.

Further details concerning the slot 171 as a COR feature of the golf club head 100 can be found in U.S. patent application Ser. Nos. 13/338,197, 13/469,031, 13/828,675, filed Dec. 27, 2011, May 10, 2012, and Mar. 14, 2013, respectively, U.S. patent application Ser. No. 13/839,727, filed Mar. 15, 2013, U.S. Pat. No. 8,235,844, filed Jun. 1, 2010, U.S. Pat. No. 8,241,143, filed Dec. 13, 2011, U.S. Pat. No. 8,241,144, filed Dec. 14, 2011, all of which are incorporated herein by reference.

The slot 171 can be any of various flexible boundary structures (FBS) as described in U.S. Pat. No. 9,044,653, filed Mar. 14, 2013, which is incorporated by reference herein in its entirety. Additionally, or alternatively, the golf club head 100 can include one or more other FBS at any of various other locations on the golf club head 100. The slot 171 may be made up of curved sections, or several segments that may be a combination of curved and straight segments. Furthermore, the slot 171 may be machined or cast into the golf club head 100. Although shown in the sole portion 117 of the golf club head 100, the slot 171 may, alternatively or additionally, be incorporated into the crown portion 119 of the golf club head 100.

In some examples, the slot 171 is filled with a filler material. However, in other examples, the slot 171 is not filled with a filler material, but rather maintains an open, vacant, space within the slot 171. The filler material can be made from a non-metal, such as a thermoplastic material, thermoset material, and the like, in some implementations. The slot 171 may be filled with a material to prevent dirt and other debris from entering the slot and possibly the interior cavity 113 of the golf club head 100 when the slot 171 is a through-slot. The filler material may be any relatively low modulus materials including polyurethane, elastomeric rubber, polymer, various rubbers, foams, and fillers. The filler material should not substantially prevent deformation of the golf club head 100 when in use as this would counteract the flexibility of the golf club head 100.

According to one embodiment, the filler material is initially a viscous material that is injected or otherwise inserted into the slot 171. Examples of materials that may be suitable for use as a filler to be placed into a slot, channel, or other flexible boundary structure include, without limitation: viscoelastic elastomers; vinyl copolymers with or without inorganic fillers; polyvinyl acetate with or without mineral fillers such as barium sulfate; acrylics; polyesters; polyurethanes; polyethers; polyamides; polybutadienes; polystyrenes; polyisoprenes; polyethylenes; polyolefins; styrene/isoprene block copolymers; hydrogenated styrenic thermoplastic elastomers; metallized polyesters; metallized acrylics; epoxies; epoxy and graphite composites; natural and synthetic rubbers; piezoelectric ceramics; thermoset and thermoplastic rubbers; foamed polymers; ionomers; low-density fiber glass; bitumen; silicone; and mixtures thereof. The metallized polyesters and acrylics can comprise aluminum as the metal. Commercially available materials include resilient polymeric materials such as Scotchweld™ (e.g., DP-105™) and Scotchdamp™ from 3M, Sorbothane™ from Sorbothane, Inc., DYAD™ and GP™ from Soundcoat Company Inc., Dynamat™ from Dynamat Control of North America, Inc., NoViFlex™ Sylomer™ from Pole Star Maritime Group, LLC, Isoplast™ from The Dow Chemical Company, Legetolex™ from Piqua Technologies, Inc., and Hybrar™ from the Kuraray Co., Ltd. In some embodiments, a solid filler material may be press-fit or adhesively bonded into a slot, channel, or other flexible boundary structure. In other embodiments, a filler material may poured, injected, or otherwise inserted into a slot or channel and allowed to cure in place, forming a sufficiently hardened or resilient outer surface. In still other embodiments, a filler material may be placed into a slot or channel and sealed in place with a resilient cap or other structure formed of a metal, metal alloy, metallic, composite, hard plastic, resilient elastomeric, or other suitable material.

Referring to FIGS. 4, 8, 9A, and 14, in some examples, the golf club head 100 further includes a weight 173 attached to the cup 104. The cup 104 includes a threaded port 175 that receives and retains the weight 173. The threaded port 175 is open to an exterior and the interior cavity 113 of the golf club head 100 and includes internal threads in certain examples. In other examples, the threaded port 175 is closed to the interior cavity 113. The weight 173 includes external threads that threadably engage with the internal threads of the threaded port 175 to retain the weight 173 within the threaded port 175. When the threaded port 175 is open to the interior cavity 113, the weight 173 effectually closes the threaded port 175 to prevent access to the interior cavity 113 when threadably attached to the cup 104 within the threaded port 175. As shown, when the threaded port 175 is open to the interior cavity 113, a portion of the weight 173 is located external to the interior cavity 113 and another portion is located within the interior cavity 113. In contrast, in other examples, such as when the threaded port 175 is closed to the interior cavity 113, an entirety of the weight 173 is located external to the interior cavity 113. Although not shown, in one example, the threaded port 175 can be open to the interior cavity 113 and closed to an exterior of the golf club head 100 (e.g., the threaded port 175 faces inwardly as opposed to outwardly). In such an example, the entirety of the weight 173 would be located internally within the interior cavity 113. As defined herein, when any portion of the weight 173 is internal relative to or within the interior cavity 113, the weight 173 is considered internal to the interior cavity 113 and when any portion of the weight 173 is external relative to the interior cavity 113, the weight 173 is alternatively, or also, considered external to the interior cavity 113.

In some examples, as shown, the threaded port 175, and thus the weight 173, is located in the sole portion 117 of the golf club head 100. Moreover, according to certain examples, the threaded port 175 and the weight 173 are located closer to the heel portion 116 than the toe portion 114. In one example, the threaded port 175 and the weight are located closer to the heel portion 116 than the slot 171. The weight 173 has a mass between about 3 g and about 23 g (e.g., 6 g) in some examples.

Referring to FIGS. 9A, 11, and 14, the cup 104 further comprises a mass pad 186 attached to or co-formed with the rest of the cup 104. The mass pad 186 has a thickness greater than any other portion of the cup 104. In the illustrated example, the mass pad 186 is located proximate the sole portion 117 of the golf club head 100, and thus a sole region of the cup 104. Additionally, in certain examples, a portion of the mass pad 186 is located proximate the heel portion 116 of the golf club head 100, and thus a heel region of the cup 104. As defined herein, when located at the sole portion 117 of the golf club head 100, the mass pad 186 is considered a sole mass pad, and when located at the heel portion 116 of the golf club head 100, the mass pad 186 is considered a heel mass pad. It is recognized that when the mass pad 186 is located at both the sole portion 117 and the heel portion 116, the mass pad 186 is considered to be a sole mass pad and a heel mass pad.

Referring to FIGS. 11 and 14, in some examples, the cup 104 further includes internal ribs 187 co-formed with other portions of the cup 104. The internal ribs 187 can be in any of various locations within the cup 104. In the illustrated example, the internal ribs 187 are located (e.g., formed in) a sole region of the cup 104 closer to a toe region of the cup 104 than a heel region of the cup 104. The internal ribs 187 help to stiffen and promote desirable acoustic properties of the golf club head 100.

Referring to FIGS. 11, 14, and 15, the ring 106 includes a cantilevered portion 161, and a toe arm portion 163A and a heel arm portion 163B extending from the cantilevered portion 161. The toe arm portion 163A and the heel arm portion 163B are on opposite sides of the golf club head 100, initiate at the cantilevered portion 161, and terminate at a corresponding one of the toe cup-engagement surface 152A and the heel cup-engagement surface 152B. The cantilevered portion 161 defines at least part of the rearward portion 118 of the golf club head 100 and further defines a rearmost end of the golf club head 100. Moreover, in the illustrated examples, the cantilevered portion 161 extends from the crown portion 119 to the sole portion 117. Accordingly, the cantilevered portion 161 defines part of the sole portion 117 of the golf club head 100 in some examples, such as defining an outwardly-facing surface of the sole portion 117 of the golf club head 100.

In some examples, the cantilevered portion 161 is close to the ground plane 181 when the golf club head 100 is in the address position. According to certain examples, a ratio of the peak crown height to a vertical distance from the peak crown height to a lowest surface of the cantilevered portion 161 of the ring 106 is at least 6.0, at least 5.0, at least 4.0, or more preferably at least 3.0. Alternatively, or additionally, in some examples, a vertical distance from the peak skirt height of the skirt portion to a lowermost surface of the cantilevered portion 161 of the ring 106, when the golf club head 100 is in the address position, is no less than between 20 mm and 30 mm.

The toe arm portion 163A and the heel arm portion 163B define a toe side of the skirt portion 121 and a heel side of the skirt portion 121, respectively, as well as part of the toe portion 114 and heel portion 116, respectively, of the golf club head 100. The cantilevered portion 161 extends downwardly away from the toe arm portion 163A and the heel arm portion 163B, while the toe arm portion 163A and the heel arm portion 163B extend forwardly away from the cantilevered portion 161. Accordingly, the cantilevered portion 161 is closer to the ground plane 181 than the toe arm portion 163A and the heel arm portion 163B when the golf club head 100 is in the address position. In other words, referring to FIGS. 3, 4, and 9A, a height (HR) of the lowest surface of the ring 106 above the ground plane 181, in a vertical direction when the golf club head 100 is in the address position, at any location along the cantilevered portion 161 is less than at any location along the toe arm portion 163A and the heel arm portion 163B.

In some examples, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is different than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100. More specifically, in one example, the height HR of the lowest surface of the toe arm portion 163A at the toe portion 114 of the golf club head 100 is greater than the height HR of the lowest surface of the heel arm portion 163B at the heel portion 116 of the golf club head 100.

According to certain examples, as shown in FIGS. 3, 4, and 9A, a width (WR) of the of the ring 106, as measured in a vertical direction when the golf club head 100 is in the address position, varies in a forward-to-rearward direction (e.g., along a length of the ring 106). In one example, the width WR increases from a minimum width to a maximum width in the forward-to-rearward direction. In other words, the width WR of the ring 106 varies in the forward-to-rearward direction in certain examples. In some examples, the maximum width WR of the ring 106 is at the rearmost end of the golf club head 100. In one example, the maximum width WR of the ring 106 is as least 20 mm. According to certain examples, as shown in FIG. 14, the width WR of the ring 106 at the toe portion 114 is less than the width WR of the ring 106 at the heel portion 116. According to some additional examples, a thickness of the ring 106 can vary along the ring 106 in a forward-to-rearward direction.

Referring to FIGS. 2-4, 6, 8, 9A, and 11-15, in some examples, the golf club head 100 further includes a mass element 159 attached to the cantilevered portion 161 of the ring 106, such as at a rearmost end of the golf club head 100. The mass element 159 can be selectively removable from (e.g., interchangeable with differently weighted mass elements) or permanently attached to the cantilevered portion 161. According to one example, the mass element 159 and the weight 173 are interchangeably coupleable to the cup 104 and the cantilevered portion 161 of the ring 106. Accordingly, in some examples, the flight control technology component of the golf club head 100, the mass element 159, and the weight 173 are adjustable relative to the golf club head 100. In certain examples, the flight control technology component of the golf club head 100, the mass element 159, and the weight 173 are configured to be adjustable via a single or the same tool.

In one example, the mass element 159 includes external threads. The golf club head 100 can additionally include a mass receptacle 157 attached to the cantilevered portion 161 of the ring 106. The mass receptacle 157 can include a threaded aperture, with internal threads, that threadably engages the mass element 159 to secure the mass element 159 to the cantilevered portion 161. The mass receptacle 157 is welded to the cantilevered portion 161 in some examples and adhered to the cantilevered portion 161 in other examples. In certain examples, the mass receptacle 157 is co-formed with the cantilevered portion 161. The cantilevered portion 161 also includes a mass pad 155 (see, e.g., FIGS. 9A, 12, and 15) or a portion of the cantilevered portion 161 with a localized increase in thickness and thus mass. The mass receptacle 157 can be formed in the mass pad 155 of the cantilevered portion 161. The mass element 159 has a mass between about 15 g and about 35 g (e.g., 24 g) in some examples.

The outer peripheral shape of one or both of the mass element 159 and the weight 173 in the illustrated examples is circular. Accordingly, an orientation of one or both of the mass element 159 and the weight 173 is rotatable about a central axis of the mass element 159 and the weight 173, respectively, in any of various orientations between 0-degrees and 360-degrees. However, in other examples, the outer peripheral shape of at least one or both of the mass element 159 and the weight 173 is non-circular, such as ovular, triangular, trapezoidal, square, and the like. For example, as shown in FIG. 16, the weight 273 has an outer peripheral shape that is trapezoidal or rectangular. In certain examples, the mass element 159 and/or the weight 173, having a non-circular outer peripheral shape, is rotatable about the central axis of the mass element 159 and the weight 173, respectively, in any of various orientations between 0-degrees and at least 90-degrees in certain implementations and 0-degrees and at least 180-degrees in other implementations.

The construction and material diversity of the golf club head 100 enables flexibility of the position of the weight 173 (e.g., first weight or forward weight) relative to the position of the mass element 159 (e.g., second weight or rearward weight). In some examples, the relative positions of the weight 173 and the mass element 159 can be similar to those disclosed in U.S. patent application Ser. No. 16/752,397, filed Jan. 24, 2020. Referring to FIG. 9A, according to one example, a z-axis coordinate of the CG of the first weight (FWCG), on the z-axis of the head origin coordinate system 185, is between −30 mm and −10 mm (e.g., −21 mm), a y-axis coordinate of the CG of the first weight (FWCG), on the y-axis of the head origin coordinate system 185 is between 10 mm and 30 mm (e.g., 23 mm), and an x-axis coordinate of the CG of the first weight (FWCG), on the x-axis of the head origin coordinate system 185 is between 15 mm and 35 mm (e.g., 22 mm). According to the same, or a different, example, a z-axis coordinate of the CG of the second weight (SWCG), on the z-axis of the head origin coordinate system 185, is between −30 mm and 10 mm (e.g., −11 mm), a y-axis coordinate of the CG of the second weight (SWCG), on the y-axis of the head origin coordinate system 185 is between 90 mm and 120 mm (e.g., 110 mm), and an x-axis coordinate of the CG of the second weight (SWCG), on the x-axis of the head origin coordinate system 185 is between −20 mm and 10 mm (e.g., −7 mm).

In certain examples, the sole portion 117 of the golf club head 100 includes an inertia generating feature 177 that is elongated in a lengthwise direction. The lengthwise direction is perpendicular or oblique to the strike face 145. According to some examples, the inertia generating feature 177 includes the same features and provides the same advantages as the inertia generator disclosed in U.S. patent application Ser. No. 16/660,561, filed Oct. 22, 2019, which is incorporated herein by reference in its entirety. In the illustrated examples, the sole insert 110 forms at least a portion of the inertia generating feature 177. More specifically, in some examples, the sole insert 110 forms all or a majority of the inertia generating feature 177. The cantilevered portion 161 of the ring 106 also forms part, such as a rearmost part, of the inertia generating feature 177 in certain examples. The inertia generating feature 177 helps to increase the inertia of the golf club head 100 and lower the center-of-gravity (CG) of the golf club head 100.

The inertia generating feature 177 includes a raised or elevate platform that extends from a location rearwardly of the hosel 120 to a location proximate the rearward portion 118 of the golf club head 100. The inertia generating feature 177 includes a substantially flat or planar surface that is raised above (or protrudes from, depending on the orientation of the golf club head 100) the surrounding external surface of the sole portion 117. In certain examples, at least a portion of the inertia generating feature 177 is raised above the surrounding external surface of the sole portion 117 by at least 1.5 mm, at least 1.8 mm, at least 2.1 mm, or at least 3.0 mm. The inertia generating feature 177 also has a width that is less than an entire width (e.g., less than half the entire width) of the sole portion 117. In view of the foregoing, the inertia generating feature 177 has a complex curved geometry with multiple inflection points. Accordingly, the sole insert 110, which defines the inertia generating feature 177, has a complex curved surface that has multiple inflection points.

Referring to FIGS. 1-3 and 5, in some examples, the golf club head 100 includes a through-aperture 172 in the body 102 at the toe portion 114. The through-aperture 172 extends entirely through the wall of the body 102 such that the interior cavity 113 is accessible through the aperture 172. The aperture 172 can be used to insert a stiffener into the interior cavity 113 against an interior surface of the forward portion 112 to help set the CT of the strike face 145. Further details of the stiffener, the insertion process, and the effect of the stiffener on the CT of the strike face 145 can be found in U.S. Patent Application Publication No. 2019/0201754, published Jul. 4, 2019, which is incorporated herein by reference in its entirety. As shown, the through-aperture 172 is not located in the forward portion 112 (e.g., the strike face 145). Accordingly, in some examples, the strike face 145 is void of through-apertures open to the interior cavity 113 or the hollow interior region of the golf club head 100. Moreover, in some examples, no material having a shore D value greater than 10, greater than 5, or greater than 1 contacts an interior surface 166 of the forward portion 112, opposite the strike face 145 and open to the hollow interior region, at a location toeward and/or heelward of the geometric center of the strike face 145. In yet other examples, no material, regardless of hardness, contacts an interior surface 166 of the forward portion 112, opposite the strike face 145 and open to the hollow interior region.

The CT properties of the golf club heads disclosed herein can be defined as CT values within a central region of the strike face 145. The central region, is forty millimeter by twenty millimeter rectangular area centered on a center of the strike face and elongated in a heel-to-toe direction. The center of the strike face 145 can be a geometric center of the strike face 145 in some examples. Within the central region, the strike face 145 has a characteristic time (CT) of no more than 257 microseconds. In some examples, the CT of at least 60% of the strike face, within the central region, is at least 235 microseconds. According to some examples, the CT of at least 35% of the strike face, within the central region, is at least 240 microseconds.

The CT of the strike face 145, at the geometric center of the strike face, has an initial CT value. The initial CT value is the CT value of the strike face 145 before any impacts with a standard golf ball. As defined herein, an impact with the standard golf ball is an impact of the standard golf ball when the golf ball is traveling at a velocity of 52 meters per second. According to some examples, the initial CT value is at least 244 microseconds. In certain examples, the driver-type golf club heads disclosed herein, including the golf club head 100, are configured such that after 500 impacts of a standard golf ball at the geometric center of the strike face 145, the CT of the strike face at any point within the central region is less than 256 microseconds and the CT at the geometric center of the strike face is no more than five microseconds different than (e.g., greater than) the initial CT value.

In certain examples, the driver-type golf club heads disclosed herein, including the golf club head 100, are configured such that after 1,000, 1,500, 2,000, 2,500, or 3,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face at any point within the central region is less than 256 microseconds. According to some examples, after 2,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at any point within the central region is no more than seven microseconds or nine microseconds different that the initial CT value. Moreover, in certain examples, after 2,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at the geometric center of the strike face is no less than 249 microseconds and no more than ten microseconds different than the initial CT value. According to some examples, after 3,000 impacts of the standard golf ball at the geometric center of the strike face, the CT of the strike face 145 at any point within the central region is no more than nine microseconds or thirteen microseconds different that the initial CT value. In certain examples, such as those where the strike face 145 is made of a metallic material, an inward face progression of the strike face 145 is less than 0.01 inches after 500 impacts of the standard golf ball at the geometric center of the strike face.

Referring to FIGS. 16 and 17, and according to another example of a golf club head disclosed herein, a golf club head 200 is shown. The golf club head 200 includes features similar to the features of the golf club head 100, with like numbers (e.g., same numbers but in 200-series) referring to like features. For example, like the golf club head 100, the golf club head 200 includes a toe portion 214 and a heel portion 216, opposite the toe portion 214. Additionally, the golf club head 200 includes a forward portion 212 and a rearward portion 218, opposite the forward portion 212. The golf club head 200 additionally includes a sole portion 217, at a bottom region of the golf club head 200, and a crown portion 219, opposite the sole portion 217 and at a top region of the golf club head 200. Also, the golf club head 200 includes a skirt portion 221 that defines a transition region where the golf club head 200 transitions between the crown portion 219 and the sole portion 217. The golf club head 200 further includes an interior cavity 213 that is collectively defined and enclosed by the forward portion 212, the rearward portion 218, the crown portion 219, the sole portion 217, the heel portion 216, the toe portion 214, and the skirt portion 221. Additionally, the forward portion 212 includes a strike face 245 that extends along the forward portion 212 from the sole portion 217 to the crown portion 219, and from the toe portion 214 to the heel portion 216. Additionally, the golf club head 200 further includes a body 202, a crown insert 208 attached to the body 202 at a top of the golf club head 200, and a sole insert 210 attached to the body 202 at a bottom of the golf club head 200. The body 202 includes a cup 204 and a ring 206. The ring 206 is joined to the cup 204 at a toe-side joint 212A and a heel-side joint 212B. The cup 204 of the body 202 also includes a slot 271 in the sole portion 217 of the golf club head 200. Further, the golf club head 200 additionally includes a mass element 259 and a mass receptacle 257 attached to the ring 206 of the body 202, as well as a weight 273 attached to the cup 204. Accordingly, in view of the foregoing, the golf club head 200 shares some similarities with the golf club head 100.

Unlike the golf club head 100, however, the strike face 245 of the golf club head 200 in FIGS. 16 and 17 is not co-formed with the cup 204. Rather, the strike face 245 forms part of a strike plate 243 that is formed separately from the cup 204 and bonded to the cup 204 by the bonding tape 174. Accordingly, the strike plate 243 defines the strike face 245. The cup 204 includes a plate opening 249 at the forward portion 212 of the golf club head 200 and a plate-opening recessed ledge 247 that extends continuously about the plate opening 249. An inner periphery of the plate-opening recessed ledge 247 defines the plate opening 249. The strike plate 243 is attached to the cup 204 by fixing the strike plate 243 in seated engagement with the plate-opening recessed ledge 247. When joined to the plate-opening recessed ledge 247 in this manner, the strike plate 243 covers or encloses the plate opening 249. Moreover, the plate-opening recessed ledge 247 and the strike plate 243 are sized, shaped, and positioned relative to the crown portion 219 of the golf club head 200 such that the strike plate 243 abuts the crown portion 219 when seatably engaged with the plate-opening recessed ledge 247. The strike plate 243, abutting the crown portion 219, defines a topline of the golf club head 200. Moreover, in some examples, the visible appearance of the strike plate 243 contrasts enough with that of the crown portion 219 of the golf club head 200, which is partially defined by the cup 204, that the topline of the golf club head 200 is visibly enhanced. Because the strike plate 243 is formed separately from the cup 204, the strike plate 243 can be made of a material that is different than that of the cup 204. In one example, the strike plate 243 is made of a fiber-reinforced polymeric material. In yet another example, the strike plate 243 is made of a metallic material, such as a titanium alloy (e.g., Ti 6-4, Ti 9-1-1, and ZA 1300).

Additionally, unlike the golf club head 100, the cup 204 includes a weight track 279 in the sole portion 217 of the golf club head 200. The weight track 279 extends lengthwise in a heel-to-toe direction along the sole portion 217. In examples where the cup 204 also includes the slot 271, such as shown, the weight track 279 is substantially parallel to the slot 271 and offset from the slot 271 in a front-to-rear direction. The weight track 279 includes at least one ledge that extends lengthwise along the length of the weight track 279. In the illustrated example, the weight track 279 includes a forward ledge 297A and a rearward ledge 297B, which are spaced apart from each other in the front-to-rear direction. The weight 273, which positioned within the weight track 279, is selectively clampable to the ledge or ledges of the weight track 279 to releasably fix the weight 273 to the weight track 279. In the illustrated example, the weight 273 is selectively clampable to both the forward ledge 297A and the rearward ledge 297B. When unclamped to the one or more ledges of the weight track 279, the weight 273 is slidable along the one or more ledges, as shown by directional arrows in FIG. 16, to change a position of the weight 273 relative to the weight track 279 and, when re-clamped to the one or more ledges, adjust the mass distribution, center-of-gravity (CG), and other performance characteristics of the golf club head 200.

According to one example, the weight 273 includes a washer 273A, a nut 273B, and a fastening bolt 273C that interconnects with the washer 273A and the nut 273B to clamp down on the ledges 297A, 297B of the weight track 279. The washer 273A has a non-threaded aperture and the nut 273B has a threaded aperture. The fastening bolt 273C is threaded and passes through the non-threaded aperture of the washer 273A to threadably engage the threaded aperture of the nut 273B. Threadable engagement between the fastening bolt 273C and the nut 273B allows a gap between the washer 273A and the nut 273B to be narrowed, which facilitates the clamping of the ledge or ledges between the washer 273A and the nut 273B, or widened, which facilitates the un-clamping of the ledge or ledges from between the washer 273A and the nut 273B. The fastening bolt 273C can be rotatable relative to both the washer 273A and the nut 273B or form a one-piece monolithic construction and be co-rotatable with one of the washer 273A and the nut 273B.

To reduce the weight of the golf club head 200 and the depth of the weight track 279, the fastening bolt 273C is short. For example, the length of the fastening bolt 273C, when the weight 273 is clamped on the ledges 297A, 297B, extends no more than 3 mm past the nut 273B (or the washer 273A if the position of the nut 273B and the washer 273A are reversed). In some examples, the entire length of the fastening bolt 273C is no more than 15% greater than the combined thicknesses of the washer 273A, the nut 273B, and one of the ledges 297A, 297B.

As shown, an outer peripheral shape of the washer 273A is non-circular, such as trapezoidal or rectangular. Similarly, the outer peripheral shape of the nut 273B can be non-circular, such as trapezoidal or rectangular. Alternatively, as shown, the outer peripheral shape of the nut 273B is circular and the outer peripheral shape of the washer 273A is non-circular.

Referring to FIG. 18, and according to another example of a golf club head disclosed herein, a golf club head 300 is shown. The golf club head 300 includes features similar to the features of the golf club head 100 and the golf club head 200, with like numbers (e.g., same numbers but in 300-series) referring to like features. For example, like the golf club head 100 and the golf club head 200 includes a body 302, a crown insert 308 attached to the body 302 at a top of the golf club head 300, and a sole insert 310 attached to the body 302 at a bottom of the golf club head 300. The body 302 includes a cup 304 and a ring 306. The ring 306 is joined to the cup 304 at a toe-side joint and a heel-side joint. The cup 304 of the body 302 also includes a slot 371 in the sole portion of the golf club head 300. Further, the golf club head 300 additionally includes a mass element 359 and a mass receptacle 357 attached to the ring 306 of the body 302, as well as a weight 373 attached to the cup 304 via a fastener 379.

Additionally, like the golf club head 200, the golf club head 300 includes a strike plate 343, defining a strike face 145, that is formed separate from and attached to the cup 304. The strike plate 343 is made of a fiber-reinforced polymer in some examples and includes a base portion 347 and a cover 349 applied onto the base portion 347. The base portion 347 is thicker compared to the cover 349, the base portion 347 is made of a fiber-reinforced polymer, and the cover 349 is made of a fiber-less polymer in some examples. The cover 349 is made of polyurethane in certain examples. Also, the cover 349 includes grooves 351 or scorelines formed in the fiber-less polymer. The surface roughness of the portion of the cover 349 that defines the strike face 345 is greater than the surface roughness of the body 302. Accordingly, in view of the foregoing, the golf club head 300 shares some similarities with the golf club head 100 and the golf club head 200.

Unlike the illustrated examples of the cup 104 of the golf club head 100 and the cup 204 of the golf club head 200, however, the cup 304 has a multi-piece construction. More specifically, the cup 304 includes an upper cup piece 304A and a lower cup piece 304B. The upper cup piece 304A is formed separately from the lower cup piece 304B. Accordingly, the upper cup piece 304A and the lower cup piece 304B are joined or attached together to form the cup 304. Because the upper cup piece 304A and the lower cup piece 304B are formed separately, the upper cup piece 304A can be made of a material that is different than that of the lower cup piece 304B. The cup 304 includes a hosel 320 where a portion of the hosel 320 is formed into the upper cup piece 304A and another portion of the hosel 320 is formed into the lower cup piece 304B.

According to some examples, the upper cup piece 304A is made of a material that is different than that of the lower cup piece 304B. For example, the upper cup piece 304A can be made of a material with a density that is lower than the material of the lower cup piece 304B. In one example, the upper cup piece 304A is made of a titanium alloy and the lower cup piece 304B is made of a steel alloy. According to another example, the upper cup piece 304A is made of an aluminum alloy and the lower cup piece 304B is made of a steel alloy or a tungsten alloy, such as 10-17 density tungsten. Such configurations help to increase the mass of the cup 304 and lower the center-of-gravity (CG) of the cup 304 and the golf club head 300 compared to the single-piece cup 104 of the golf club head 100. In alternative configurations, according to some examples, the upper cup piece 304A is made of an aluminum alloy and the lower cup piece 304B is made of a titanium alloy. These later configurations help to lower the overall mass of the cup 304. According to some examples, the upper cup piece 304A and the lower cup piece 304B are made using different manufacturing techniques. For example, the upper cup piece 304A, front body portion 4602, and any of the disclosed components, can be made by stamping, forging, metal-injection-molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM, and the lower cup piece 304B, and any of the disclosed components, can be made by another one or a different combination of stamping, forging, metal-injection-molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM. Thus, any references to cup in this disclosure may be replaced with stamped cup, forged cup, milled cup, metal-injection-molding (MIM) cup, metal additive manufacturing (metal AM) cup, and/or freeform injection molded cup, and combinations thereof. For example, a cup may be both a milled cup, as well as any of the other variation, as would be the case of a cup that is forged and then milled, or cast and then milled, and thus may be referred to as a forged-milled cup and/or a cast-milled cup. Likewise, duplicative but in the interest of eliminating any confusion, the front body portion 4602 may be both a milled front body portion 4602, as well as any of the other variation, as would be the case of a front body portion 4602 that is forged and then milled, or cast and then milled, and thus may be referred to as a forged-milled front body portion 4602 and/or a cast-milled front body portion 4602. Further, the milling may be further defined by the extent of the total surface area that is milled, the extent of the interior exposed surface area (that exposed to the interior of the club head) that is milled, and/or the extent of the externally exposed surface area (that exposed to the external environment) that is milled. For instance the simplest embodiment is a 100% milled total surface area of the cup 304, and/or front body portion 4602, whereby every surface has been milled, however preferred embodiments have no more than 90%, 80%, 70%, 60%, 50%, 45%, or 40% milled total surface area. Further embodiments have at least 5%, 10%, 15%, 20%, or 35% milled total surface area. Another embodiment has at least 50% milled interior exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled interior exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled interior exposed surface area. Another embodiment has at least 50% milled externally exposed surface area, and in further embodiments at least 60%, 70%, 80%, 90%, or 100% milled externally exposed surface area. However, further embodiments have no more than 95%, 90%, or 85% milled externally exposed surface area. Forging of the cup 304 and/or front body portion 4602 components, which often have very thin areas and relatively thick areas, induces residual stresses due to plastic deformation and temperature gradients during the cooling process. Subsequent milling removes material and relieves some of the residual stresses. However, subsequent milling may also introduce new residual stresses, particularly if the machining process generates significant heat, and depending on the material and final thickness of the area being milled. Further, titanium alloy has poor thermal conductivity and higher strength compared to aluminum alloy, which can make it more prone to machining issues. For instance, during milling of titanium alloys the heat generated tends to remain more localized, which can lead to localized thermal stresses. Further, titanium alloys have a tendency to work-harden during machining, which can also contribute to the development of new residual stresses. The cup 304, and/or front body portion 4602, is exposed to severe stress upon impact with a golf ball, and controlling residual improves durability and facilitates improved performance. Any of the disclosure relating to the cup 304, and its variations and embodiments, applies equally to the later disclosed front body portion 4602, and its variations and embodiments, and likewise any disclosure relating to the front body portion 4602, and its variations and embodiments, applies equally to the cup 304, and its variations and embodiments.

Various examples of combinations of materials and mass properties for the upper cup piece 304A and the lower cup piece 304B are shown in Table 2 below. In Table 2A-2C when the upper cup piece 304A and the lower cup piece 304B are the same material, as in examples 1A and 6A, 1B and 6B, and 1C and 6C, the upper cup piece 304A and the lower cup piece 304B may be an integral single component and thus simply a cup 304 and/or front body portion 4602 and the combined disclosure of the individual upper cup piece 304A and lower cup piece 304B may be added together for such a single component embodiment.

TABLE 2A

Density

CG (z-axis

Delta-
Delta-

Material
(g/cc)
Mass (g)
(mm)
Mass (g)
CG
CG

Example
Upper
Lower
Upper
Lower
Upper
Lower
Upper
Combined
Combined
Combined
Combined

1A
Ti-64
Ti-64
4.4
4.4
37.5
37.5
15
−15
75
0
0

2A
Ti-64
Steel
4.4
7.8
37.5
66.5
15
−15
104.0
−4.2
−2.2

3A
Al-7075
Steel
2.8
7.8
23.9
66.5
15
−15
90.3
−7.1
−3.2

4A
Al-7075
W-10
2.8
10
23.9
85.2
15
−15
109.1
−8.4
−4.6

5A
Al-7075
Ti-64
2.8
4.4
23.9
37.5
15
−15
61.4
−3.3
−1.0

6A
Al-7075
Al-7075
2.8
2.8
23.9
23.9
15
−15
47.7
0.0
0.0

TABLE 2B

Material
Density (g/cc)
Mass (g)
Mass (g)

Example
Upper
Lower
Upper
Lower
Upper
Lower
Combined

1B
Ti
Ti
≤4.6
≤4.6
≤45
≤45
≤90

alloy
alloy

2B
Ti
Steel
≤ 4.6
≤8
≤45
≤75
≤120

alloy
alloy

3B
Alum
Steel
≤3
≤8
≤30
≤75
≤110

alloy
alloy

4B
Alum
Tungsten
≤3
≤20
≤30
≤105
≤125

alloy
alloy

5B
Alum
Ti
≤3
≤4.6
≤30
≤45
≤70

alloy
alloy

6B
Alum
Alum
≤3
≤3
≤30
≤30
≤55

alloy
alloy

TABLE 2C

Material
Density (g/cc)
Mass (g)
Mass (g)

Example
Upper
Lower
Upper
Lower
Upper
Lower
Combined

1C
Ti
Ti
≤4.6
≤4.6
≥25
≥25
≥65

alloy
alloy

2C
Ti
Steel
≤4.6
≤8
≥25
≥55
≥90

alloy
alloy

3C
Alum
Steel
≤3
≤8
≥15
≥55
≥75

alloy
alloy

4C
Alum
Tungsten
≤3
≤20
≥15
≥65
≥85

alloy
alloy

5C
Alum
Ti
≤3
≤4.6
≥15
≥25
≥45

alloy
alloy

6C
Alum
Alum
≤3
≤3
≥15
≥15
≥35

alloy
alloy

As shown, the cup 304 includes a port 375 that receives and retains the weight 373. The port 375 is configured to retain the weight 373 in a fixed location on the sole portion of the golf club head 300. However, in other examples, the port 375 can be replaced with a weight track, similar to the weight track 279 of the golf club head 200, such that the weight 373 can be selectively adjustable and moved into any of various positions along the weight track. In this manner, a weight track, and a corresponding ledge or ledges of the weight track, can form part of one piece of a multi-piece cup.

Although the cup 304 is shown to have a two-piece construction, in other examples, the cup 304 has a three-piece construction or constructed with more than three pieces. According to one instance, the cup 304 has a crown-toe piece, a crown-heel piece, and a sole piece. The crown-toe piece and the crown-heel piece are made of titanium alloys and the sole piece is made of a steel alloy in certain implementations. The titanium alloy of the crown-toe piece can be the same as or different than the titanium alloy of the crown-heel piece.

Referring to FIGS. 19 and 20, and according to another example of a golf club head disclosed herein, a golf club head 400 is shown. The golf club head 400 includes features similar to the features of the golf club head 100, the golf club head 200, and the golf club head 300, with like numbers (e.g., same numbers but in 400-series) referring to like features. For example, like the golf club head 100, the golf club head 200, and the golf club head 300, the golf club head 400 includes a body 402, a crown insert 408 attached to the body 402 at a top of the golf club head 400, and a sole insert 410 attached to the body 402 at a bottom of the golf club head 400. The body 402 includes a cup 404 and a ring 406. The ring 406 is joined to the cup 404 at a toe-side joint 412A and a heel-side joint 412B. Additionally, like the golf club head 200 and the golf club head 300, the golf club head 400 includes a strike plate 443, defining a strike face 445, that is formed separate from and attached to the cup 404. Accordingly, in view of the foregoing, the golf club head 400 shares some similarities with the golf club head 100, the golf club head 200, and the golf club head 300.

Furthermore, the golf club head 400 additionally includes a weight 473 attached to the cup 404 via a fastener 479. As shown, the cup 404 includes a port 475 that receives and retains the weight 473. The port 475 is configured to retain the weight 473 in a fixed location on the sole portion of the golf club head 400. However, in other examples, the port 475 can be replaced with a weight track, similar to the weight track 279 of the golf club head 200, such that the weight 473 can be selectively adjustable and moved into any of various positions along the weight track. In this manner, a weight track, and a corresponding ledge or ledges of the weight track, can form part of the cup 404.

Also, like the golf club head 100, the golf club head 200, and the golf club head 300, the golf club head 400 additionally includes a mass element 459 and a mass receptacle 457. However, unlike some examples, of the receptacles of the previously discussed golf club heads, the mass receptacle 457 of the golf club head 400 forms a one-piece monolithic construction with a cantilevered portion 461 of the ring 406. Accordingly, in certain examples, the mass receptacle 457 is co-cast with the ring 406. The mass receptacle 457 includes an opening or recess that is configured to nestably receive the mass element 459. The mass element 459 can be made of a material, such as tungsten, that is different (e.g., denser) than the material of the ring 406. The mass element 459 is bonded, such as via an adhesive, to the ring 406 to secure the mass element 459 within the mass receptacle 457. In some examples, the mass element 459 includes prongs 463 that engage corresponding apertures in the mass receptacle 457 when bonded to the ring 406. Engagement between the prongs 463 and the corresponding apertures of the mass receptacle 457 help to strengthen and stiffen the coupling between the mass element 459 and the ring 406.

Referring to FIG. 21, the ring 406 includes a toe arm portion 463A that defines a toe side of a skirt portion 421 of the golf club head 400 and a heel arm portion 463B that defines a heel side of the skirt portion 421. Moreover, the toe arm portion 463A and the heel arm portion 463B define part of a toe portion 414 and a heel portion 416, respectively, of the golf club head 400 (see, e.g., FIGS. 19 and 20). The cantilevered portion 461 extends downwardly away from the toe arm portion 463A and the heel arm portion 463B, while the toe arm portion 463A and the heel arm portion 463B extend forwardly away from the cantilevered portion 461. Accordingly, the cantilevered portion 461 is closer to the ground plane 181 than the toe arm portion 463A and the heel arm portion 463B when the golf club head 400 is in the address position. In FIG. 21, the ring 406 is shown in a position corresponding with the position of the ring 406 when the golf club head 400 is in the address position relative to the ground plane 181.

In some examples, the height HR of the lowest surface (and in some examples, an entirety) of the toe arm portion 463A at the toe portion 414 of the golf club head 400 is different than the height HR of the lowest surface (and in some examples, an entirety) of the heel arm portion 463B at the heel portion 416 of the golf club head 400. More specifically, in one example, the height HR of the lowest surface of the toe arm portion 463A at the toe portion 414 of the golf club head 400 is greater than the height HR of the lowest surface of the heel arm portion 463B at the heel portion 416 of the golf club head 100.

According to certain examples, the width WR of the toe arm portion 463A of the ring 406 at the toe portion 414 is less than the width WR of the heel arm portion 463B of the ring 406 at the heel portion 416. According to some additional examples, a thickness (TR) of the ring 406 can vary along the ring 406 in a forward-to-rearward direction. For example, in some examples, the thickness TR of the ring 406 varies from a minimum thickness to a maximum thickness in a forward-to-rearward direction. In certain examples, as shown, the thickness TR of the toe arm portion 463A of the ring 406 at the toe portion 414 is less than the thickness TR of the heel arm portion 463B of the ring 406 at the heel portion 416.

The golf club heads disclosed herein, including the golf club head 100, the golf club head 200, and the golf club head 300, each has a volume, equal to the volumetric displacement of the golf club head, that is between 390 cubic centimeters (cm³or cc) and about 600 cm³. In more particular examples, the volume of each one of the golf club heads disclosed herein is between about 350 cm³and about 500 cm³or between about 420 cm³and about 500 cm³. The total mass of each one of the golf club heads disclosed herein is between about 145 g and about 245 g, in some examples, and between 185 g and 210 g in other examples.

The golf club heads disclosed herein have a multi-piece construction. For example, with regards to the golf club head 100, the cup 104, the ring 106, the crown insert 108, and the sole insert 110 each comprises one piece of the multi-piece construction. Because each piece of the multi-piece construction is separately formed and attached together, each piece can be made of a material different than at least one other of the pieces. Such a multi-material construction allows for flexibility of the material composition, and thus the mass composition and distribution, of the golf club heads.

The following properties of the golf club heads disclosed herein proceeds with reference to the golf club head 100. However, unless otherwise noted, the properties described with reference to the golf club head 100 also apply to the golf club head 200, the golf club head 300, and the golf club head 400. The golf club head 100 is made from at least one first material, having a density between 0.9 g/cc and 3.5 g/cc, at least one second material, having a density between 3.6 g/cc and 5.5 g/cc, and at least one third material, having a density between 5.6 g/cc and 20.0 g/cc. In a first example, the cup 104 is made of the third material, the ring 106 is made of the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this first example, according to one instance, the cup 104 is made of a steel alloy, the ring 106 is made of a titanium alloy, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. In a second example, the cup 104 is made of the second and third material, the ring 106 is made of the first or the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this second example, according to one instance, the cup 104 is made of a steel alloy and a titanium alloy, the ring 106 is made of a titanium alloy, aluminum alloy, or plastic, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material.

According to some examples, the at least one first material has a first mass no more than 55% of the total mass of the golf club head 100 and no less than 25% of the total mass of the golf club head 100 (e.g., between 50 g and 110 g). In certain examples, the first mass of the at least one first material is no more than 45% of the total mass of the golf club head 100 and no less than 30% of the total mass of the golf club head 100. The first mass of the at least one first material can be greater than the second mass of the at least one second material. Alternatively, or additionally, the first mass of the at least one first material can be within 10 g of the second mass of the at least one second material.

In some examples, the at least one second material has a second mass no more than 65% of the total mass of the golf club head 100 and no less than 20% of the total mass of the golf club head 100 (e.g., between 40 g and 130 g). According to certain examples, the second mass of the at least one second material is no more than 50% of the total mass of the golf club head 100. The second mass of the at least one second material is less than two times the first mass of the at least one first material in certain examples. The second mass of the at least one second material is between 0.9 times and 1.8 times the first mass of the at least one first material in some examples. In one example, the second mass of the at least one second material is less than 0.9 times, or less than 1.8 times, the first mass of the at least one first material.

The at least one third material has a third mass equal to the total mass of the golf club head 100 less the first mass of the at least one first material and the second mass of the at least one second material. In one example, the third mass of the at least one third material is no less than 5% of the total mass of the golf club head 100 and no more than 50% of the total mass of the golf club head 100 (e.g., between 10 g and 100 g). According to another example, the third mass of the at least one third material is no less than 10% of the total mass of the golf club head 100 and no more than 20% of the total mass of the golf club head 100.

According to one example, the cup 104 of the body 102 of the golf club head 100 is made from the at least one first material and the at least one first material is a first metal material that has a density between 4.0 g/cc and 8.0 g/cc. In this example, the ring 106 of the body 102 of the golf club head 100 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc. According to certain implementations, the first metal material of the cup 104 is a titanium alloy and/or a steel alloy and the material of the ring 106 is an aluminum alloy and/or a magnesium alloy. In some implementations, the first metal material of the cup 104 is a titanium alloy and/or a steel alloy and the material of the ring 106 is a non-metal material, such as a plastic or polymeric material. Accordingly, in some examples, the ring 106 is made of any of various materials, such as titanium alloys, aluminum alloys, and fiber-reinforced polymeric materials.

The ring 106, in some examples, is made of one of 6000-series, 7000-series, or 8000-series aluminum, which can be anodized to have a particular color the same as or different than the cup 104. According to some examples, the ring 106 can be anodized to have any one of an array of colors, including blue, red, orange, green, purple, etc. Contrasting colors between the ring 105 and the cup 104 may help with alignment or suit a user's preferences. In one example, the ring 106 is made of 7075 aluminum. According to some examples, the ring 106 is made of a fiber-reinforced polycarbonate material. The ring 106 can be made from a plastic with a non-conductive vacuum metallizing coating, which may also have any of various colors. Accordingly, in certain examples, the ring 106 is made of a titanium alloy, a steel alloy, a boron-infused steel alloy, a copper alloy, a beryllium alloy, composite material, hard plastic, resilient elastomeric material, carbon-fiber reinforced thermoplastic with short or long fibers. The ring 106 can be made via an injection molded, cast molded, physical vapor deposition, or CNC milled technique.

As described herein, the ring (e.g., the ring 106) of any of the club heads disclosed herein can comprise various different materials and features, and be made of different materials and have different properties than the cup (e.g., the cup 104), which is formed separately and later coupled to the ring. In addition to or alternative to other materials described herein, the ring can comprise metallic materials, polymeric materials, and/or composite materials, and can include various external coatings.

In some embodiments, the ring comprises anodized aluminum, such as 6000, 7000, and 8000 series aluminum. In one specific example, the ring comprises 7075 grade aluminum. The anodized aluminum can be colored, such as red, green, blue, gray, white, orange, purple, pink, fuchsia, black, clear, yellow, gold, silver, or metallic colors. In some embodiments, the ring can have a color that contrasts from a majority color located on other parts of the club head (e.g., the crown insert, the sole insert, the cup, the rear weight, etc.).

In some embodiments, the ring, as well as any of the disclosed components, can comprise any combination of metals, metal alloys (e.g., Ti alloys, steel alloys, boron infused steel alloys, aluminum alloys, copper alloys, beryllium alloys, magnesium alloys), composite materials (e.g., carbon fiber reinforced polymer, with short or long fibers), hard plastics, resilient elastomers, other polymeric materials, and/or other suitable materials. Any material selection for the ring, as well as any of the disclosed components, can also be combined with any of various formation methods, such as any combination of the following: casting, injection molding, sintering, machining, milling, forging, metal injection molding (MIM), metal additive manufacturing (metal AM), freeform injection molding that combines MIM and metal AM, extruding, stamping, and rolling.

A plastic ring (fiber reinforced polycarbonate ring) may offer both mass savings e.g. about 5 grams compared to an aluminum ring, cost savings as well, give greater design flexibility due to processes used to form the ring e.g. injection molded thermoplastic, and perform similarly to an aluminum ring in abuse testing e.g. slamming the club head into a concrete cart path (extreme abuse) or shaking it in a bag where other metal clubs can repeatedly impact it (normal abuse).

In some embodiments, the ring can comprise a polymeric material (e.g., plastic) with a non-conductive vacuum metallizing (NCVM) coating. For example, in some embodiments, the ring may include a primer layer having an average thickness of about 5-11 micrometers (μm) or about 8.5 μm, and under coating layer on top of the primer layer having an average thickness of about 5-11 μm or about 8.5 μm, a NCVM layer on top of under coating layer having an average thickness of about 1.1-3.5 μm or about 2.5 μm, a color coating layer on top of the NCVM layer having an average thickness of about 25-35 μm or about 29 μm, and a top coating (UV protection coat) outer layer on top of the color coating layer having an average thickness of about 20-35 μm or about 26 μm. In general, for a NCVM coated part or ring the NCVM layer will be the thinnest and the color coating layer and the top coating layers will be the thickest and generally about 8-15 times thicker than NCVM layer. Generally, all the layers will combine to have a total average thickness of about 60-90 μm or about 75 μm. The described layers and NCVM coating could be applied to other parts other than the ring, such as the crown, sole, forward cup, and removable weights, and it can be applied prior to assembly.

In some embodiments, the ring can comprise a physical vapor deposition (PVD) coating or film layer. In some embodiments, the ring can include a paint layer, or other outer coloring layer. Conventionally, painting a golf club heads is all done by hand and requires masking various components to prevent unwanted spray on unwanted surfaces. Hand painting, however, can lead to great inconsistency from club to club. Separately forming the ring not only allows for greater access to the rearward portion of the face for milling operations to remove unwanted alpha case and allows for machining in various face patterns, but it also eliminates the need for masking off various components. The ring can be painted in isolation prior to assembly. Or in the case of anodized aluminum, no painting may be necessary, eliminating a step in the process such that the ring can simply be bonded or attached to a cup that may also be fully finished. Similarly if the ring is coated using PVD or NCVM, this coating can be applied to the ring prior to assembly, again eliminating several steps. This also allows for attachment of various color rings that may be selectable by an end user to provide an alignment or aesthetic benefit to the user. Whether the ring is a NCVM coated ring or a PVD coated ring, as mentioned above, it can be colored an array of colors, such as red, green, blue, gray, white, orange, purple, pink, fuchsia, black, clear, yellow, gold, silver, or metallic colors.

The following properties of the golf club heads disclosed herein proceeds with reference to the golf club head 100. However, unless otherwise noted, the properties described with reference to the golf club head 100 also apply to the golf club head 200, the golf club head 300, and the golf club head 400. The golf club head 100 is made from two of at least one first material, having a density between 0.9 g/cc and 3.5 g/cc, at least one second material, having a density between 3.6 g/cc and 5.5 g/cc, and at least one third material, having a density between 5.6 g/cc and 20.0 g/cc. In a first example, the cup 104 is made of the second material and the ring 106, the crown insert 108, and the sole insert 110 are made of the first material. In this first example, according to one instance, the cup 104 is made of a titanium alloy, the ring 106 is made of an aluminum alloy, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. In this first example, according to another instance, the cup 104 is made of a titanium alloy, the ring 106 is made of plastic, and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material. According to a second example, the cup 104 is made of the second material, the ring 106 is made of the second material, and the crown insert 108 and the sole insert 110 are made of the first material. In this second example, according to one instance, the cup 104 and the ring 106 are made of a titanium alloy and the crown insert 108 and the sole insert 110 are made of a fiber-reinforced polymeric material.

In some examples, the at least one first material is a fiber-reinforced polymeric material that includes continuous fibers embedded in a polymeric matrix (e.g., epoxy or resin), which is a thermoset polymer is certain examples. The continuous fibers are considered continuous because each one of the fibers is continuous across a length, width, or diagonal of the part formed by the fiber-reinforced polymeric material. The continuous fibers can be long fibers having a length of at least 3 millimeters, 10 millimeters, or even 50 millimeters. In other embodiments, shorter fibers can be used having a length of between 0.5 and 2.0 millimeters. Incorporation of the fiber reinforcement increases the tensile strength, however it may also reduce elongation to break therefore a careful balance can be struck to maintain sufficient elongation. Therefore, one embodiment includes 35-55% long fiber reinforcement, while in an even further embodiment has 40-50% long fiber reinforcement. The continuous fibers, as well as the fiber-reinforced polymeric material in general, can be the same or similar to that described in Paragraph 295 of U.S. Patent Application Publication No. 2016/0184662, published Jun. 30, 2016, now U.S. Pat. No. 9,468,816, issued Oct. 18, 2016, which is incorporated herein by reference in its entirety. In several examples, the crown insert 108 and the sole insert 110 are made of the fiber-reinforced polymeric material. Accordingly, in some examples, each one of the continuous fibers of the fiber-reinforced polymeric material does not extend from the crown portion 119 to the sole portion 117 of the golf club head 100. Alternatively, or additionally, in certain examples, each one of the continuous fibers of the fiber-reinforced polymeric material does not extend from the crown portion 119 to the forward portion 112 of the golf club head 100. The crown insert 108 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc in one example. The sole insert 110 is made of a material that has a density between 0.5 g/cc and 4.0 g/cc in one example.

In certain examples, the first material is a fiber-reinforced polymeric material as described in U.S. patent application Ser. No. 17/006,561, filed Aug. 28, 2020. Composite materials that are useful for making club-head components comprise a fiber portion and a resin portion. In general the resin portion serves as a “matrix” in which the fibers are embedded in a defined manner. In a composite for club-heads, the fiber portion is configured as multiple fibrous layers or plies that are impregnated with the resin component. The fibers in each layer have a respective orientation, which is typically different from one layer to the next and precisely controlled. The usual number of layers for a striking face is substantial, e.g., forty or more. However for a sole or crown, the number of layers can be substantially decreased to, e.g., three or more, four or more, five or more, six or more, examples of which will be provided below. During fabrication of the composite material, the layers (each comprising respectively oriented fibers impregnated in uncured or partially cured resin; each such layer being called a “prepreg” layer) are placed superimposed on each other in a “lay-up” manner. After forming the prepreg lay-up, the resin is cured to a rigid condition. If interested, a specific strength may be calculated by dividing the tensile strength by the density of the material. This is also known as the strength-to-weight ratio or strength/weight ratio.

In tests involving certain club-head configurations, composite portions formed of prepreg plies having a relatively low fiber areal weight (FAW) have been found to provide superior attributes in several areas, such as impact resistance, durability, and overall club performance. FAW is the weight of the fiber portion of a given quantity of prepreg, in units of g/m². FAW values below 100 g/m², and more desirably below 70 g/m², can be particularly effective. A particularly suitable fibrous material for use in making prepreg plies is carbon fiber, as noted. More than one fibrous material can be used. In other embodiments, however, prepreg plies having FAW values below 70 g/m²and above 100 g/m²may be used. Generally, cost is the primary prohibitive factor in prepreg plies having FAW values below 70 g/m².

FIG. 26 is a front elevation view of a strike plate 943, which can replace any one of the strike plates disclosed herein. The strike plate 943 is made of composite materials, and can be termed a composite strike plate in some examples. The non-metal or composite material of the strike plate 943 comprises a fiber-reinforced polymer comprising fibers embedded in a resin. A percent composition of the resin in the fiber-reinforced polymer is between 38% and 44%. Further details concerning the construction and manufacturing processes for the composite strike plate 943 are described in U.S. Pat. No. 7,871,340 and U.S. Published Patent Application Nos. 2011/0275451, 2012/0083361, and 2012/0199282, which are incorporated herein by reference. The composite strike plate 943 is attached to an insert support structure located at the opening at the front portion of a golf club head, such as one disclosed herein.

In some examples, the strike plate 943 can be machined from a composite plaque. In an example, the composite plaque can be substantially rectangular with a length between about 90 mm and about 130 mm or between about 100 mm and about 120 mm, preferably about 110 mm±1.0 mm, and a width between about 50 mm and about 90 mm or between about 6 mm and about 80 mm, preferably about 70 mm+1.0 mm plaque size and dimensions. The strike plate 943 is then machined from the plaque to create a desired face profile. For example, the face profile length 912 can be between about 80 mm and about 120 mm or between about 90 mm and about 110 mm, preferably about 102 mm. The face profile width 911 can be between about 40 mm and about 65 mm or between about 45 mm and about 60 mm, preferably about 53 mm. The height 913 of a preferred impact zone 953 on the strike face, defined by the strike plate 943 and centered on a geometric center of the strike face, can be between about 25 mm and about 50 mm, between about 30 mm and about 40 mm, or between about 17 mm and about 45 mm, such as preferably about 34 mm. The length 914 of the preferred impact zone 953 can be between about 40 mm and about 70 mm, between about 28 mm and about 65 mm, or between about 45 mm and about 65 mm, preferably about 55.5 mm or 56 mm. In certain examples, the preferred impact zone 953 of the strike face defined by the strike plate 943 has an area between 500 mm²and 1,800 mm². Alternatively, the strike plate 943 can be molded to provide the desired face dimensions and profile.

Additional features can be machined or molded into face the strike plate 943 to create the desired face profile. For example, as shown in FIG. 27, a notch 920 can be machined or molded into the backside of a heel portion of the strike plate 943. The notch 920 in the back of the strike plate 943 allows for the golf club head to utilize flight control technology (FCT) in the hosel, in some examples. The notch 920 can be configured to accept at least a portion of the hosel within the strike plate 943. Alternatively or additionally, the notch 920 can be configured to accept at least a portion of the club head body within the strike plate 943. The notch may allow for the reduction of center-face y-axis location (CFY) by accommodating at least a portion of the hosel and/or at least a portion of the club body within the strike plate 943, allowing the preferred impact zone 953 of the strike plate 943 to be closer to a plane passing through a center point location of the hosel. The strike plate 943 can be configured to provide a CFY no more than about 18 mm and no less than about 9 mm, preferably between about 11.0 mm and about 16.0 mm, and more preferably no more than about 15.5 mm and no less than about 11.5 mm. The strike plate 943 can be configured to provide face progression no more than about 21 mm and no less than about 12 mm, preferably no more than about 19.5 mm and no less than about 13 mm and more preferably no more than about 18 mm and no less than about 14.5 mm. In some embodiments, a difference between CFY and face progression is at least 3 mm and no more than 12 mm.

In another example, backside bumps 4230A, 4230B, 4230C, 4230D may be machined or molded into the backside of the strike plate 943. The backside bumps 4230A, 4230B, 4230C, 4230D can be configured to provide for a bond gap. A bond gap is an empty space between the club head body and the strike plate 943 that is filled with adhesive during manufacturing. The backside bumps 4230A, 4230B, 4230C, 4230D protrude to separate the face from the club head body when bonding the strike plate 943 to the club head body during manufacturing. In some examples, too large or too small of a bond gap may lead to durability issues of the club head, the strike plate 943, or both. Further, too large of a bond gap can allow too much adhesive to be used during manufacturing, adding unwanted additional mass to the club head. The backside bumps 4230A, 4230B, 4230C, 4230D can protrude between about 0.1 mm and 0.5 mm, preferably about 0.25 mm. In some embodiments, the backside bumps are configured to provide for a minimum bond gap, such as a minimum bond gap of about 0.25 mm and a maximum bond gap of about 0.45 mm.

Further, one or more of the edges of the strike plate 943 can be machined or molded with a chamfer. In an example, the strike plate 943 includes a chamfer substantially around the inside perimeter edge of the strike plate 943, such as a chamfer between about 0.5 mm and about 1.1 mm, preferably 0.8 mm.

FIG. 27 is a is a bottom perspective view of the strike plate 943. The strike plate 943 has a heel portion 941 and a toe portion 942. The notch 920 is machined or molded into the heel portion 941. In this example, the strike plate 943 has a variable thickness, such as with a peak thickness 947 within the preferred impact zone 953. The peak thickness 947 can be between about 2 mm and about 7.5 mm, between about 4.3 mm and 5.15 mm, between about 4.0 mm and about 5.15 or 5.5 mm, or between about 3.8 mm and about 4.8 mm, preferably 4.1 mm+0.1 mm, mm+0.1 mm, or 4.5 mm+0.1 mm. The peak thickness 947 can be located at the geometric center of the strike face defines by the strike plate 943. A minimum thickness of the strike plate 943 is between 3.0 mm and 4.0 mm in some examples.

Additionally, in certain examples, the preferred impact zone 953 is off-center or offset relative to the geometric center of the strike face, and can be thicker toeward of the geometric center of the strike face. In some examples, the thickness of the strike plate 943 within the preferred impact zone 953 is variable (e.g., between about 3.5 mm and about 5.0 mm) and the thickness of the strike plate 943 outside of the preferred impact zone 953 is constant (e.g., between 3.5 mm and 4.2 mm) and less than within preferred impact zone 953. In some examples, the strike plate 943 have a thickness between 3.5 mm and 6.0 mm.

The strike plate 943 has a toe edge region and a heel edge region outside of the preferred impact zone 953 such that the preferred impact zone is between the toe edge region and the heel edge region. The toe edge region is closer to the toe portion than the heel edge region. The heel edge region is closer to the heel portion than the toe edge region. The toe edge region thickness is less than the maximum thickness. A thickness of the strike plate 943 transitions from the maximum thickness, within the preferred impact zone 953, to a toe edge region thickness, within the toe edge region, between 3.85 mm and 4.5 mm.

In some embodiments, the strike plate 943 is manufactured from multiple layers of composite materials. Exemplary composite materials and methods for making the same are described in U.S. patent application Ser. No. 13/452,370 (published as U.S. Pat. App. Pub. No. 2012/0199282), which is incorporated by reference. In some embodiments, an inner and outer surface of the composite face can include a scrim layer, such as to reinforce the strike plate 943 with glass fibers making up a scrim weave. Multiple quasi-isotropic panels (Q's) can also be included, with each Q panel using multiple plies of unidirectional composite panels offset from each other. In an exemplary four-ply Q panel, the unidirectional composite panels are oriented at 90°, −45°, 0°, and 45°, which provide for structural stability in each direction. Clusters of unidirectional strips (C's) can also be included, with each C using multiple unidirectional composite strips. In an exemplary four-strip C, four 27 mm strips are oriented at 0°, 125°, 90°, and 55°. C's can be provided to increase thickness of the strike plate 943 in a localized area, such as in the center face at the preferred impact zone. Some Q's and C's can have additional or fewer plies (e.g., three-ply rather than four-ply), such as to fine tune the thickness, mass, localized thickness, and provide for other properties of the strike plate 943, such as to increase or decrease COR of the strike plate 943.

In some embodiments, the strike face, such as the strike plate 243, of some examples of the golf club head disclosed herein is manufactured from multiple layers of composite materials. Exemplary composite materials and methods for making the same are described in U.S. patent application Ser. No. 13/452,370 (published as U.S. Pat. App. Pub. No. 2012/0199282), which is incorporated by reference. In some embodiments, an inner and outer surface of the composite face can include a scrim layer, such as to reinforce the strike face with glass fibers making up a scrim weave. Multiple quasi-isotropic panels (Q's) can also be included, with each Q panel using multiple plies of unidirectional composite panels offset from each other. In an exemplary four-ply Q panel, the unidirectional composite panels are oriented at 90°, −45°, 0°, and 45°, which provide for structural stability in each direction. Clusters of unidirectional strips (C's) can also be included, with each C using multiple unidirectional composite strips. In an exemplary four-strip C, four 27 mm strips are oriented at 0°, 125°, 90°, and 55°. C's can be provided to increase thickness of the strike face, or other composite features, in a localized area, such as in the center face at the preferred impact zone. Some Q's and C's can have additional or fewer plies (e.g., three-ply rather than four-ply), such as to fine tune the thickness, mass, localized thickness, and provide for other properties of the strike face, such as to increase or decrease COR of the strike face.

Additional composite materials and methods for making the same are described in U.S. Pat. Nos. 8,163,119 and 10,046,212, which is incorporated by reference. For example, the usual number of layers for a strike plate is substantial, e.g., fifty or more. However, improvements have been made in the art such that the layers may be decreased to between 30 and 50 layers. According to one example, the strike plate, according to any of the various examples disclosed herein, when made of a fiber-reinforced polymeric material, can be made in a manner the same as, or similar to, that described in U.S. patent application Ser. No. 17/321,315, filed May 14, 2021, and U.S. Provisional Patent Application No. 63/312,771, filed Feb. 22, 2022, which are incorporated herein by reference in their entireties.

The Area Weight (AW) is calculated by multiplying the density times the thickness. For the plies shown above made from composite material the density is about 1.5 g/cm³and for titanium the density is about 4.5 g/cm³.

In general, a composite face plate or composite face insert may have a peak thickness that varies between about 3.8 mm and 5.15 mm. In general, the composite face plate is formed from multiple composite plies or layers. The usual number of layers for a composite striking face is substantial, e.g., forty or more, preferably between 30 to 75 plies, more preferably, 50 to 70 plies, even more preferably 55 to 65 plies.

In an example, a first composite face insert can have a peak thickness of 4.1 mm and an edge thickness of 3.65 mm, including 12 Q's and 2 C's, resulting in a mass of 24.7 g. In another example, a second composite face insert can have a peak thickness of 4.25 mm and an edge thickness of 3.8 mm, including 12 Q's and 2 C's, resulting in a mass of 25.6 g. The additional thickness and mass is provided by including additional plies in one or more of the Q's or C's, such as by using two 4-ply Q's instead of two 3-ply Q's. In yet another example, a third composite face insert can have a peak thickness of 4.5 mm and an edge thickness of 3.9 mm, including 12 Q's and 3 C's, resulting in a mass of 26.2 g. Additional and different combinations of Q's and C's can be provided for a composite strike plate (e.g., face insert) with a mass between about 20 g and about 30 g, or between about 15 g and about 35 g. In some examples, wherein the strike plate, such as the strike plate 943, has a total mass between 22 grams and 28 grams.

FIG. 28A is a section view of a heel portion 41 of the strike plate 943. The heel portion 941 can include a notch 920. In embodiments with a chamfer on an inside edge of the strike plate 943, no chamfer 950 is provided on the notch 920. The notch 920 can have a notch edge thickness 944 less than the edge thickness 945 of the strike plate 943 (see, e.g., FIG. 28B). For example, the notch edge thickness 944 can be between 1.5 mm and 2.1 mm, preferably 1.8 mm.

FIG. 28B is a section view of a toe portion 942 of the strike plate 943. The toe portion 942 includes a chamfer 951 on the inside edge of the strike plate 943. In some embodiments, the edge thickness 945 can be between about 3.35 mm and about 4.2 mm, preferably 3.65 mm±0.1 mm, 3.8 mm±0.1 mm, or 3.9 mm±0.1 mm.

FIG. 29 is a section view of a polymer layer 900 of the strike plate 943. The polymer layer 900 can be provided on the outer surface of the strike plate 943 to provide for better performance of the strike plate 943, such as in wet conditions. Exemplary polymer layers are described in U.S. patent application Ser. No. 13/330,486 (patented as U.S. Pat. No. 8,979,669), which is incorporated by reference. The polymer layer 900 may include polyurethane and/or other polymer materials. The polymer layer may have a polymer maximum thickness 960 between about 0.2 mm and 0.7 mm or about 0.3 mm and about 0.5 mm, preferably 0.40 mm±0.05 mm. The polymer layer may have a polymer minimum thickness 970 between about 0.05 mm and 0.15 mm, preferably 0.09 mm±0.02 mm. The polymer layer can be configured with alternating maximum thicknesses 960 and minimum thicknesses 970 to create score lines on the strike plate 943. Further, in some embodiments, teeth and/or another texture may be provided on the thicker areas of the polymer layer 900 between the score lines.

In some examples, the crown insert, such as the crown insert 108, and the sole insert, such as the sole insert 110, are made of a carbon-fiber reinforced polymeric material. In one example, the crown insert is made of layers of unidirectional tape, woven cloth, and composite plies.

Referring to FIG. 4, the golf club head 100 has a face-back dimension (FBD) defined as the distance between a hypothetical plane 169, passing through the center face 183 of the strike face 145 and parallel to the strike face 145, and a rearmost point on the golf club head 100 in a face-back direction 165 perpendicular to the hypothetical plane 169. As defined herein, the center face 183 is located at 0% of the face-back dimension (FBD) and the rearmost point is located at 100% of the face-back dimension (FBD). Under this definition, the golf club head 100 can be divided into a face section that extends, in the face-back direction 165, from 0% of the face-back dimension (FBD) to 25% of the face-back dimension (FBD), a middle section that extends, in the face-back direction 165, from 25% to 75% of the face-back dimension (FBD), and a back section that extends, in the face-back direction 165, from 75% to 100% of the face-back dimension (FBD). According to some examples, at least 95% by weight of the middle section is made of a material having a density between 0.9 g/cc and 4.0 g/cc. In certain examples, at least 95% by weight of the middle section is made of material having a density between 0.9 g/cc and 2.0 g/cc. In some examples, at least 95% by weight of the middle section and at least 95% by weight of the back section are made of a material having a density between 0.9 g/cc and 2.0 g/cc, excluding any attached weights and any housings for the attached weights. No more than 20% by weight of the middle section and no more than 20% by weight of the back section are made of a material having a density between 4.0 g/cc and 20.0 g/cc, according to various examples.

In some examples, the golf club head 100 includes one or more of the following materials: carbon steel, stainless steel (e.g. 17-4 PH stainless steel), alloy steel, Fe—Mn—Al alloy, nickel-based ferroalloy, cast iron, super alloy steel, aluminum alloy (including but not limited to 3000 series alloys, 5000 series alloys, 6000 series alloys, such as 6061-T6, and 7000 series alloys, such as 7075), magnesium alloy, copper alloy, titanium alloy (including but not limited to 6-4 titanium, 3-2.5, 6-4, SP700, 15-3-3-3, 10-2-3, Ti 9-1-1, ZA 1300, or other alpha/near alpha, alpha-beta, and beta/near beta titanium alloys) or mixtures thereof.

In one example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is a 9-1-1 titanium alloy. Titanium alloys comprising aluminum (e.g., 8.5-9.5% Al), vanadium (e.g., 0.9-1.3% V), and molybdenum (e.g., 0.8-1.1% Mo), optionally with other minor alloying elements and impurities, herein collectively referred to a “9-1-1 Ti”, can have less significant alpha case, which renders HF acid etching unnecessary or at least less necessary compared to faces made from conventional 6-4 Ti and other titanium alloys. Further, 9-1-1 Ti can have minimum mechanical properties of 820 MPa yield strength, 958 MPa tensile strength, and 10.2% elongation. These minimum properties can be significantly superior to typical cast titanium alloys, such as 6-4 Ti, which can have minimum mechanical properties of 812 MPa yield strength, 936 MPa tensile strength, and ˜6% elongation. In certain examples, the titanium alloy is 8-1-1 Ti.

In another example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is an alpha-beta titanium alloy comprising 6.5% to 10% Al by weight, 0.5% to 3.25% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti (one example is sometimes referred to as “1300” or “ZA1300” titanium alloy). The alpha-beta titanium alloy or ZA1300 titanium alloy has a first ultimate tensile strength of at least 1,000 MPa in some examples and at least 1,100 MPa in other examples. An ultimate tensile strength of the material forming the body 102, other than the strike face 145, can be less than the first ultimate tensile strength by at least 10%. In another representative example, the alloy may comprise 6.75% to 9.75% Al by weight, 0.75% to 3.25% or 2.75% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti. In yet another representative example, the alloy may comprise 7% to 9% Al by weight, 1.75% to 3.25% Mo by weight, 1.25% to 2.75% Cr by weight, 0.5% to 1.5% V by weight, and/or 0.25% to 0.75% Fe by weight, with the balance comprising Ti. In a further representative example, the alloy may comprise 7.5% to 8.5% Al by weight, 2.0% to 3.0% Mo by weight, 1.5% to 2.5% Cr by weight, 0.75% to 1.25% V by weight, and/or 0.375% to 0.625% Fe by weight, with the balance comprising Ti. In another representative example, the alloy may comprise 8% Al by weight, 2.5% Mo by weight, 2% Cr by weight, 1% V by weight, and/or 0.5% Fe by weight, with the balance comprising Ti (such titanium alloys can have the formula Ti-8Al-2.5Mo-2Cr-1V-0.5Fe). As used herein, reference to “Ti-8Al-2.5Mo-2Cr-1V-0.5Fe” refers to a titanium alloy including the referenced elements in any of the proportions given above. Certain examples may also comprise trace quantities of K, Mn, and/or Zr, and/or various impurities.

Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have minimum mechanical properties of 1150 MPa yield strength, 1180 MPa ultimate tensile strength, and 8% elongation. These minimum properties can be significantly superior to other cast titanium alloys, including 6-4 Ti and 9-1-1 Ti, which can have the minimum mechanical properties noted above. In some examples, Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have a tensile strength of from about 1180 MPa to about 1460 MPa, a yield strength of from about 1150 MPa to about 1415 MPa, an elongation of from about 8% to about 12%, a modulus of elasticity of about 110 GPa, a density of about 4.45 g/cm³, and a hardness of about 43 on the Rockwell C scale (43 HRC). In particular examples, the Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy can have a tensile strength of about 1320 MPa, a yield strength of about 1284 MPa, and an elongation of about 10%. The Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy, particularly when used to cast golf club head bodies, promotes less deflection for the same thickness due to a higher ultimate tensile strength compared to other materials. In some implementations, providing less deflection with the same thickness benefits golfers with higher swing speeds because over time the face of the golf club head will maintain its original shape over time.

In yet certain examples, the golf club head 100 is made of a non-metal material with a density less than about 2 g/cm³, such as between about 1 g/cm³to about 2 g/cm³. The non-metal material may include a polymer, such as fiber-reinforced polymeric material. The polymer can be either thermoset or thermoplastic, and can be amorphous, crystalline and/or a semi-crystalline structure. The polymer may also be formed of an engineering plastic such as a crystalline or semi-crystalline engineering plastic or an amorphous engineering plastic. Potential engineering plastic candidates include polyphenylene sulfide ether (PPS), polyethelipide (PEI), polycarbonate (PC), polypropylene (PP), acrylonitrile-butadience styrene plastics (ABS), polyoxymethylene plastic (POM), nylon 6, nylon 6-6, nylon 12, polymethyl methacrylate (PMMA), polypheylene oxide (PPO), polybothlene terephthalate (PBT), polysulfone (PSU), polyether sulfone (PES), polyether ether ketone (PEEK) or mixtures thereof. Organic fibers, such as fiberglass, carbon fiber, or metallic fiber, can be added into the engineering plastic, so as to enhance structural strength. The reinforcing fibers can be continuous long fibers or short fibers. One of the advantages of PSU is that it is relatively stiff with relatively low damping which produces a better sounding or more metallic sounding golf club compared to other polymers which may be overdamped. Additionally, PSU requires less post processing in that it does not require a finish or paint to achieve a final finished golf club head.

One exemplary material from which any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, can be made from is a thermoplastic continuous carbon fiber composite laminate material having long, aligned carbon fibers in a PPS (polyphenylene sulfide) matrix or base. A commercial example of a fiber-reinforced polymer, from which the sole insert 110, the crown insert 108, and/or the strike face can be made, is TEPEX® DYNALITE 207 manufactured by Lanxess®. TEPEX® DYNALITE 207 is a high strength, lightweight material, arranged in sheets, having multiple layers of continuous carbon fiber reinforcement in a PPS thermoplastic matrix or polymer to embed the fibers. The material may have a 54% fiber volume, but can have other fiber volumes (such as a volume of 42% to 57%). According to one example, the material weighs 200 g/m². Another commercial example of a fiber-reinforced polymer, from which the sole insert 110, crown insert 108, and/or the strike face is made, is TEPEX® DYNALITE 208. This material also has a carbon fiber volume range of 42 to 57%, including a 45% volume in one example, and a weight of 200 g/m². DYNALITE 208 differs from DYNALITE 207 in that it has a TPU (thermoplastic polyurethane) matrix or base rather than a polyphenylene sulfide (PPS) matrix.

By way of example, the fibers of each sheet of TEPEX® DYNALITE 207 sheet (or other fiber-reinforced polymer material, such as DYNALITE 208) are oriented in the same direction with the sheets being oriented in different directions relative to each other, and the sheets are placed in a two-piece (male/female) matched die, heated past the melt temperature, and formed to shape when the die is closed. This process may be referred to as thermoforming and is especially well-suited for forming the sole insert 110, the crown insert 108, and/or the strike face. After the sole insert 110, the crown insert 108, and/or the strike face are formed (separately, in some implementations) by the thermoforming process, each is cooled and removed from the matched die. In some implementations, the sole insert 110, the crown insert 108, and/or the strike face has a uniform thickness, which facilitates use of the thermoforming process and ease of manufacture. However, in other implementations, the sole insert 110, the crown insert 108, and/or the strike face may have a variable thickness to strengthen select local areas of the insert by, for example, adding additional plies in select areas to enhance durability, acoustic properties, or other properties of the respective inserts.

In some examples, any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, can be made by a process other than thermoforming, such as injection molding or thermosetting. In a thermoset process, any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, may be made from “prepreg” plies of woven or unidirectional composite fiber fabric (such as carbon fiber composite fabric) that is preimpregnated with resin and hardener formulations that activate when heated. The prepreg plies are placed in a mold suitable for a thermosetting process, such as a bladder mold or compression mold, and stacked/oriented with the carbon or other fibers oriented in different directions. The plies are heated to activate the chemical reaction and form the crown insert 108 and/or a sole insert. Each insert is cooled and removed from its respective mold.

The carbon fiber reinforcement material for any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, made by the thermoset manufacturing process, may be a carbon fiber known as “34-700” fiber, available from Grafil, Inc., of Sacramento, California, which has a tensile modulus of 234 Gpa (34 Msi) and a tensile strength of 4500 Mpa (650 Ksi). Another suitable fiber, also available from Grafil, Inc., is a carbon fiber known as “TR50S” fiber which has a tensile modulus of 240 Gpa (35 Msi) and a tensile strength of 4900 Mpa (710 Ksi). Exemplary epoxy resins for the prepreg plies used to form the thermoset crown and sole inserts include Newport 301 and 350 and are available from Newport Adhesives & Composites, Inc., of Irvine, California. In one example, the prepreg sheets have a quasi-isotropic fiber reinforcement of 34-700 fiber having an areal weight between about 20 g/m{circumflex over ( )}2 to about 200 g/m{circumflex over ( )}2 preferably about 70 g/m{circumflex over ( )}2 and impregnated with an epoxy resin (e.g., Newport 301), resulting in a resin content (R/C) of about 40%. For convenience of reference, the plipary composition of a prepreg sheet can be specified in abbreviated form by identifying its fiber areal weight, type of fiber, e.g., 70 FAW 34-700. The abbreviated form can further identify the resin system and resin content, e.g., 70 FAW 34-700/301, R/C 40%.

In some examples, polymers used in the manufacturing of the golf club head 100 may include without limitation, synthetic and natural rubbers, thermoset polymers such as thermoset polyurethanes or thermoset polyureas, as well as thermoplastic polymers including thermoplastic elastomers such as thermoplastic polyurethanes, thermoplastic polyureas, metallocene catalyzed polymer, unimodalethylene/carboxylic acid copolymers, unimodal ethylene/carboxylic acid/carboxylate terpolymers, bimodal ethylene/carboxylic acid copolymers, bimodal ethylene/carboxylic acid/carboxylate terpolymers, polyamides (PA), polyketones (PK), copolyamides, polyesters, copolyesters, polycarbonates, polyphenylene sulfide (PPS), cyclic olefin copolymers (COC), polyolefins, halogenated polyolefins [e.g. chlorinated polyethylene (CPE)], halogenated polyalkylene compounds, polyalkenamer, polyphenylene oxides, polyphenylene sulfides, diallylphthalate polymers, polyimides, polyvinyl chlorides, polyamide-ionomers, polyurethane ionomers, polyvinyl alcohols, polyarylates, polyacrylates, polyphenylene ethers, impact-modified polyphenylene ethers, polystyrenes, high impact polystyrenes, acrylonitrile-butadiene-styrene copolymers, styrene-acrylonitriles (SAN), acrylonitrile-styrene-acrylonitriles, styrene-maleic anhydride (S/MA) polymers, styrenic block copolymers including styrene-butadiene-styrene (SBS), styrene-ethylene-butylene-styrene, (SEBS) and styrene-ethylene-propylene-styrene (SEPS), styrenic terpolymers, functionalized styrenic block copolymers including hydroxylated, functionalized styrenic copolymers, and terpolymers, cellulosic polymers, liquid crystal polymers (LCP), ethylene-propylene-diene terpolymers (EPDM), ethylene-vinyl acetate copolymers (EVA), ethylene-propylene copolymers, propylene elastomers (such as those described in U.S. Pat. No. 6,525,157, to Kim et al, the entire contents of which is hereby incorporated by reference), ethylene vinyl acetates, polyureas, and polysiloxanes and any and all combinations thereof.

Of these preferred are polyamides (PA), polyphthalimide (PPA), polyketones (PK), copolyamides, polyesters, copolyesters, polycarbonates, polyphenylene sulfide (PPS), cyclic olefin copolymers (COC), polyphenylene oxides, diallylphthalate polymers, polyarylates, polyacrylates, polyphenylene ethers, and impact-modified polyphenylene ethers. Especially preferred polymers for use in the golf club heads of the present invention are the family of so called high performance engineering thermoplastics which are known for their toughness and stability at high temperatures. These polymers include the polysulfones, the polyethelipides, and the polyamide-imides. Of these, the most preferred are the polysufones.

Aromatic polysulfones are a family of polymers produced from the condensation polymerization of 4,4′-dichlorodiphenylsulfone with itself or one or more dihydric phenols. The aromatic polysulfones include the thermoplastics sometimes called polyether sulfones, and the general structure of their repeating unit has a diaryl sulfone structure which may be represented as -arylene-SO2-arylene-. These units may be linked to one another by carbon-to-carbon bonds, carbon-oxygen-carbon bonds, carbon-sulfur-carbon bonds, or via a short alkylene linkage, so as to form a thermally stable thermoplastic polymer. Polymers in this family are completely amorphous, exhibit high glass-transition temperatures, and offer high strength and stiffness properties even at high temperatures, making them useful for demanding engineering applications. The polymers also possess good ductility and toughness and are transparent in their natural state by virtue of their fully amorphous nature. Additional key attributes include resistance to hydrolysis by hot water/steam and excellent resistance to acids and bases. The polysulfones are fully thermoplastic, allowing fabrication by most standard methods such as injection molding, extrusion, and thermoforming. They also enjoy a broad range of high temperature engineering uses.

Three commercially important polysulfones are a) polysulfone (PSU); b) Polyethersulfone (PES also referred to as PESU); and c) Polyphenylene sulfoner (PPSU).

In some examples, one exemplary material from which any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, can be made from is a composite material, such as a carbon fiber reinforced polymeric material, made of a composite including multiple plies or layers of a fibrous material (e.g., graphite, or carbon fiber including turbostratic or graphitic carbon fiber or a hybrid structure with both graphitic and turbostratic parts present). Examples of some of these composite materials for use in the and their fabrication procedures are described in U.S. patent application Ser. No. 10/442,348 (now U.S. Pat. No. 7,267,620), Ser. No. 10/831,496 (now U.S. Pat. No. 7,140,974), Ser. Nos. 11/642,310, 11/825,138, 11/998,436, 11/895,195, 11/823,638, 12/004,386, 12,004,387, 11/960,609, 11/960,610, and 12/156,947, which are incorporated herein by reference in their entirety. The composite material may be manufactured according to the methods described at least in U.S. patent application Ser. No. 11/825,138, the entire contents of which are herein incorporated by reference.

Alternatively, short or long fiber-reinforced formulations of the previously referenced polymers can be used. Exemplary formulations include a Nylon 6/6 polyamide formulation, which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 285. This material has a Tensile Strength of 35000 psi (241 MPa) as measured by ASTM D 638; a Tensile Elongation of 2.0-3.0% as measured by ASTM D 638; a Tensile Modulus of 3.30×106 psi (22754 MPa) as measured by ASTM D 638; a Flexural Strength of 50000 psi (345 MPa) as measured by ASTM D 790; and a Flexural Modulus of 2.60×106 psi (17927 MPa) as measured by ASTM D 790.

Other materials also include is a polyphthalamide (PPA) formulation which is 40% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 4087 UP. This material has a Tensile Strength of 360 MPa as measured by ISO 527; a Tensile Elongation of 1.4% as measured by ISO 527; a Tensile Modulus of 41500 MPa as measured by ISO 527; a Flexural Strength of 580 MPa as measured by ISO 178; and a Flexural Modulus of 34500 MPa as measured by ISO 178.

Yet other materials include is a polyphenylene sulfide (PPS) formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 1385 UP. This material has a Tensile Strength of 255 MPa as measured by ISO 527; a Tensile Elongation of 1.3% as measured by ISO 527; a Tensile Modulus of 28500 MPa as measured by ISO 527; a Flexural Strength of 385 MPa as measured by ISO 178; and a Flexural Modulus of 23,000 MPa as measured by ISO 178.

Especially preferred materials include a polysulfone (PSU) formulation which is 20% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 983. This material has a Tensile Strength of 124 MPa as measured by ISO 527; a Tensile Elongation of 2% as measured by ISO 527; a Tensile Modulus of 11032 MPa as measured by ISO 527; a Flexural Strength of 186 MPa as measured by ISO 178; and a Flexural Modulus of 9653 MPa as measured by ISO 178.

Also, preferred materials may include a polysulfone (PSU) formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 985. This material has a Tensile Strength of 138 MPa as measured by ISO 527; a Tensile Elongation of 1.2% as measured by ISO 527; a Tensile Modulus of 20685 MPa as measured by ISO 527; a Flexural Strength of 193 MPa as measured by ISO 178; and a Flexural Modulus of 12411 MPa as measured by ISO 178.

Further preferred materials include a polysulfone (PSU) formulation which is 40% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 987. This material has a Tensile Strength of 155 MPa as measured by ISO 527; a Tensile Elongation of 1% as measured by ISO 527; a Tensile Modulus of 24132 MPa as measured by ISO 527; a Flexural Strength of 241 MPa as measured by ISO 178; and a Flexural Modulus of 19306 MPa as measured by ISO 178.

Any one or more of the sole insert 110, the crown insert 108, the cup 104, the ring 106, and/or the strike face, such as the strike plate 243, can have a complex three-dimensional shape and curvature corresponding generally to a desired shape and curvature of the golf club head 100. It will be appreciated that other types of club heads, such as fairway wood-type club heads, hybrid club heads, iron-type club heads, and putter-type golf club heads, may be manufactured using one or more of the principles, methods, and materials described herein.

Referring to FIGS. 33, 34, and 42, according to some examples, a method 550 of making the golf club heads of the present disclosure, such as the golf club head 100, includes (block 552) laser ablating a first-part surface 520 of a first part 502 of a golf club head such that a first-part ablated surface 522 is formed in the first part 502. The method 550 also includes (block 554) laser ablating a second-part surface 524 of a second part 504 of the golf club head 100 such that a second-part ablated surface 526 is formed in the second part 504. The method 550 additionally includes (block 556) bonding together the first-part ablated surface 522 and the second-part ablated surface 526. Generally, the method 550 helps to produce bonding surfaces (i.e., faying surfaces) of a golf club head with features that promote strong and reliable bonds between the bonding surfaces. More specifically, the features formed by ablating the bonding surfaces of the golf club head with a laser promote an increase in the pattern uniformity and surface energy of the bonding surfaces, which helps to strengthen the bond between the bonding surfaces and increase the overall reliability and performance of the golf club head. Also, ablating the bonding surfaces with a laser enables the repeatability of surface characteristics across multiple parts and batches of parts. As defined herein, each one of the first-part ablated surface 522 and/or the second-part ablated surface 526 can be a single continuous surface or multiple spaced apart (e.g., intermittent) surfaces.

Conventional processes for bonding together surfaces of a golf club head, including surface preparation via non-laser ablation methods, may not provide a sufficient pattern uniformity and surface energy for producing strong and reliable bonds. For example, chemical ablation and media-blast ablation processes are unable to achieve pattern uniformities and surface energies of bonding surfaces that are achievable by the laser ablation of the present disclosure. The patterns of peaks and valleys on bonding surfaces ablated via a chemical ablation process or a media-blast ablation process are irregular and inconsistent, which leads to lower and non-uniform bonding strength across a bond between the bonding surfaces.

As shown in FIG. 33, a first-part laser 506 is configured to generate a first-part laser beam 508 and direct the first-part laser beam 508 at the first-part surface 520 of the first part 502. The first-part laser beam 508 impacts the first-part surface 520, which sublimates a portion of the first-part surface 520 up to a desired depth. More specifically, the energy of the first-part laser beam 508 is sufficient to transition the portion of the first-part surface 520 from a solid state directly to a gas state. In some examples, the desired depth is between 5 micrometers and 100 micrometers, between 20 micrometers and 50 micrometers, or approximately 30 micrometers. The gas sublimated from the first-part surface 520 can be suctioned away, such as by a vacuum pump (not shown).

The depth of the portion of the first-part surface 520 that is sublimated (e.g., removed) is dependent on the material of the first-part surface 520 and the characteristics of the first-part laser beam 508. The characteristics of the first-part laser beam 508 include the intensity (e.g., optical power per unit area) of, the pulse frequency of, and the duration of the impact on the first-part surface 520 by the first-part laser beam 508. After the portion of the first-part surface 520 is removed, the first-part ablated surface 522 is exposed. Accordingly, generally speaking, the first-part laser beam 508 removes a top surface of the first part 502 so that a fresh surface of the first part 502 is exposed. The first-part ablated surface 522 (e.g., fresh surface or exposed surface) is relatively free of contaminants (e.g., oxides, moisture, etc.) present on the first-part surface 520.

Similarly, as shown in FIG. 34, a second-part laser 510 is configured to generate a second-part laser beam 510 and direct the second-part laser beam 512 at the second-part surface 524 of the second part 504. The second-part laser beam 512 impacts the second-part surface 524, which sublimates a portion of the second-part surface 524 up to a desired depth. More specifically, the energy of the second-part laser beam 512 is sufficient to transition the portion of the second-part surface 524 from a solid state directly to a gas state. The gas sublimated from the second-part surface 524 can be suctioned away, such as by a vacuum pump (not shown). The depth of the portion of the second-part surface 524 that is sublimated is dependent on the material of the second-part surface 524 and the characteristics of the second-part laser beam 512. Like the first-part laser beam 508, the characteristics of the second-part laser beam 512 include the intensity (e.g., optical power per unit area) of, the pulse frequency of, and the duration of the impact on the second-part surface 524 by the second-part laser beam 512. Generally, the first-part laser beam 508 and the second-part laser beam 512 are highly focused beams of laser radiation. After the portion of the second-part surface 524 is removed, the second-part ablated surface 526 is exposed. Accordingly, generally speaking, the second-part laser beam 512 removes a top surface of the second part 504 so that a fresh surface of the second part 504 is exposed. The second-part ablated surface 526 is relatively free of contaminants present on the second-part surface 524.

In certain examples of the method 550, the first-part laser beam 508 is moved along the first-part surface 520 at a first-part rate to form the first-part ablated surface 522 in the first part 502. Similarly, in some examples, the second-part laser beam 510 is moved along the second-part surface 524 at a second-part rate to form the second-part ablated surface 526 in the second part 504. In this manner, a laser beam with a relatively small footprint can be used to form an ablated surface with a relatively larger surface area. Moreover, in various examples, a laser beam can be split into separate sub-beams, using optics, to move along and form separate portions of an ablated surface. Also, according to some examples, multiple laser beams generated from multiple lasers can be used to form an ablated surface in a single part. The rate at which a laser beam moves along a corresponding part is dependent on the type of material of the part. For example, a given laser beam may need to be moved along a given part at a faster rate, compared to another part, when the material of the given part sublimates faster than the material of the other part. In contrast, a given laser beam may need to be moved along a given part at a slower rate, compared to another part, when the material of the given part sublimates slower than the material of the other part.

The rate of sublimation, and thus the rate of movement of a laser beam along a part, is dependent on the type of laser generating the laser beam and the characteristics of the generated laser beam. Different types of lasers generate different types of laser beams. For example, a carbon-dioxide laser generates a laser beam that is different than the one generated by a fiber laser. Likewise, an Nd-YAG (neodymium-dopped yttrium aluminum garnet) laser generates a laser beam that is different than the ones generated by a carbon-dioxide laser and fiber laser, respectively. Additionally, in some examples, a laser can be selectively controlled to adjust characteristics of the generated laser. For example, a laser can be selectively controlled to adjust one or both of an intensity or pulse frequency of the generated laser. Generally, the higher the intensity of the laser beam or the higher the pulse frequency of the laser beam, the higher the rate of sublimation.

After the first part 502 is laser ablated, to form the first-part ablated surface 522, and the second part 504 is laser ablated, to form the second-part ablated surface 526, the first-part ablated surface 522 and the second-part ablated surface 526 are bonded together. Referring to FIG. 35, the first-part ablated surface 522 and the second-part ablated surface 526, when facing each other, are bonded together along a bondline 528 to form a bonded joint. The bondline 528 is defined as the structure, including, but not limited to, the material, between the first-part ablated surface 522 and the second-part ablated surface 526. Accordingly, in certain examples, the first-part ablated surface 522 and the second-part ablated surface 526 are directly bonded together along the bondline 528. In other words, in such examples, other than the material of the bondline 528, no other intervening layer is interposed between the first-part ablated surface 522 and the second-part ablated surface 526. In some examples, the bondline 528 includes the bonding tape 174 when the first-part ablated surface 522 and the second-part ablated surface 526 are adhesively bonded. The bonding tape 174 has a maximum thickness and a minimum thickness, or alternatively an average thickness, along the bondline 528.

In some examples, the type of the first-part laser 506, the rate of movement of the first laser beam 508 (i.e., first-part rate), and/or the characteristics of the first-part laser beam 508 is dependent on the type of material of the first part 502. Similarly, in some examples, the type of the second-part laser 510, the rate of movement of the second-part laser beam 512 (i.e., second-part rate), and/or the characteristics of the second-part laser beam 512 is dependent on the type of material of the second part 504.

According to certain examples, the first part 502 is made of a first material and the second part is made of a second material, where the first material is different than the second material. In one example, the first part 502 is made of a first type of metallic material and the second part 504 is made of a second type of metallic material. In another example, the first part 502 is made of a first type of non-metallic material and the second part 504 is made of a second type of non-metallic material. In yet a further example, the first part 502 is made of a non-metallic material and the second part 504 is made of a metallic material. In the above examples, at least one of the type of the first-part laser 506, the rate of movement of the first-part laser beam 508, or the characteristics of the first-part laser beam 508 is different than the type of the second-part laser 510, the rate of movement of the second-part laser beam 512, or the characteristics of the second-part laser beam 512, respectively. According to some examples, the type of the first-part laser 506 is different than that of the second-part laser 510 (e.g., such that the first-part laser 506 is different than and separate from the second-part laser 510). In some examples, the first-part rate is different than the second-part rate. In one example, the intensity of the first-part laser beam 508 is different than the second-part laser beam 512. Additionally, or alternatively, according to certain examples, the pulse frequency of the first-part laser beam 508 is different than the pulse frequency of the second-part laser beam 512.

According to some examples, the first material is a fiber-reinforced polymeric material and the second material is a metallic material. In one example, the fiber-reinforced polymeric material is at least one of a glass-fiber-reinforced polymeric material or a carbon-fiber-reinforced polymeric material, such as one of those described above, and the metallic material is a titanium alloy, such as a cast titanium material. In these examples, at least one of: the first-part laser 506 is a carbon dioxide laser and the second-part laser 510 is a fiber laser; the first-part rate is slower than the second-part rate; the intensity of the first-part laser beam 508 is less than the intensity of the second-part laser beam 512; or the pulse frequency of the first-part laser beam 508 is less than the pulse frequency of the second-part laser beam 512. When the first-part rate is slower than the second-part rate, in some examples, the first-part rate is between 600 mm/s and 800 mm/s (e.g., 700 mm/s), and the second-part rate is between 600 mm/s and 800 mm/s (e.g., 700 mm/s). When the intensity of the first-part laser beam 508 is less than the intensity of the second-part laser beam 512, in certain examples, the intensity of the first-part laser beam 508 is between 40 watts and 60 watts, and the intensity of the second-part laser beam 512 is between 40 watts and 60 watts. When the pulse frequency of the first-part laser beam 508 is less than the pulse frequency of the second-part laser beam 512, in some examples, the pulse frequency of the first-part laser beam 508 is between 40 kHz and 60 kHz, and the pulse frequency of the second-part laser beam 512 is between 40 kHz and 60 kHz.

When either the first material of the first part 502 or the second material of the second part 504 is a fiber-reinforced polymeric material, which includes a plurality of reinforcement fibers embedded in a resin or epoxy matrix, the corresponding first-part surface 520 or the second-part surface 524 is defined entirely by the resin or epoxy matrix of the fiber-reinforced polymeric material. Accordingly, the first-part laser beam 508 or the second-part laser beam 512 impacts and ablates only the resin or epoxy matrix, without ablating the reinforcement fibers embedded therein. Moreover, in some examples, the first part 502 or the second part 504 is made of plies of a carbon-fiber-reinforced polymeric material sandwiched between opposing outer plies of a glass-fiber-reinforced polymeric material. In such examples, the corresponding laser beam impacts and ablates only the resin or epoxy matrix of the glass-fiber-reinforced polymeric material.

As presented previously, due the ability to precisely control the energy, pulse frequency, and directionality of a laser, laser ablation of a surface can result in a fresh (e.g., relatively uncontaminated) surface having a high uniformity of peaks and valleys, and a high surface energy. Generally, each pulse of the laser beam sublimates and removes a localized portion of the surface being ablated. The removed portion of the surface defines a valley (e.g., dimple or depression) that has a shape that corresponds with a cross-sectional shape of the laser beam and a depth that corresponds with the intensity and frequency of the laser beam. Because the laser beam is moved relative to the surface being ablated, each pulse of the laser beam contacts a different portion of the surface, which results in disparate and spaced apart valleys corresponding with the removed portions. Because the portions of the surface between the removed portions are not removed, the unremoved portions of the surface define peaks between diagonal ones of the valleys. In this manner, as the laser beam is moved relative to the surface, a pattern of peaks and valleys in the surface is formed.

Referring to FIG. 33, sublimation of the first-part surface 520 results in a first-part ablated surface 522 having a first-part ablation pattern of peaks and valleys. Similarly, referring to FIG. 34, sublimation of the second-part surface 524 results in a second-part ablated surface 526 having a second-part ablation pattern of peaks and valleys. Example of an ablation pattern of peaks of valleys, which can be representative of the first-part ablation pattern and the second-part ablation pattern, are shown in FIGS. 36, 37, 45, and 46.

An ablation pattern 540 includes a plurality of peaks 542 spaced apart by a plurality of valleys 544. Generally, the laser beam is moved and pulsed such that the valleys are located relative to each other to form a desired pattern. The pattern of valleys can be symmetrical or non-symmetrical. Moreover, the spacing between valleys can be uniform or non-uniform. In one example, such as shown in FIGS. 36, 45, and 46, the ablation pattern 540 is symmetrical and the spacing between the valleys of the ablation pattern 540 is uniform. As shown in FIG. 36, in one example of a symmetrical pattern, the valleys of the ablation pattern 540 are uniformly spaced and closely spaced together, which means each valley is contiguous with at least one adjacent valley and at least one adjacent peak of the pattern of peaks and valleys. In the illustrated example of FIG. 36, some valleys, of the ablation pattern 540 of peaks and valleys, are contiguous with four adjacent valleys and four adjacent peaks. Likewise, in the illustrated example of FIG. 36, some peaks, of the ablation pattern 540 of peaks and valleys, are contiguous with four adjacent peaks and four adjacent valleys.

In some examples, each one of the valleys 544 is separated from an adjacent one of the valleys 544, across one of the peaks 542 and along a length L (or width) of the part, by a valley-to-valley distance Dvv. The valley-to-valley distance Dvv is defined as the distance from a center point of one of the valleys 544 and the center point of an adjacent one of the valleys 544. Moreover, each one of the valleys 544 has a valley depth dv measured from a hypothetical boundary 546 that is generally co-planar with the surface prior to being laser ablated. Referring to FIGS. 45 and 46, each one of the valleys 544 has a major dimension D1 (e.g., maximum dimension) and a minor dimension D2 (e.g., minimum dimension). The major dimension D1 is equal to or less than the minor dimension D2. For example, with reference to FIG. 45, when each one of the valleys 544 is substantially circular, the major dimension D1 is equal to the minor dimension D2. However, in other examples, as shown in FIG. 46, each one of the valleys 544 has a non-circular shape (e.g., an oval shape) such that the major dimension D1 is greater than the minor dimension D2. In some examples, such as when the surface, ablated by the laser beam, is flat, the resulting ablation pattern includes valleys 544 that are circular. However, according to certain examples, such as when the surface, ablated by the laser beam, is curved or contoured, the curvature of the surfaces causes the valleys 544 of the resulting ablation pattern to have an oval shape.

In some examples, the major dimension D1 of at least one of the valleys 544 is between 40 micrometers and 80 micrometers, and the minor dimension D2 is equal to the major dimension D1 or may vary by as much as 10% or 20% or by 10-20 micrometers. Additionally, or alternatively, the valley-to-valley distance Dvv between two valleys 544 can range from 80%-200% (preferably at least 120%) of the major dimension D1 of any one of the two valleys 544. As defined herein, in relation to the valleys 544, a first valley is adjacent a second valley when the second valley is the nearest neighbor to the first valley. Moreover, in some examples, such as those with uniform spacing between valleys, a given valley can be considered to be adjacent to multiple valleys. The center point of a valley 544 is defined as the location of greatest depth of the valley 544, which will typically be half of the major dimension inwards from an outer perimeter of the valley 544. The outer perimeter (e.g., perimeter) of a valley 544 is defined as the transition region where a change in the valley depth dv of the valley 544, versus an unablated surface, is no more than 5 micrometers, preferably between 0 to 2 micrometers versus an unablated surface.

According to one example, the uniformity of an ablation pattern of peaks and valleys, as used herein, can be defined in terms of the variation of the size of the valleys of the ablation pattern. As previously mentioned, the substantially non-controllable ablation pattern left behind by some ablation process, such as media-blast ablation processes, include valleys of widely disparate sizes, shapes, and spacing. The ability to precisely control the energy, pulse frequency, and directionality of the laser results in an ablation pattern where all the valleys of the pattern have a uniform size. The uniformity of the sizes of the valleys of the ablation pattern formed by the laser beam can be expressed by the percent difference in the size of one valley of the ablation pattern relative to any other one (e.g., all other ones) of the valleys of the ablation pattern. The percent difference, as pertaining to the size of the valleys, is equal to the ratio (expressed as a percentage) of the size of one valley in the pattern and the size of any other one of the valleys in the pattern. The lower the percent difference in the size of the valleys of the ablation pattern, the higher the uniformity of the ablation pattern. In some examples, the percent difference of the size of one valley of a given pattern and the size of any other one of the valleys of the given pattern is no more than 20%. In other words, the size of one valley is within 20% of the size of any other one, or all other ones, of the valleys. In other examples, the percent difference of the size of one valley of a given pattern and the size of any other one of the valleys of the given pattern is no more than 10%.

The size of a valley can be expressed as a cross-sectional area, the major dimension D1, the minor dimension D2, the depth dv, or other characteristic of the size of the valley. In certain examples, the major dimension D1 or the minor dimension D2 of one valley is within 20% of the corresponding major dimension D1 or the minor dimension D2 of any other one, or all other ones, of the valleys. According to one example, the major dimension D1 of one valley is within 20% of the major dimension D1 of any other one, or all other ones, of the valleys, and the minor dimension D2 of the one valley is within 20% of the minor dimension D2 of any other one, or all other ones, of the valleys. In certain examples, the major dimension D1 or the minor dimension D2 of one valley is within 10% of the corresponding major dimension D1 or the minor dimension D2 of any other one, or all other ones, of the valleys. According to one example, the major dimension D1 of one valley is within 10% of the major dimension D1 of any other one, or all other ones, of the valleys, and the minor dimension D2 of the one valley is within 10% of the minor dimension D2 of any other one, or all other ones, of the valleys. Although the above examples reference the major dimension D1 and the minor dimension D2 of the valleys, other characteristics of the size of the valleys, such as cross-sectional area and depth, can be interchanged with the major dimension D1 and the minor dimension D2.

Additionally, or alternatively, in some examples, the uniformity of an ablation pattern of peaks and valleys, as used herein, can be defined in terms of the variation of the distance between adjacent valleys of the ablation pattern. The ability to precisely control the energy, pulse frequency, and directionality of the laser results in an ablation pattern where all the valleys of the pattern are uniformly spaced apart from each other. The uniformity of the distance between the valleys of the ablation pattern formed by the laser beam can be expressed by the percent difference in the distance between two adjacent valleys of the ablation pattern relative to the distance between any other two adjacent valleys (e.g., all adjacent valleys) of the ablation pattern. The percent difference, as pertaining to the distances between valleys, is equal to the ratio (expressed as a percentage) of the distance between two adjacent valleys in the pattern and the distance between any other two adjacent valleys in the pattern. The lower the percent difference in the distances between the valleys of the ablation pattern, the higher the uniformity of the ablation pattern. In some examples, the percent difference of the distances between two adjacent valleys of a given pattern and the difference between any other two adjacent valleys of the given pattern is no more than 20%. In other words, the distance between two adjacent valleys is within 20% of the distance between any other two adjacent valleys. In other examples, the percent difference of the distances between two adjacent valleys of a given pattern and the difference between any other two adjacent valleys of the given pattern is no more than 10%.

Corresponding with the uniformity of the peaks and valleys of the ablation pattern on the ablated surfaces of the parts disclosed herein, laser ablating a surface of a part of the golf club head also promotes a higher surface energy compared to surfaces treated using other types of ablation processes. As presented above, a higher surface energy of surfaces to be bonded enables a stronger and more reliable bond between the surfaces. The surface energy of a surface is inversely proportional to the water contact angle of the surface. In other words, the lower the water contact angle of the surface, the higher the surface energy of that surface. The water contact angle is defined as the angle (through the water) a drop of water, on a surface, makes with the surface. The lower the water contact angle, the higher the wettability of the surface, which promotes the adhesiveness of the adhesive and the ability of the adhesive to bond to the surface. Accordingly, the lower the water contact angle, the better the bond, and the higher the strength of the bond. In some examples, the water contact angle can be measured by using a goniometer or other measuring device. According to Table 4 below, the water contact angle for various laser ablated surfaces of several examples of a golf club head, prior to forming a bonded joint, are shown.

TABLE 4

Crown-Hosel
Crown-Toe
Sole-Hosel
Sole-Toe

Example 1
14°
6°
10°
5°

Example 2
16°
12°
10°
6°

Example 3
14°
13°
10°
10°

Example 4
11°
13°
10°
2°

Example 5
16°
13°
10°
12°

Example 6
14°
21°
10°
6°

Example 7
14°
14°
10°
6°

Example 8
15°
15°
16°
15°

Example 9
18°
18°
9°
10°

Example 10
18°
17°
8°
2°

In Table 4, the crown-hosel surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the crown portion 119 than the sole portion 117, and closer to the hosel 120 than the toe portion 114; the crown-toe surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the crown portion 119 than the sole portion 117, and closer to the toe portion 114 than the hosel 120; the sole-hosel surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the sole portion 117 than the crown portion 119, and closer to the hosel 120 than the toe portion 114; and the sole-toe surface is a portion of the front-ledge ablated surface 179A of the body 102 that is closer to the sole portion 117 than the crown portion 119, and closer to the toe portion 114 than the hosel 120. Accordingly, with reference to Table 4, in some examples, the second-part ablated surface 526, or any laser ablated surface of the golf club head 100, has a water contact angle between 2° and 25°, or between 5° and 18°. According to yet certain examples, the water contact angle of an ablated surface of the golf club head 100 is less than 50°, less than 45°, less than 40°, less than 35°, less than 30°, less than 25°, or less than 20°. In some examples, the water contact angle of an ablated surface of the golf club head 100 is greater than zero degrees and less than 30° or greater than zero degrees and less than 25°. In certain examples, the water contact angle of an ablated surface of the golf club head 100 is between 1° and 18°.

Referring to FIGS. 38, 40, and 41, in some examples, the first part 502 is the strike plate 143 of the golf club head 100 and the second part 504 is the body 102 of the golf club head 100. In certain examples, the strike plate 143 can be made of a fiber-reinforced polymeric material and the body 102 can be made of a different material, such as a cast titanium material, non-cast titanium material, an aluminum material, a steel material, a tungsten material, a plastic material, and/or the like. The strike plate 143 is made of a plurality of stacked plies of fiber-reinforced polymeric material in certain examples. In one example, the strike plate 143 is made of between 35-70 stacked plies of fiber-reinforced polymeric material (each having continuous fibers at a given angle) and has a thickness between 3.5 mm and 6.0 mm, inclusive. The angle of the fibers of the plies can vary from ply-to-ply. Alternatively, the strike plate 143 can be made of a metallic material, such as a titanium alloy, and the body 102 can be made of the same metallic material or a different metallic material, such as a different titanium alloy. Also, the body 102, as presented above, can be made of multiple, separately formed and subsequently attached, pieces where each piece is made of a different material.

When the first part 502 is the strike plate 143 of the golf club head 100, the first-part surface 520 includes the interior surface 166 or rear surface of the strike plate 143, which is opposite the strike face 145 of the strike plate 143. Accordingly, as shown in FIG. 38, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the interior surface 166 within and along a designated first-part bond area 548, at least partially on the interior surface 166, to form a strike-plate-interior ablated surface 179C. Accordingly, only a portion (e.g., outer peripheral portion) of the entire interior surface 166 of the strike plate 143 is laser ablated, with the remaining portion of the interior surface 166 being non-ablated. The first-part ablated surface 522 includes, at least partially, the strike-plate-interior ablated surface 179C. In some examples, the first-part surface 520 also includes a peripheral edge surface 167 of the strike plate 145 and the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact (e.g., an entirety of) the peripheral edge surface 167 such that a strike-plate-edge ablated surface 179D is formed. Accordingly, the first-part ablated surface 522 can further include the strike-plate-edge ablated surface 179D and the designated first-part bond area 548 can further include the peripheral edge surface 167. The strike-plate-interior ablated surface 179C and the strike-plate-edge ablated surface 179D have the same ablation pattern in certain examples. In some examples, an orientation of the strike plate 143 relative to the first-part laser 506 is adjusted when laser ablating the peripheral edge surface 167, compared to when laser ablating the interior surface 166, because of the angle of the peripheral edge surface 167 relative to the interior surface 166.

When the second part 504 is the body 102, the second-part surface 524 includes the plate-opening recessed ledge 147 of the body 102. Accordingly, as shown in FIG. 39, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the plate-opening recessed ledge 147, within and along a designated second-part bond area, to form a front-ledge ablated surface 179A. The second-part ablated surface 526 includes, at least partially, the front-ledge ablated surface 179A. In some examples, the second-part surface 524 also includes the sidewall 146, extending about the plate-opening recessed ledge 147, and the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact (e.g., an entirety of) the sidewall 146 such that a front-sidewall ablated surface 179B is formed. Accordingly, the second-part ablated surface 526 can further include the front-sidewall ablated surface 179B and the designated second-part bond area can further include the sidewall 146. The front-ledge ablated surface 179A and the front-sidewall ablated surface 179B have the same ablation pattern in certain examples. In some examples, an orientation of the body 102 relative to the second-part laser 510 is adjusted when laser ablating the sidewall 146, compared to when laser ablating the plate-opening recessed ledge 147, because of the angle of the sidewall 146 relative to the plate-opening recessed ledge 147.

In view of the foregoing, according to some examples, such as with the golf club head 300 of FIG. 18, the second-part ablated surface 526 is defined by the ablated surfaces of two sub-components (e.g., the upper cup piece 304A and the lower cup piece 304B) made of different materials. Therefore, when the second-part ablated surface 526 is laser ablated, the different materials defining the second-part ablated surface 526 can be laser ablated in a single, continuous step. A first material of the different materials can define a first surface area of the second-part ablated surface 526 and the second material of the different materials can define a second surface area of the second-part ablated surface. The first surface area and the second surface area can be different in some examples. According to certain examples, the first surface area is greater than the second surface area, and the first material, defining the first surface area, has a lower density than the second material, defining the second surface area. Both the upper cup piece 304A and the lower cup piece 304B include a front ledge and a sidewall (similar to the plate opening recessed ledge 147 and the sidewall 146), which can be laser ablated to define the second-part ablated surface 526.

Referring to FIGS. 10-13, in some examples, the first part 502 is one of the crown insert 108 or the sole insert 110, and the second part 504 is the body 102. In certain examples, the crown insert 108 and/or the sole insert 110 can be made of a fiber-reinforced polymeric material and the body 102 can be made of a different material, such as a cast titanium material, non-cast titanium material, an aluminum material, a steel material, a tungsten material, a plastic material, and/or the like. Alternatively, the crown insert 108 and/or the sole insert 110 can be made of a metallic material, such as a titanium alloy, and the body 102 can be made of the same metallic material or a different metallic material, such as a different titanium alloy.

When the first part 502 is the crown insert 108, the first-part surface 520 includes an interior surface 108A of the crown insert 108. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the interior surface 108A of the crown insert 108 within and along a designated first-part bond area 548, at least partially on the interior surface 108A of the crown insert 108, to form a crown-insert ablated surface 108B. The first-part ablated surface 522 includes, at least partially, the crown-insert ablated surface 108B. Accordingly, only a portion (e.g., outer peripheral portion) of the entire interior surface of the crown insert 108 is laser ablated, with the remaining portion of the interior surface of the crown insert 108 being non-ablated. In some examples, the bond area on the interior surface 108A of the crown insert 108 will range from 2,000 mm²to 2,500 mm², such as at least 2,248 mm². Moreover, in certain examples, a total surface area of the interior surface 108A of the crown insert 108 is between 7,000 mm²and 12,000 mm²or between 9,000 mm²and 11,000 mm²(e.g., a minimum surface area between 7,000 mm²and 9,000 mm²), such as between 9,379 mm²and 10,366 mm²(e.g., around 9,873 mm²). In some examples, a percentage of the total surface area of the interior surface 108A occupied by the bond area on the interior surface 108A of the crown insert 108 is no more than 25%, 30%, 35%, or 40% and no less than 10%, 15%, 20%, or 25%. According to certain examples, the percentage of the total surface area of the interior surface 108A occupied by the bond area on the interior surface 108A of the crown insert 108 is between 20% and 25%, such as 22%, between 20% and 27%, or between 22% and 25%.

In some examples, the bond area on the interior surface 110A of the sole insert 110 will range from 1,800 mm²to 2,200 mm², such as at least 2,076 mm². Moreover, in certain examples, a total surface area of the interior surface 110A of the sole insert 110 is between 7,000 mm²and 12,000 mm²or between 9,000 mm²and 11,000 mm²(e.g., a minimum surface area between 7,000 mm²and 9,000 mm²), such as between 8,182 mm²and 9,043 mm²(e.g., around 8,613 mm²). In some examples, a percentage of the total surface area of the interior surface 110A occupied by the bond area on the interior surface 110A of the sole insert 110 is no more than 25%, 30%, 35%, or 40% and no less than 10%, 15%, 20%, or 25%. According to certain examples, the percentage of the total surface area of the interior surface 110A occupied by the bond area on the interior surface 110A of the sole insert 110 is between 20% and 27%, between 22% and 25%, or between 21% and 26%, such as 24%.

In some examples, the bond area on the interior surface of the strike plate 143 will range from 1,770 mm²to 2,170 mm², such as at least 1,976 mm². Moreover, in certain examples, a total surface area of the interior surface of the strike plate 143 is less than 7,000 mm², such as between 1,500 mm²and 7,000 mm², between 3,200 mm²and 4,700 mm², or between 3,572 mm²and 3,949 mm²(e.g., around 3,761 mm²). In some examples, a percentage of the total surface area of the interior surface of the strike plate 143 occupied by the bond area on the interior surface of the strike plate 143 is no more than 55%, 60%, 65%, or 70% and no less than 30%, 35%, 40%, or 45%. According to certain examples, the percentage of the total surface area of the interior surface of the strike plate 143 occupied by the bond area on the interior surface of the strike plate 143 is between 47% and 58%, such as 52%.

In some examples, the first-part surface 520 also includes a peripheral edge surface of the crown insert 108 and the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact (e.g., an entirety of) the peripheral edge surface of the crown insert 108 such that a crown-insert-edge ablated surface 108C is formed. Accordingly, the first-part ablated surface 522 can further include the crown-insert-edge ablated surface 108C and the designated first-part bond area 548 can further include the peripheral edge surface of the crown insert 108. The crown-insert ablated surface 108B and the crown-insert-edge ablated surface 108C can have the same ablation pattern in certain examples. In some examples, an orientation of the crown insert 108 relative to the first-part laser 506 is adjusted when laser ablating the peripheral edge surface of the crown insert 108, compared to when laser ablating the interior surface 108A, because of the angle of the peripheral edge surface relative to the interior surface 108A.

When the first part 502 is the crown insert 108, the second-part surface 524 includes the crown-opening recessed ledge 168. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the crown-opening recessed ledge 168 within and along a designated second-part bond area, at least partially on the crown-opening recessed ledge 168, to form a top-ledge ablated surface 141A. The second-part ablated surface 526 includes, at least partially, the top-ledge ablated surface 141A. In some examples, the second-part surface 524 also includes atop recessed-ledge sidewall, circumferentially surrounding and defining a depth of the crown-opening recessed ledge 168, and the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact (e.g., an entirety of) the top recessed-ledge sidewall such that a top-sidewall ablated surface 141B is formed. Accordingly, the second-part ablated surface 526 can further include the top-sidewall ablated surface 141B and a designated second-part bond area can further include the top recessed-ledge sidewall. The top-ledge ablated surface 141A and the top-sidewall ablated surface 141B can have the same ablation pattern in certain examples. In some examples, an orientation of the body 102 relative to the second-part laser 510 is adjusted when laser ablating the top recessed-ledge sidewall, compared to when laser ablating the crown-opening recessed ledge 168, because of the angle of the top recessed-ledge sidewall relative to the crown-opening recessed ledge 168.

In view of the foregoing, according to some examples, the second-part ablated surface 526 is defined by the ablated surfaces of two sub-components (e.g., the cup 104 and the ring 106) made of different materials. Therefore, when the second-part ablated surface 526 is laser ablated, the different materials defining the second-part ablated surface 526 can be laser ablated in a single, continuous step.

When the first part 502 is the sole insert 110, the first-part surface 520 includes an interior surface 110A of the sole insert 110. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the interior surface 110A of the sole insert 110 within and along a designated first-part bond area 548, at least partially on the interior surface 110A of the crown insert 110, to form a sole-insert ablated surface 1101B. The first-part ablated surface 522 includes, at least partially, the sole-insert ablated surface 110B. Accordingly, only a portion (e.g., outer peripheral portion) of the entire interior surface of the sole insert 110 is laser ablated, with the remaining portion of the interior surface of the sole insert 110 being non-ablated. In some examples, the first-part surface 520 also includes a peripheral edge surface of the sole insert 110 and the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact (e.g., an entirety of) the peripheral edge surface of the sole insert 110 such that a sole-insert-edge ablated surface 110C is formed. Accordingly, the first-part ablated surface 522 can further include the sole-insert-edge ablated surface 110C and the designated first-part bond area 548 can further include the peripheral edge surface of the sole insert 110. The sole-insert ablated surface 110B and the sole-insert-edge ablated surface 110C can have the same ablation pattern in certain examples. In some examples, an orientation of the sole insert 110 relative to the first-part laser 506 is adjusted when laser ablating the peripheral edge surface of the sole insert 110, compared to when laser ablating the interior surface 110A, because of the angle of the peripheral edge surface relative to the interior surface 110A.

Furthermore, when the first part 502 is the sole insert 110, the second-part surface 524 includes the sole-opening recessed ledge 170. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the sole-opening recessed ledge 170 within and along a designated second-part bond area, at least partially on the sole-opening recessed ledge 170, to form a bottom-ledge ablated surface 142A. The second-part ablated surface 526 includes, at least partially, the bottom-ledge ablated surface 142A. In some examples, the second-part surface 524 also includes a bottom recessed-ledge sidewall, circumferentially surrounding and defining a depth of the sole-opening recessed ledge 170, and the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact (e.g., an entirety of) the bottom recessed-ledge sidewall such that a bottom-sidewall ablated surface 142B is formed. Accordingly, the second-part ablated surface 526 can further include the bottom-sidewall ablated surface 142B and the designated second-part bond area can further include the bottom recessed-ledge sidewall. The bottom-ledge ablated surface 142A and the bottom-sidewall ablated surface 142B can have the same ablation pattern in certain examples. In some examples, an orientation of the body 102 relative to the second-part laser 510 is adjusted when laser ablating the bottom recessed-ledge sidewall, compared to when laser ablating the sole-opening recessed ledge 170, because of the angle of the bottom recessed-ledge sidewall relative to the sole-opening recessed ledge 170.

As disclosed above, in some examples, an orientation of a part being laser ablated can be adjusted relative to the laser that is ablating the part. In one example, as shown by directional arrows, with dashed lines, in FIG. 39, the part is held stationary and the orientation of the laser or the directionality of the laser beam is changed relative to the part. The orientation of the laser can be changed by moving the laser, such as via a numerically-controlled robot, or adjusting the directionality of the laser beam generated by the laser, such as by using electronically controllable optical components.

According to another example, as shown by directional arrows, with solid lines, in FIG. 39, the laser is held stationary (or the directionality of the laser beam is held constant), and the orientation of the part is adjusted or the part is moved relative to the laser beam. The orientation of the part can be adjusted by fixing the part to an adjustable platform, that can be translationally moved or rotated to translationally move or rotate the part relative to the laser beam.

Although in some examples, the methods disclosed herein may be performed manually, in other examples, the methods are automated. As used herein, automated means operated at least partially by automatic equipment, such as computer-numerically-controlled (CNC) machines. The process of controlling the laser, including the directionality and/or characteristics of the laser beam, and/or controlling the orientation/position of the part relative to the laser beam is automated in some examples. For example, an electronic controller can control the laser and part-adjustment components (e.g., motors, cylinders, gears, rails, etc.) that hold and adjust the orientation/position of the part.

Because the golf club head 100 has both a crown insert 108 and a sole insert 110 attached to the body 102, in some examples, the method 550 can be performed to make a golf club head that has more than one first part 502 coupled to the second part 504. In other words, in at least one example, the golf club head 100 includes at least two first parts 502 coupled to the second part 504. Moreover, because the golf club head 100 also includes a strike plate 148 attached to the body 102, in certain examples, the method 550 can be performed to make a golf club head that has at least three first parts 502 coupled to the second part 504.

As described above, the body 102 of the golf club head 100 includes multiple pieces that are attached together to form a multi-piece construction. For example, referring to FIGS. 14 and 15, the body 102 of the golf club head 100 includes the cup 104 and the ring 106. Accordingly, in some examples, the method 550 can be performed to make a body of a golf club head that includes the first part 502 and the second part 504. The first part 502 is the ring 106 and the second part 504 is the cup 104 in certain examples. As disclosed above, the ring 106 and the cup 104 can be made of different materials. For example, the ring 106 can be made of a metallic material or a plastic material having a relatively lower density that the material of the cup 104, which can be made of a cast titanium material.

When the first part 502 is the ring 106 and the second part 504 is the cup 104, the first-part surface 520 includes the toe cup-engagement surface 152A and the heel cup-engagement surface 152B. Accordingly, the first laser 506 generates the first-part laser beam 508 and directs the first-part laser beam 508 to impact the toe cup-engagement surface 152A and the heel cup-engagement surface 152B within and along a designated first-part bond area, at least partially on the toe cup-engagement surface 152A and the heel cup-engagement surface 152B, to form a toe cup-engagement ablated surface 148C and a heel cup-engagement surface 148D, respectively. The first-part ablated surface 522 includes, at least partially, the toe cup-engagement ablated surface 148C and the heel cup-engagement surface 148D. The toe cup-engagement ablated surface 148C and the heel cup-engagement surface 148D can have the same ablation pattern in certain examples.

Correspondingly, when the first part 502 is the ring 106 and the second part 504 is the cup 104, the second-part surface 524 includes the toe ring-engagement surface 150A and the heel ring-engagement surface 150B. Accordingly, the second laser 510 generates the second-part laser beam 512 and directs the second-part laser beam 512 to impact the toe ring-engagement surface 150A and the heel ring-engagement surface 150B within and along a designated second-part bond area, at least partially on the toe ring-engagement surface 150A and the heel ring-engagement surface 150B, to form a toe ring-engagement ablated surface 148A and a heel ring-engagement surface 148B, respectively. The first-part ablated surface 522 includes, at least partially, the toe ring-engagement ablated surface 148A and the heel ring-engagement surface 148B. The toe ring-engagement ablated surface 148A and the heel ring-engagement surface 148B can have the same ablation pattern in certain examples.

After the ring 106 is bonded to the cup 104, the ring 106 and the cup 104 can collectively define a second part 504 to which a first part 502 is bonded according to the method 550. In other words, the second part 504 can have a multi-piece construction. In fact, with reference to FIG. 18, the cup can have a multi-piece construction, such that one piece of the cup is the first part 502 and another piece of the cup is the second part 504, such that the multiple pieces (e.g., made of the same or different materials) of the cup have ablated surfaces bonded together after the manner of the method 550.

As used herein, dashed leader lines are used to indicate features in a prior state. For example, a surface referenced by a dashed leader line indicates that surface prior to being modified into a surface referenced by a solid leader line. This methodology is helpful in understanding the correlation between a surface before and after being ablated.

In some examples, the step of laser ablating the first-part surface 520 or the step of laser ablating the second-part surface 524 is performed to remove alpha case from a corresponding one of the first part 502 or the second part 504. In such examples, the corresponding one of the first part 502 or the second part 504 is made of a titanium alloy that is prone to developing a layer of alpha case on the first-part surface 520 or the second-part surface 524, respectively, during manufacturing (e.g., casting) of the corresponding part (see, e.g., U.S. Pat. No. 10,780,327, issued Sep. 22, 2020, which is incorporated herein by reference). The corresponding one of the first-part surface 520 or the second-part surface 524 is ablated to a depth sufficient to remove the layer of alpha case from the corresponding part. Using the laser ablation method disclosed herein enables the alpha case to be removed with more precision, efficiency, and lower waste materials that conventional methods, such as chemical etching, computer numerically-controlled (CNC) machine, or abrasion techniques.

Referring to FIGS. 43 and 44, in alternative examples, only one of the two surfaces forming the bondline 528 is laser ablated. According to one example, a method 560 of making the golf club heads of the present disclosure, such as the golf club head 100, includes (block 562) laser ablating the second-part surface 524 of the second part 504 of the golf club head 100 such that the second-part ablated surface 526 is formed in the second part 504. The method 560 additionally includes (block 564) bonding together the first-part surface 520, of the first part 502 of the golf club head 100, and the second-part ablated surface 526 of the second part 504. In other words, instead of the second-part ablated surface 526 being bonded to a first-part ablated surface of the first part 502, the second-part ablated surface 526 of the second part 504 is bonded to a non-ablated surface (i.e., the first-part surface 520) of the first part 502.

In certain examples, the second part 504 in the method 560 is made of a titanium alloy, such as a cast alloy, and the first part 502 in the method 560 is made of a fiber-reinforced polymeric material. For example, the first part 502 can be the strike plate 143, the second part 504 can be the body 102, and the second-part ablated surface 526 can define the plate-opening recessed ledge 147 of the body 102. However, unlike the strike plate 143 shown in FIG. 38, the interior surface 166 of the strike plate 143 used in the method 560 is not laser ablated. Instead, the interior surface 166 of the strike plate 143 is untreated or treated using a different type of surface treatment, such as media blasting or chemical etching. According to another example, the first part 502 can be one of the crown insert 108 or the sole insert 110, the second part 504 can be the body 102, and the second-part ablated surface 526 can define one of the top plate-opening recess ledge or the sole-opening recessed ledge.

According to some examples, the method 560 is used to make a golf club head similar to the golf club head 100, except the strike plate 143, the crown insert 108, and/or the sole insert 110 does not have a laser-ablated surface. Instead, in some examples, only the body 102, which can be made of a cast titanium alloy, includes laser-ablated surfaces. According to one example, the body 102 includes the top-ledge ablated surface 141A, the bottom-ledge ablated surface 141A, and the front-ledge ablated surface 179A, but the crown insert 108 does not include the crown-insert ablated surface 108B, the sole insert 110 does not include the sole-insert ablated surface 110B, and the strike plate 143 does not include the strike-plate-interior ablated surface 179C.

Each bonded joint of the golf club head 100 is defined by two bonded surfaces (e.g., faying surfaces). Because a bonded joint has two equal and opposite bonded surfaces, a surface area of each bonded joint (i.e., bond area of each bonded joint) is defined as the surface area of just one of the two bonded surfaces. In other words, as defined herein, the bond area of each bonded joint does not include the surface area of both bonded surfaces of the bonded joint. Accordingly, as used herein, the bond area of a bonded joint, defined between two surfaces of the golf club head disclosed herein, is the surface area of the portion of any one (but just one) of the two surfaces of the bonded joint that is covered by or in direct contact with an adhesive between the two surfaces. In view of this definition, the bond area is equal to the surface area of one of two surfaces of the adhesive (e.g., the bonding tape 174) defining the bonded joint. Accordingly, as used herein, the maximum surface area of a side of the bonding tape 174, bonded to a part to form a bonded joint with the part, is equal to the bond area of the bonded joint, as described in detail below.

In some examples, at least one of the two bonded surfaces of at least one bonded joint of the golf club head 100 is a laser ablated surface. Accordingly, the bond area of a bonded joint defined by a laser ablated surface can be the surface area of the laser ablated surface. Therefore, unless otherwise noted, a surface area of an ablated surface is equal to the bond area of the bonded joint defined by the laser ablated surface. Moreover, the bond area of a bonded joint defined by a non-ablated surface (e.g., the first-part surface 520 of FIG. 44) and an ablated surface is the surface area of the portion of the non-ablated surface that is bonded to the ablated surface or the portion of the non-ablated surface that is covered by or in direct contact with the bonding tape 174. Accordingly, a non-ablated surface can have a total surface area that is larger than the surface area of the portion of the non-ablated surface bonded to the ablated surface of a bonded joint.

As defined herein, the surface area of a laser ablated surface is the area of the portion of the surface covered by the pattern of peaks and valleys formed by the laser beam. Accordingly, the surface area of a laser ablated surface can be calculated as a length times a width of the portion of the surface that includes the pattern of peaks and valleys, or calculated by the combined surface area of the peaks and valleys of the pattern of peaks and valleys. Moreover, because in some examples, the bonded surfaces of a bonded joint are contoured, to provide a more convenient way of calculating the area of the bonded surfaces, as defined herein, the surface area of a surface is a projected surface area, which is the surface area of the surface projected onto a hypothetical plane substantially facing the surface.

Generally, a total bond area of the golf club head 100 is higher than conventional golf club heads. Moreover, a high percentage, such as 50%-100%, of the total bond area of the golf club head 100 is defined by laser ablated surfaces bonded together using the bonding tape 174. According to one example, the second-part ablated surface 526 of the golf club head 100 has a surface area between 800 mm²and 2,880 mm². In this, or other examples, the second-part ablated surface 526 of the golf club head 100 has a surface area of at least 1,560 mm², of at least 1,770 mm², of at least 2,062 mm², or of at least 2,600 mm². As defined previously, the first-part surface 520 or the first-part ablated surface 522 of the golf club head 100 can have corresponding surface areas because they would define the side of a bonded joint opposite the second-part ablated surface 526. Referring to Table 5 below, areas of some features and the bond area (in mm²) of bonded surfaces of bonded joints of several examples of the golf club heads disclosed herein, which can be the same as or different than the examples of Table 4, is shown.

TABLE 5

Ex-
Ex-
Ex-

ample
ample
ample

1
2
3

Plate Opening Area
2266
1674
1330-2720

Front-Ledge Ablated Surface Area
1010
—
800-1220

Front-Sidewall Ablated Surface Area
806
—
640-970

Strike Face Ablated Surface Area
1073
1073
850-1290

Lower Cup Piece Ablated Surface Area
—
599
470-720

Lower Cup Piece Ledge Ablated Surface
—
267
210-330

Area

Lower Cup Piece Sidewall Ablated
—
222
170-270

Surface Area

Ring-Engagement Ablated Surface Area
80
—
60-100

Cup-Engagement Ablated Surface Area
112
—
80-140

Cup Top-Ledge Ablated Surface Area
1424
—
1130-2000

Cup Bottom-Ledge Ablated Surface Area
1000
—
800-1200

Ring Top-Ledge Ablated Surface Area
935
—
740-1130

Ring Bottom-Ledge Ablated Surface Area
1420
—
1130-1710

In some examples, the forward sole-opening recessed ledge 170A (e.g., the cup bottom-ledge ablated surface area of Table 5) defines a bond area of about 1,054 mm², the forward crown-opening recessed ledge 168A (e.g., the cup top-ledge ablated surface area of Table 5) defines a bond area of about 1,910 mm², the toe ring-engagement surface 150A and the heel ring-engagement surface 150B (e.g., the ring-engagement ablated surface area of Table 5) or the toe cup-engagement surface 152A and the heel cup-engagement surface 152B (e.g., the cup-engagement ablated surface area of Table 5) are about 98 mm², the plate-opening recessed ledge 147 and the sidewall 146 (e.g., the front-ledge ablated surface area and the front-sidewall ablated surface area) define a bond area of about 2,240 mm², a total bond area defined by the cup 104 is 5,300 mm². According to the same or alternative examples, the rearward crown-opening recessed ledge 168B (e.g., the ring top-ledge ablated surface area of Table 5) defines a bond area of about 928 mm², the rearward sole-opening recessed ledge 170B (e.g., the ring bottom-ledge ablated surface area of Table 5) defines a bond area of about 1,222 mm², and a total bond area defined by the ring 106 is 2,250 mm².

In view of the foregoing, in some examples, the golf club head 100 includes a single component or piece (e.g., the ring 106) that is bonded to three other components or pieces of the golf club head 100 where a total bonded area between these four components or pieces of the golf club head 100 is between 1,950 mm²and 2,500 mm², or more preferably between 2,100 mm²and 2,400 mm². According to some examples, the golf club head 100 includes a single component or piece (e.g., the cup 104) that is bonded to three other components or pieces of the golf club head 100 where a total bonded area between these four components or pieces of the golf club head 100 is between 2,250 mm²and 3,400 mm², or more preferably between 2,900 mm²and 3,200 mm². According to yet some examples, the golf club head 100 includes a single component or piece (e.g., the cup 104) that is bonded to four other components or pieces of the golf club head 100 where a total bonded area between these five components or pieces of the golf club head 100 is between 4,750 mm²and 6,200 mm², or more preferably between 4,900 mm²and 5,500 mm². In certain examples, the golf club head includes a single component or piece (e.g., the upper cup piece 304A) that is bonded to five other components or pieces of the golf club head 100 where a total bonded area between these six components or pieces of the golf club head 100 is between 5,500 mm²and 7,000 mm², or more preferably between 5,700 mm²and 6,300 mm².

The golf club heads of the present disclosure have a high bond area, between multiple pieces of the golf club heads, relative to a volume of the golf club heads. In other words, for a given size of a golf club head, the amount of bonded area is significantly higher than for conventional golf club heads. According to some examples, the volume of a golf club head, such as the golf club head 100, disclosed herein is between 450 cc and 600 cc, and more preferably between 450 cc and 470 cc. Moreover, in certain examples, a bond-volume ratio, or a ratio of a combined bond area of the plurality of bonded joints of the golf club head to a volume of the golf club head is at least 3.75 mm²/cc and at most 15.5 mm²/cc (e.g., at least 9.1 mm²/cc and at most 14.0 mm²/cc). In some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 7.9 mm²/cc and at most 13.7 mm²/cc (e.g., at least 8.1 mm²/cc and at most 12.2 mm²/cc). In yet some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 3.75 mm²/cc and at most 7.5 mm²/cc (e.g., at least 4.8 mm²/cc and at most 7.1 mm²/cc).

According to some alternative examples, a bond-volume ratio, or a ratio of a combined bond area of the plurality of bonded joints of the golf club head to a volume of the golf club head is at least 10 mm²/cc and at most 18.8 mm²/cc (e.g., at least 10 mm²/cc and at most 15.5 mm²/cc or at least 11.6 mm²/cc and at most 17.7 mm²/cc). In some examples, the bond-volume ratio of at least some of the examples of golf club heads disclosed herein is at least 10.5 mm²/cc and at most 15.3 mm²/cc, at least 11.6 mm²/cc and at most 18.8 mm²/cc, or at least 12.1 mm²/cc and at most 17.5 mm²/cc.

The golf club head disclosed herein is made of multiple pieces adhesively bonded together. Accordingly, in some examples, the golf club head disclosed herein includes multiple pieces coupled together via the bonding tape 174 such that no portions or pieces of the golf club head are welded together.

The bond area of a bonded joint is defined by a width (W_BA) and a length (L_BA) of the bonded joint (see, e.g., FIG. 15). In other words, the surface area of a side of the boding tape 174 is defined by the width (W_BA) and the length (L_BA) of the bonded joint. The width W_BAcan be variable along the length L_BAof a bonded joint. Generally, the length L_BAof the bond area of a bonded joint is greater than the width W_BAof the bond area of the bonded joint. The bonded joint can be continuous such that a length L_BAof the bond area of the bonded joint is continuous. However, in some examples, the bonded joint is non-continuous or intermittent such that the length L_BAof the bond area of the bonded joint is a summation of the lengths of the intervals of the bonded joint. Although the width W_BAand the length L_BAof the bonded area of only two bonded joints (e.g., the bonded area associated with the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B) are shown in FIG. 15, it is recognized that, although not specifically labeled, the bonded area of each one of the bonded joints of the golf club head 100 has a corresponding width W_BAand length L_BA, similar to those shown in FIG. 15, that are not labeled for ease in showing and labeling other features of the golf club head 100. Additionally, regarding the length L_BA, as defined herein, the length L_BAof the bond area of a bonded joint is the maximum length of the bond area. Accordingly, where a bond area can be considered to have two different lengths, such as a maximum length (e.g., along an outer perimeter of the bond area, such as shown in FIG. 15) and a minimum length (e.g., along an inner perimeter of the bond area), the length L_BAof the bond area is defined herein to be the largest or maximum length of the bond area.

According to some examples, the bond area of, or the bonding tape 174 forming, at least one bonded joint of the golf club head 100 has a length L_BA, which can be a continuous or segmented length, of between 174 mm and 405 mm, such as at least 250 mm. For example, the combined bond area defined by the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B has a length L_BAof at least 268 mm, of at least 300 mm, at least 316 mm, at least 353 mm, or at least 370 mm. As another example, the combined bond area defined by the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B has a length L_BAof at least 281 mm, of at least 314 mm, at least 331 mm, at least 350 mm, or at least 367 mm. According to yet another example, the bond area defined by the plate-opening recessed ledge 147 has a length L_BAof at least 174 mm, of at least 194 mm, at least 205 mm, at least 250 mm, or at least 262 mm. According to some examples, a combined length of the plurality of bonded joints is at least 723 mm and at most 1,094 mm, such as between 852 mm and 953 mm.

Unless otherwise noted, the bonding tape 174 has a length and a width the same as, or substantially equal to, the bond length or the bond width of the bonded joint. For example, in some instances, the width of the bonding tape 174 is between, and inclusive or, 1 mm and 9 mm, between, and inclusive of, 2 mm and 7 mm, between, and inclusive of, 2 mm and 5 mm, or between, and inclusive of, 2.5 mm and 3.5 mm. Moreover, like the bond area of the bonded joints of the golf club head 100, the width of the bonding tape 174 can be variable along a length of the bonding tape 174. Additionally, for a given surface of a bonded joint (e.g., a surface of a ledge), the bonding tape 174 can adhere to a certain percentage of the total surface area of that given surface. In some examples, the percentage is less than 100% or less than 99%, is between, and inclusive of, 75% and 99% or between, and inclusive of 85% and 99%. The total surface area of a bonded surface can be equal to the total surface area covered by the part bonded to the bonded surface.

In some examples, a length-area ratio, equal to a ratio of the length L_BAto the bond area of a bonded joint of, or the length to the surface area of the bonding tape 174 forming, the bond defined by the forward crown-opening recessed ledge 168A and the rearward crown-opening recessed ledge 168B is between 0.13 and 0.16, such as around 0.15. In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B is between 0.13 and 0.16, such as around 0.15.

In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between the forward sole-opening recessed ledge 170A and the rearward sole-opening recessed ledge 170B is between 0.13 and 0.16, such as around 0.15.

In yet some examples, the length-area ratio of the bond, defined by the bonding tape 174, between plate-opening recessed ledge 147 is between 0.10 and 0.13, such as around 0.11.

As previously disclosed, at least one bonded joint of the golf club heads disclosed herein is formed by the bonding tape 174. More specifically, the bonding tape 174 is situated between two parts and adhesively bonds together the two parts. The shape of the bonding tape 174 corresponds with the shape of the bonded surfaces (e.g., ablated surfaces) of the two parts that are bonded together. In some examples, the shape of the bonding tape 174 is substantially identical to the shape of at least one of the bonded surfaces of the two parts bonded together. Moreover, when the shape of the bonding tape 174 is substantially identical to the shape of the at least one of the bonded surfaces, the size of the bonding tape 174 can be identical to or smaller than the size of the at least one of the bonded surfaces. The bonding tape 174 is not flowable in a precured state (i.e., before the bonding tape 174 is cured). In other words, in a precured state, the bonding tape 174 has a fixed shape (e.g., without pressure, does not flow or conform to the outline of a container). In some examples, as shown in FIG. 47, the bonding tape 174 forms part of a bonding tape package 254 that is cut from a sheet 250. The shape of the bonding tape package 254, cut from the sheet 250, corresponds with the shape of the intended bonded surfaces. Where the bonded surfaces are continuous (e.g., form an annulus), the bonding tape package 254 can also form a continuous shape. Alternatively, as shown, to help with handling and manufacturing of the golf club head, the bonding tape package 254 can be cut into segments that collectively form an annulus shape or non-annulus shape as the case may be. Cuts 252, defining the shape of the bonding tape package 254, can be formed in the sheet 250 via any of various techniques, such as laser cutting, die cutting, grinding, water jet cutting, drilling, and the like.

Referring to FIG. 48, the bonding tape package 254, and thus the sheet 250, includes a laminated structure having the bonding tape 174 sandwiched between a first release layer 256A and a second release layer 256B. In a pre-cured state, the bonding tape 174 is made of a tacky material. The first release layer 256A and the second release layer 256B help to keep the bonding tape 174 from sticking to itself or other objects, such as during transportation, storage, and handling of the bonding tape 174. Accordingly, the first release layer 256A and the second release layer 256B are made from a low-stick material. In some examples, the first release layer 256A and the second release layer 256B are made from a polymeric material, such as polyethylene or polyethylene terephthalate. In one example, the first release layer 256A is made of a material that is different than the second release layer 256B. According to some instances, the first release layer 256A is made of polyethylene and the second release layer 256B is made of polyethylene terephthalate.

The bonding tape 174 of the bonding tape package 254 has a thickness t1. Additionally, the first release layer 256A has a thickness t2 and the second release layer 256B has a thickness t3. In some examples, the thickness t1 of the bonding tape 174 is greater than the thickness t2 of the first release layer 256A and the thickness t3 of the second release layer 256B. In one example, the thickness t2 of the first release layer 256A is different than the thickness t2 of the second release layer 256B. According to one example, the thickness t1 of the bonding tape 174 is between, and inclusive of, 90 μm and 550 μm (e.g., 100 μm or 150 μm), between, and inclusive of, 250 μm and 330 μm, or between, and inclusive of, 300 μm and 390 μm, the thickness t2 of the first release layer 256A is about 100 μm, and the thickness t2 of the second release layer 256B is about 75 μm.

The bonding tape 174 is made of an adhesive material. According to some examples, the adhesive material of the bonding tape 174 is a thermo-activated adhesive. In other words, the adhesion strength of the bonding tape 174 is maximized after the bonding tape 174 is cured (i.e., heated to a predetermined temperature for a predetermined period of time). The predetermined temperature is associated with a curing temperature and curing period of the adhesive material. In some examples, the bonding tape 174 is made of a thermosetting material, such as a thermosetting acrylic material. According to certain examples, the curing temperature (and associated curing period) of the bonding tape 174 is between, and inclusive of, 90° C. (120 minutes) and 120° C. (20 minutes), or between, and inclusive of, 100° C. (60 minutes) and 115° C. (35 minutes), such as 110° C. (40 minutes). In some other examples, the curing temperature (associated curing period) of the bonding tape 174 is at least 100° C. or at least 120° C. (between, and inclusive of, 60 minutes and 180 minutes), such as between, and inclusive of, 120° C. and 230° C. or between, and inclusive of, 140° C. and 190° C.. During curing, the thermosetting material undergoes an irreversible chemical change by producing cross-linked polymer chains. Moreover, after curing, a temperature necessary to reflow the bonding tape 174 is at least 160° C., at least 180° C., at least 200° C., or at least 220° C.

In some examples, the adhesive material of the bonding tape 174 can be left in a pre-cured state, at room temperature, for up to 24 hours without compromising the adhesion properties of the bonding tape 174. Accordingly, the use of the bonding tape 174 enables flexibility in the handling and storage of the bonding tape 174, including parts bonded by the bonding tape 174, and flexibility in the timing of the manufacturing steps of the golf club head. For example, because the bonding tape 174 can be exposed in a pre-cured state at room temperature for periods of time longer than some conventional adhesives, some steps, such as the temporary adhesion of the bonding tape 174 to a part, can be performed well before the bonding tape 174 is actually cured. Additionally, in some examples, the unique properties of the bonding tape 174 allow the bonding tape 174 to be applied to parts at one facility and cured at another facility. Being able to prep parts with bonding tape 174 well in advance of curing the bonding tape 174 can promote speed and efficiency in assembling a golf club head, which can broaden the locations in which the golf club head manufacturing can be finalized (e.g., on-site at a retailer).

After the bonding tape 174 is cured, the shear strength of the bonding tape 174, which is a measure of the ability of the bonding tape 174 to resist separation of parts bonded by the bonding tape 174, is at least 10 Mpa (e.g., between, and inclusive of, 11 MPa and 21 MPa), at least 11 MPa, at least 12 MPa, at least 13 MPa, at least 26 MPa, at least 30 MPa, or at least 35 MPa. To promote adhesion between the bonding tape 174 and parts forming the bond, pressure should be applied to the parts such that, when the bonding tape 174 is being cured, opposing compression forces from the parts are acting on the bonding tape 174. In other words, while the bonding tape 174 is being cured, the parts forming the bond should be compressed against the bonding tape 174. Ideally, the pressure applied to the parts should be uniform to promote a uniform adhesion of the bonding tape 174 along the parts, and thus a uniform adhesion strength along the bond. However, uniformly compressing one part toward another part, particularly when the parts are contoured or have complex shapes, can be difficult. Described herein are examples of systems, apparatuses, and methods that promote uniform compression of bonded parts, while the bonding tape 174 between the bonded parts is being cured, in an accurate, a reliable, a clean, and an efficient manner. Moreover, as described in more detail, the use of the bonding tape 174, as opposed to a flowable adhesive, enables the uniform compression of bonded parts using the systems, apparatuses, and methods described herein.

Referring to FIGS. 49-52, according to one example, a system for manufacturing a golf club head, such as the golf club head 100, includes a tape-retention fixture 260. The system also includes a vacuum device 268 and at least one tube 266 fluidically connected to the vacuum device 268. The vacuum device 268 can be any of various vacuum devices or suction devices that are selectively operable to generate a negative pressure differential or pressure drop. The tape-retention fixture 260 also includes conduits 264 open to a recess 262 formed in the tape-retention fixture 260. The pattern (e.g., the size, spacing, and areal density) of conduits 264 can vary along the recess 262 based on characteristics (e.g., the width) of the bonding tape package 254. From the recess 262, the conduits 264 pass through the tape-retention fixture 260 where they are fluidically coupled to the at least one tube 266. In the illustrated example, the system includes three tubes 266, the conduits 264 are arranged into three sets of conduits 264, and each one of the three sets of conduits are fluidically coupled with a corresponding one of the three tubes 266 (such as via one of three manifolds formed in the tape-retention fixture 260). Fluidic coupling between the conduits 264, the tubes 266 and the vacuum device 268 enables the vacuum device 268 to selectively control the pressure in the conduits 264 and the tubes 266.

The recess 262 has a shape corresponding with the shape of the bonding tape package 254, cut from the sheet 250. In this manner, the bonding tape package 254 can be seated in the recess 262, as shown in FIG. 50. In certain examples, an automated robot can be used to secure and insert the tape package 254 into the recess 262. A depth of the recess 262 is such that a portion of the bonding tape package 254 protrudes from the recess 262 when the bonding tape package 254 is seated in the recess 262. When the bonding tape package 254 is seated in the recess 262, the first release layer 256A and the second release layer 256B are attached to the bonding tape 174. In the illustrated example, the bonding tape package 254 is seated in the recess 262 such that the second release layer 256B is positioned within the recess 262 and the first release layer 256A just outside the recess 262. In this manner, the second release layer 256B faces inwardly toward the recess 262 and contacts a bottom of the recess 262, to directly cover the conduits 264, and the first release layer 256A faces outwardly away from the recess 262.

With the bonding tape package 254 seated in the recess 262, activation of the vacuum device 268 reduces the pressure in the conduits 264. Because the bonding tape package 254 covers the openings of the conduits 264 in the recess 262, the drop in pressure in the conduits 264 urges the bonding tape package 254 against the bottom of the recess 262, via a suction force, which helps to retain the bonding tape package 254 in the recess 262. When the bonding tape package 254 is urged against the bottom of the recess 262, which is shown in FIG. 50, the first release layer 256A is removed from the bonding tape 174, as shown in FIG. 51. Because the bonding tape package 254 is retained in the recess 262, via the suction force, and the peel off force of the first release layer 256A is less than the suction force, the first release layer 256A can be peeled off the bonding tape 174 without removing the bonding tape package 254 from the recess 262.

After the first release layer 256A is removed, a surface of the bonding tape 174, facing away from the recess, is exposed. While retaining the bonding tape package 254 in the recess 262, via the suction force, a part can be pressed against the exposed surface of the bonding tape 174, as shown in FIG. 52, which temporarily adheres the bonding tape 174 to the part via the tackiness of the bonding tape 174. The recess 262 can be configured to have an outer peripheral shape that matches the outer peripheral shape of the part, such that the recess acts as a guide to align the part relative to the bonding tape 174. When the part is temporarily adhered to the exposed surface of the bonding tape 174, the vacuum device 268 is selectively controlled to release the suction force, which allows the bonding tape package 254 to be removed from the recess 262 by lifting the part away from the recess 262. As shown in FIG. 53, the bonding tape package 254 is temporarily adhered to an interior surface of the part such that the second release layer 256B is accessible. When ready, the second release layer 256B can be removed to expose another surface of the bonding tape 174 in preparation for pressing newly exposed surface of the bonding tape 174 against a second part, which temporarily adheres the bonding tape 174 to the second part via the tackiness of the bonding tape 174, as shown in FIG. 56. In this manner, the bonding tape 174 forms a temporary bond between two parts, which enables the parts to be handled and prepared for permanent bonding without shifting of the parts relative to each other. It is noted that the parts, which are temporarily bonded together, are pre-formed parts (i.e., parts that have been formed into a permanent form or shape in preparation for final assembly).

The tape-retention fixture 260, including the conduits 264 and the recess 262, can be configured to accommodate one of many parts of a golf club head. For a golf club head that has multiple bonded joints joining together multiple sets of parts, additional tape-retention fixtures 260 can be employed and configured to accommodate other parts of the golf club head. In the illustrated example of FIGS. 49-52, the tape-retention fixture 260 is specifically configured to temporarily adhere the bonding tape 174 to the crown insert 108 of the golf club head 100. More specifically, as shown in FIG. 53, the bonding tape package 254 is temporarily adhered to an interior surface 108A of the crown insert 108, which, as shown in FIGS. 55 and 57A, is then temporarily adhered to the crown-opening recessed ledge 168 in preparation for permanently bonding the crown insert 108 to the crown-opening recessed ledge 168. The interior surface 108A is opposite an exterior surface 108E of the crown insert 108.

However, in other examples, with reference to FIGS. 54 and 56, the tape-retention fixture 260 can be specifically configured to temporarily adhere the bonding tape 174 to the sole insert 110 of the golf club head 100. More specifically, as shown in FIG. 54, the bonding tape package 254 is temporarily adhered to an interior surface 110A of the sole insert 110, which, as shown in FIG. 56, is then temporarily adhered to the sole-opening recessed ledge 170 in preparation for permanently bonding the sole insert 110 to the sole-opening recessed ledge 170. The interior surface 110A is opposite an exterior surface 110E of the sole insert 110.

In yet other examples, with reference to FIGS. 40 and 41, the tape-retention fixture 260 can be specifically configured to temporarily adhere the bonding tape 174 to the strike plate 143 of the golf club head 100. More specifically, the bonding tape package 254 is temporarily adhered to the interior surface 166 of the strike plate 143, which is then temporarily adhered to the plate-opening recessed ledge 147 in preparation for permanently bonding the strike plate 143 to the plate-opening recessed ledge 147.

According to some examples, with reference to FIGS. 14 and 15, the tape-retention fixture 260 can be specifically configured to temporarily adhere the bonding tape 174 to the ring 106 of the golf club head 100. More specifically, the bonding tape 174 of respective ones of bonding tape packages 254 are temporarily adhered to the toe cup-engagement surface 152A and the heel cup-engagement surface 152B of the ring 106, which is then temporarily adhered to the toe ring-engagement surface 150A and the heel ring-engagement surface 150B, respectively, of the cup 104 in preparation for permanently bonding the ring 106 to the cup 104. When permanently bonded, for example, a heel-side ring strip 182A of the bonding tape 174 is between the heel cup-engagement surface 152B and the heel ring-engagement surface 150B, and a toe-side ring strip 182B of the bonding tape 174 is between the toe cup-engagement surface 152A and the toe ring-engagement surface 150A.

Although in the illustrated examples above, the bonding tape 174 is used to bond together multiple parts of a driver-type golf club head, in other examples, bonding tape can be used to bond together multiple parts of other types of golf club heads in the same or a similar manner as described above. According to one example, as shown in FIG. 63, bonding tape is used to bond together multiple parts of a fairway-metal type golf club head 1100. The golf club head 1100 has a forward portion 1112 and a sole portion 1117. Additionally, the golf club head 1110 includes a body 1102 that defines a crown opening 1162 at a crown portion of the golf club head 1110 and a plate opening 1149 at the forward portion 1112 of the golf club head 1110.

The golf club head 1110 further includes a crown insert 1108 that is attached to the body 1102 over the crown opening 1162 so as to cover the crown opening 1162. The crown insert 1108 is adhered to the body 1102 over the crown opening 1162 by a crown-opening strip 1174 of bonding tape 1174. The crown-opening strip 1174 can be a single continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the crown-opening strip 1174 is a single continuous strip in the shape of an outer periphery of the crown insert 1108. When attached, the crown-opening strip 1174 is interposed between the crown insert 1108 and the body 1102 to adhere the crown insert 1108 to the body 1102. In some examples, the crown insert 1108 is made of a non-metal material, such as a fiber-reinforced polymeric material as described above.

The golf club head 1110 also includes a strike plate 1143 that is attached to the body 1102 over the plate opening 1149 so as to cover the plate opening 1149. In some examples, the strike plate 1143 includes a wrap-around portion that effectively wraps around a strike face 1145, thus forming part of the crown portion, a toe portion, a heel portion, and/or the sole portion 1117 of the golf club head 1100. The strike plate 1143 is adhered to the body 1102 over the plate opening 1149 by a plate-opening strip 1176 of bonding tape 1174. The plate-opening strip 1176 can be a single continuous or non-continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the plate-opening strip 1176 is a single, non-continuous strip in the shape of an outer periphery of the strike plate 1143. When attached, the plate-opening strip 1176 is interposed between the strike plate 1143 and the body 1102 to adhere the strike plate 1143 to the body 1102.

According to certain examples, the strike plate 1145 is made of a non-metal material, such as a fiber-reinforced polymeric material as described above, and the body 1102 is made of a metallic material. In some examples, the strike plate 1145 is made of a first metallic material and the body 1102 is made of a second metallic material. In one example, the strike plate 1145 is made of a titanium alloy and the body 1102 is made of a steel alloy. According to another example, the strike plate 1145 is made of a steel alloy and the body 1102 is made of a titanium alloy. Typically, when a strike plate and a body are made of a metallic material, the metallic materials are welded together and when one of the metallic materials is heat treated, the other of the metallic materials experiences a less than ideal heat treatment (such as a second heat treatment, an overtreatment, or an undertreatment). However, the bonding tape 1174 eliminates the need for a weldment, and thus the body 1102 and the strike plate 1145 can be heat treated separately, under different individualized heat treatment conditions conducive to the particular types of metallic materials of the body 1102 and the strike plate 1145. Although the metal-to-metal adhesive bond facilitated by the bonding tape 1174 is shown associated with a fairway-metal type golf club head, in other examples, the bonding tape 1174 can facilitate a metal-to-metal adhesive bond between a strike plate and a body, and/or between individual body components, of other types of golf club heads, such as driver-type golf club heads, iron-type golf club heads (e.g., having an interior volume of at least 5 cubic centimeters (such as between, and inclusive of, 5 cc and 20 cc), hybrid-type golf club heads, putter-type golf club heads, and the like. Accordingly, the golf club heads of the present disclosure have an interior volume of at least 5 cc, and up to 600 cc.

In certain examples, the golf club head 1100 also includes a sole slot 1191 and a slot cover 1190 attached to the sole portion 1117 over the sole slot 1191, thus covering the sole slot 1191. The slot cover 1190 is adhered to the body 1102 over the sole slot 1191 by a slot strip 1179 of bonding tape 1174. The slot strip 1179 can be a single continuous or non-continuous strip of bonding tape 1174 or multiple strips of bonding tape 1174. In the illustrated example, the slot strip 1179 is a single, continuous strip in the shape of an outer periphery of the sole slot 1191. When attached, the slot strip 1179 is interposed between the slot cover 1190 and the body 1102 to adhere the slot strip 1179 to the body 1102. In some examples, a portion of the strike plate 1143 defines a portion of the sole slot 1191, and the slot cover 1190 is also adhered to the portion of the strike plate 1143 that defines the sole slot 1191 via the slot strip 1179. The slot cover 1190 is made of a polymeric material (e.g., thermoplastic polyurethane) in some examples. In certain examples, the slot cover 1190 is flat.

According to another example, as shown in FIG. 64, bonding tape is used to bond together multiple parts of an iron-metal type golf club head 1200. The golf club head 1200 has a forward portion 1212 and a rear portion 1218. Additionally, the golf club head 1210 includes a body 1202 that defines a rear opening 1249 of the rear portion 1218 of the golf club head 1210. The golf club head 1210 also includes a rear badge 1292 (e.g., rear insert, rear cover, rear plate, etc.) that is attached to the body 1202 over the rear opening 1249 so as to cover the rear opening 1249. In certain examples, a rear ledge 1295, formed in the rear portion 1218, defines the rear opening 1249. The rear badge 1292 is adhered to the body 1202 over the rear opening 1249 by a rear-opening strip 1276 of bonding tape 1274. The rear-opening strip 1276 can be a single continuous or non-continuous strip of bonding tape 1274 or multiple strips of bonding tape 1274. In the illustrated example, the rear-opening strip 1276 is a single, non-continuous strip in the shape of an outer periphery of the rear badge 1292. When attached, the rear-opening strip 1276 is interposed between the rear badge 1292 and the body 1202 to adhere the rear badge 1292 to the body 1202.

In some examples, the body 1202 is made of a metallic material (e.g., steel) and the rear badge 1292 is made of a non-metallic material (e.g., a polymer). In alternative examples, both the body 1202 and the rear badge 1292 are made of a metallic material.

Referring to FIGS. 65-69, in some examples, a golf club head includes a crown made of a fiber-reinforced polymeric material that wraps around a transition between the crown and the strike face, such that the fiber-reinforced polymeric material is directly adjacent or abuts the strike face. FIGS. 65-69 illustrate an exemplary golf club head 4600 that includes a face plate 4610 and an oversized crown 4620, also referred to as a crown panel, that extends to the front of the club head adjacent to the upper side of the face plate 4610, and in some embodiments forms a topline and/or rear perimeter portion of the club head. The oversized crown 4620 is adhered to the body portion 4602 with bonding tape 174, such as described above, and the face plate 4610 can be adhered to the body portion 4602 with bonding tape 174. The crown 4620 and face plate 4610 can comprise nonmetallic composite materials, in some embodiments, such that the topline is formed where a portion of the composite material of the crown extends to be adjacent to a portion of the face plate. While much of this disclosure is related to relationships of the crown 4620, the face plate 4610, and the associated support structure, it is important to appreciate at the outset that the disclosure and relationships also apply to a sole plate 4640 having a portion wrapping around the front of the club head to be adjacent the face plate 4610 (see, e.g., FIGS. 67-69), which may occur at the toe of the face plate 4610, as seen in FIGS. 68 and 69, at the heel of the face plate 4610, as seen in FIG. 68, at the lower portion of the face plate 4610, as seen in FIGS. 67 and 69, and any combinations thereof. Similarly, the disclosure and relationships also apply to individual plates that may form only a portion of the skirt, and may be located at the toe or heel, and may not constitute a portion of the sole. The sole plate 4640 can be adhered to the body portion 4602 with bonding tape 174, such as described above.

The club head include a body 4602 that includes a hosel portion and provides a primary structural support for the club head, and various other components are coupled to the body, which may include the face plate 4610 and the crown 4620, and in some embodiments a sole plate 4640, one or more weights, and/or other features. In some embodiments, the body includes a front body portion (labeled as 4602) and a rear ring portion attached together (e.g., welded, bonded, or mechanically attached) at the heel and toe ends, or integrally formed. Whether attached together or integrally formed, the front body portion 4602 and the rear ring portion compose a frame that serves as the supporting structure for the attachment of other components, which may include the crown 4620, the face plate 4610, and/or the sole plate 4640. Further, as disclosed later in detail, the face plate 4610 may be attached to, or integrally formed with the frame and/or front body portion 4602 and therefore the use of the term plate is not to imply a separate component, although it may be a separate component as disclosed in more detail later. Similarly, the sole plate 4640 may be attached to, or integrally formed with the frame, front body portion 4602, and/or rear ring portion, and therefore the use of the term plate is not to imply a separate component, although it may be as disclosed in more detail later.

After at least two parts of the golf club head 100 are temporarily bonded together by the bonding tape 174, when in an uncured state, the at least two parts of the golf club head 100 are permanently bonded together, by converting the bonding tape 174 into a cured state, via the application of heat and pressure. Referring to FIGS. 58-62, according to some examples, pressure is applied to the golf club head 100 in a uniform manner with a vacuum bag 274 when the golf club head 100 is sealed within the vacuum bag 274. In some examples, such as shown in FIGS. 58 and 59, the vacuum bag 274 is a reusable vacuum bag 294. However, in alternative examples, as shown in FIGS. 60 and 61, the vacuum bag 274 is a disposable vacuum bag 292. In either case, with the golf club head 100 inside the vacuum bag 274, the vacuum bag 274 is sealable and fluidically coupled to a vacuum device 269, which is configured to reduce the pressure within the vacuum bag 274, to a pressure below ambient or environmental conditions, when the vacuum bag 274 is sealed with the golf club head 100 inside. Reducing the pressure within the vacuum bag 274 creates a pressure differential between air outside the vacuum bag 274 and inside the vacuum bag 274. The pressure differential causes the vacuum bag 274 to collapse onto the golf club head 100 and to apply a pressure onto the golf club head 100 proportional to the pressure differential. Because the pressure differential is uniform about the vacuum bag 274, the pressure applied onto the golf club head 100 is correspondingly uniform. Accordingly, the pressure applied to the bonding tape 174 also is uniform.

It is noted that when the vacuum bag 274 is used to apply a uniform pressure to the golf club head 100, the parts of the golf club head 100 being bonded together are in a fully-formed state (i.e., parts that have been formed into a permanent form or shape in preparation for final assembly). For example, for parts that are made of a fiber-reinforced polymeric material, the fiber-reinforced material has been previously shaped and cured into a final shape. Accordingly, the collapsed vacuum bag 274 is used solely to apply pressure to the bonding tape 174 and, with the parts of the golf club head 100 in a fully-formed state, does not shape or contribute to the formation of the individual parts.

As shown in FIGS. 58 and 59, in some examples, the pressure differential, which can be measured by a pressure gauge 272, is between, and inclusive of, 30 cmHg and 70 cmHg, between, and inclusive of, 40 cmHg and 60 cmHg, or substantially 50 cmHg.

Referring back to FIGS. 58 and 59, the reusable vacuum bag 274 is configured for repeated use. Accordingly, the reusable vacuum bag 274 is made from a material and has a thickness that is suitable for repeated use. In one example, the reusable vacuum bag 274 is made of polyethylene or other similar plastic material. Alternatively, the reusable vacuum bag 274 can be made of a rubber or rubber-like material, such as silicone. Moreover, in certain examples, the reusable vacuum bag 274 has a thickness of between, and inclusive of, 60 microns and 100 microns, between, and inclusive of, 70 microns and 90 microns, or substantially 80 microns. The reusable vacuum bag 274 can have a vacuum port 290 that is built into the vacuum bag 274. The vacuum port 290 is configured to receive a coupling from the vacuum device 269 in a selectively releasable and repeated manner.

As shown in FIGS. 60 and 61, the disposable vacuum bag 274 is configured for single use. Accordingly, the disposable vacuum bag 274 can be made from a material that is less durable than the reusable vacuum bag 274. For example, the disposable vacuum bag 274 can be made of a plastic material that is thinner than the reusable vacuum bag 274. Moreover, in some examples, the vacuum device 269 can be specifically configured for use with the disposable vacuum bag 274. In one example, the vacuum device 269 can be similar to a shrink-wrap machine that creates the pressure differential and seals an opening of the disposable vacuum bag 274 after the pressure differential is met. Accordingly, in some examples, the disposable vacuum bag 274 is a shrink-wrap or a heat-shrink material.

When the vacuum bag 274 is collapsed against and applies pressure onto the golf club head 100, according to the pressure differential created by the vacuum device 269, the golf club head 100 is heated to at least the curing temperature of the bonding tape 174. As stated above, the concurrent application of the pressure and heat cures the bonding tape 174 between parts to permanently bond the parts together. Referring to FIG. 62, in some examples, with the vacuum bag 274 collapsed against and applying pressure to the golf club head 100, the vacuum bag 274 and golf club head 100 is located in an enclosed cavity 227 of an oven 276. The oven 276 includes a heating element 278 that is configured to heat the enclosed cavity 277 and thus apply heat 280 to the golf club head 100 in the vacuum bag 274 when positioned in the enclosed cavity 227. Although a disposable vacuum bag 274, collapsed against the golf club head 100, is shown in the oven 276, in other examples, a reusable vacuum bag 270, collapsed against the golf club head 100, can be used instead. Moreover, although the oven 276 can be used to apply the heat 280 to the golf club head 100, when pressurized by the vacuum bag 274, in other examples, heat can be applied in ways other than an oven.

In alternative examples, rather than collapse the vacuum bag 274 by reducing the pressure within the vacuum bag 274, the pressure outside the vacuum bag 274 can be increased to create the necessary pressure differential to collapse the vacuum bag 274 onto the golf club head 100. For example, in some examples, the oven 276 is fluidically coupled to a vacuum device, which is selectively operable to increase the pressure within the enclosed cavity 227 when a vacuum bag 274, sealed to enclose the golf club head 100 within the vacuum bag 274, is positioned within the enclosed cavity 227. In this manner, the oven 276, acting as an autoclave, can concurrently apply heat and create the pressure differential necessary to cure the bonding tape 174.

Because of the unique characteristics of the bonding tape 174, compared to flowable adhesives, the bonding tape 174 can be cured, via pressure and heat, with little to no bleeding or flowing of the bonding tape 174 out of the bonded joint during pressurization and heating of the bonding tape 174. Accordingly, the pressure necessary to cure the bonding tape 174 can be applied via the vacuum bag 274. In contrast, with conventional flowable adhesives, the application of pressure by a vacuum bag would cause the adhesives to flow out of the bonded joint and smear against the interior of the vacuum bag and the part. Such a result would create unnecessary delays, expense, and labor associated with removing excess adhesives from the part. Moreover, bleeding of the adhesives onto the vacuum bag would prevent the vacuum bag from being reusable for pressurizing other parts. Additional advantages associated with the use of the bonding tape 174 include a reduction in the complexity of the bonding process and the necessary training required to implement the bonding process, which translates into lower training costs.

In some examples, for golf club heads with multiple parts bonded together via multiple bonded joints, such as the golf club head 100, all the bonded joints are formed concurrently by concurrently pressurizing and heating the bonding tape 174 forming the bonded joints. In other words, the bonding tape 174 of all the bonded joints of the golf club head 100 can be cured (e.g., pressurized and heated) in a single pressurization and heating step using one vacuum bag. For example, the strike plate 143, the crown insert 108, and the sole insert 110 can be bonded to the body 102 by curing the bonding tape 174 between them at the same time. However, in other examples, at least one bonded joint of the golf club head 100 can be formed in a first pressurizing and heating step, using a first vacuum bag, and at least another bonded joint of the golf club head 100 can be formed subsequently in a second pressurizing and heating step, using the first vacuum bag or a second vacuum bag. For example, the crown insert 108 and the sole insert 110 can be bonded to the body, by curing the bonding tape 174 between them at a first time, and the strike plate 143 can be bonded to the body 102, by curing the bonding tape 174 between them at a second time, different (e.g., later or earlier) than the first time. By staggering the curing of the bonding tape 174 in this manner, inspection of one or more bonded joints, from an inside of the golf club head 100, can be performed before the inside of the golf club head 100 is enclosed.

Although the bonding tape 174 does not flow during pressurization and heating of the bonding tape 174, it may expand. Unlike conventional, flowable adhesives, the expansion of bonding tape 174 is predictable and controllable. Accordingly, the size and positioning of the bonding tape 174, between the parts to be bonded, can be selected to accommodate the expansion of the bonding tape 174 and ensure the bonding tape 174 is properly distributed in the bonded joint without bleeding (e.g., squeeze out) from the bonded joint during pressurization and heating. Referring to FIG. 57A, in some examples, the bonding tape 174 is temporarily applied to a first part such that when the first part is temporarily bonded to a second part via the bonding tape 174, an offset OS is defined between an outer peripheral edge of the first part and an outer peripheral edge of the bonding tape 174. In some examples, the offset OS, defined between an outer peripheral edge of the first part and an outer peripheral edge of the bonding tape 174, is at least 0.25 mm, at least 0.5 mm, or at least 1.0 mm. According to these or other examples, the offset OS is no more than 2.5 mm, 3.0 mm, or 5.0 mm. The outer peripheral edge of the first part defines an outermost bondline between the first part and the second part. The amount of offset OS is dependent on at least the amount (e.g., surface area) of the bonding tape 174 forming the bonded joint.

In the example of FIG. 57A, the first part is the crown insert 108 and the second part is the body 102 such that the offset OS is associated with the crown insert 108 and an outer periphery 108D of the crown insert 108 (see also FIG. 53). According to another example, as shown in FIG. 54, the first part is the sole insert 110 and the second part is the body 102 such that the offset OS is associated with the sole insert 110 and an outer periphery 110D of the sole insert 110. The offset OS associated with the crown insert 108 can be different than the offset OS associated with the sole insert 110. In some examples, the offset OS associated with the crown insert 108 is at least double that associated with the sole insert 110. In one example, the offset OS associated with the crown insert 108 is substantially 2 mm and the offset OS associated with the sole insert 110 is substantially 1 mm. Although not shown, the bonding tape 174 used to bond together the ring 106 and the cup 104 can be offset relative to one or both of the engagement surfaces of the ring 106 and the cup 104.

Referring to FIG. 57B, in some alternative examples, the bonding tape 174 is applied onto a part, in preparation for attachment to a second part, without an offset between the outer peripheral edge of the first part and the bonding tape 174. In such examples, a gap filler 197 can function as a physical barrier to prevent bleeding or squeeze out of the bonding tape 174 from the bonded joint during pressurization and heating. The gap filler 197 is positioned in a gap defined between the second part and the outer peripheries of the bonding tape 174 and the first part. In the example of FIG. 57B, the first part is the crown insert 108 and the second part is the body 102. Accordingly, the gap filler 197 is positioned between the outer periphery 108D of the crown insert 108 and a sidewall 168C of the crown-opening recessed ledge 168. With the gap filler 197 in this position, the bonding tape 174 is prevented from expanding or bleeding out of the bonded joint during pressurization and heating of the bonding tape 174.

The gap filler 197 is made from any of various materials capable of keeping its shape (e.g., not flowing or bleeding) when the bonding tape 174 is heating and pressurized during curing of the bonding tape 174. Accordingly, the material of the gap filler 197 is different than that of the bonding tape 174. In some example, the material of the gap filler 197 is also different than that of the first part and the second part. In one example, the gap filler 197 is made of a flowable material that is curable to become non-flowable, and remain relatively non-flowable when the bonding tape 174 is cured. According to some examples, the gap filler 197 is made of an adhesive material, such as an epoxy-based structural adhesive.

According to some examples, the gap filler 197 is injected into the gap between the second part and the outer peripheries of the bonding tape 174 and the first part, after the first part is temporarily adhered to the second part via the bonding tape 174 and before the bonding tape 174 is cured. The gap filler 197 is then cured. The curing conditions of the gap filler 197 are different than those of the bonding tape 174, such that curing of the gap filler 197 does not cure the bonding tape 174. In some examples, the gap filler 197 is cured at approximately room temperature for a predetermined period, such as at least 2 hours. After the gap filler 197 is cured, the bonding tape 174 is then pressurized and heated, as presented above, to cure the bonding tape 174 and form the bonded joint between the first part and the second part.

According to some examples, the golf club heads of the present disclosure are configured to be swung at a swing speed such that each collision with a golf ball imparts a force onto the strike face of the golf club heads in the range of 10,000 g to 20,000 g, where g is equal to the force per unit mass due to gravity. The bonding tape of the golf club heads, as described herein, is configured to withstand (e.g., maintain an adequate adhesive bond between bonded parts of the golf club head to maintain proper performance characteristics of the golf club head after) repeated impacts with a golf ball at swing speeds of at least 70 miles per hour (mph) (e.g., between, and inclusive of, 70 mph and 100 mph).

Although not specifically shown, the golf club head 100 of the present disclosure may include other features to promote the performance characteristics of the golf club head 100. For example, the golf club head 100, in some implementations, includes movable weight features similar to those described in more detail in U.S. Pat. Nos. 6,773,360; 7,166,040; 7,452,285; 7,628,707; 7,186,190; 7,591,738; 7,963,861; 7,621,823; 7,448,963; 7,568,985; 7,578,753; 7,717,804; 7,717,805; 7,530,904; 7,540,811; 7,407,447; 7,632,194; 7,846,041; 7,419,441; 7,713,142; 7,744,484; 7,223,180; 7,410,425; and 7,410,426, the entire contents of each of which are incorporated herein by reference in their entirety.

In certain implementations, for example, the golf club head 100 includes slidable weight features similar to those described in more detail in U.S. Pat. Nos. 7,775,905 and 8,444,505; U.S. patent application Ser. No. 13/898,313, filed on May 20, 2013; U.S. patent application Ser. No. 14/047,880, filed on Oct. 7, 2013; U.S. Patent Application No. 61/702,667, filed on Sep. 18, 2012; U.S. patent application Ser. No. 13/841,325, filed on Mar. 15, 2013; U.S. patent application Ser. No. 13/946,918, filed on Jul. 19, 2013; U.S. patent application Ser. No. 14/789,838, filed on Jul. 1, 2015; U.S. Patent Application No. 62/020,972, filed on Jul. 3, 2014; Patent Application No. 62/065,552, filed on Oct. 17, 2014; and Patent Application No. 62/141,160, filed on Mar. 31, 2015, the entire contents of each of which are hereby incorporated herein by reference in their entirety.

According to some implementations, the golf club head 100 includes aerodynamic shape features similar to those described in more detail in U.S. Patent Application Publication No. 2013/0123040A1, the entire contents of which are incorporated herein by reference in their entirety.

In certain implementations, the golf club head 100 includes removable shaft features similar to those described in more detail in U.S. Pat. No. 8,303,431, the contents of which are incorporated by reference herein in in their entirety.

According to yet some implementations, the golf club head 100 includes adjustable loft/lie features similar to those described in more detail in U.S. Pat. Nos. 8,025,587; 8,235,831; 8,337,319; U.S. Patent Application Publication No. 2011/0312437A1; U.S. Patent Application Publication No. 2012/0258818A1; U.S. Patent Application Publication No. 2012/0122601A1; U.S. Patent Application Publication No. 2012/0071264A1; and U.S. patent application Ser. No. 13/686,677, the entire contents of which are incorporated by reference herein in their entirety.

Additionally, in some implementations, the golf club head 100 includes adjustable sole features similar to those described in more detail in U.S. Pat. No. 8,337,319; U.S. Patent Application Publication Nos. 2011/0152000A1, 2011/0312437, 2012/0122601A1; and U.S. patent application Ser. No. 13/686,677, the entire contents of each of which are incorporated by reference herein in their entirety.

In some implementations, the golf club head 100 includes composite face portion features similar to those described in more detail in U.S. patent application Ser. Nos. 11/998,435; 11/642,310; 11/825,138; 11/823,638; 12/004,386; 12/004,387; 11/960,609; 11/960,610; and U.S. Pat. No. 7,267,620, which are herein incorporated by reference in their entirety.

According to one embodiment, a method of making a golf club head, such as the golf club head 100, includes one or more of the following steps: (1) forming a body having a sole opening, forming a composite laminate sole insert, injection molding a thermoplastic composite head component over the sole insert to create a sole insert unit, and joining the sole insert unit to the body; (2) forming a body having a crown opening, forming a composite laminate crown insert, injection molding a thermoplastic composite head component over the crown insert to create a crown insert unit, and joining the crown insert unit to the body; (3) forming a weight track, capable of supporting one or more slidable weights, in the body; (4) forming the sole insert and/or the crown insert from a thermoplastic composite material having a matrix compatible for bonding with the body; (5) forming the sole insert and/or the crown insert from a continuous fiber composite material having continuous fibers selected from the group consisting of glass fibers, aramide fibers, carbon fibers and any combination thereof, and having a thermoplastic matrix consisting of polyphenylene sulfide (PPS), polyamides, polypropylene, thermoplastic polyurethanes, thermoplastic polyureas, polyamide-amides (PAI), polyether amides (PEI), polyetheretherketones (PEEK), and any combinations thereof; (6) forming both the sole insert and the weight track from thermoplastic composite materials having a compatible matrix; (7) forming the sole insert from a thermosetting material, coating a sole insert with a heat activated adhesive, and forming the weight track from a thermoplastic material capable of being injection molded over the sole insert after the coating step; (8) forming the body from a material selected from the group consisting of titanium, one or more titanium alloys, aluminum, one or more aluminum alloys, steel, one or more steel alloys, polymers, plastics, and any combination thereof; (9) forming the body with a crown opening, forming the crown insert from a composite laminate material, and joining the crown insert to the body such that the crown insert overlies the crown opening; (10) selecting a composite head component from the group consisting of one or more ribs to reinforce the golf club head, one or more ribs to tune acoustic properties of the golf club head, one or more weight ports to receive a fixed weight in a sole portion of the golf club head, one or more weight tracks to receive a slidable weight, and combinations thereof; (11) forming the sole insert and the crown insert from a continuous carbon fiber composite material; (12) forming the sole insert and the crown insert by thermosetting using materials suitable for thermosetting, and coating the sole insert with a heat activated adhesive; and (13) forming the body from titanium, titanium alloy or a combination thereof to have the crown opening, the sole insert, and the weight track from a thermoplastic carbon fiber material having a matrix selected from the group consisting of polyphenylene sulfide (PPS), polyamides, polypropylene, thermoplastic polyurethanes, thermoplastic polyureas, polyamide-amides (PAI), polyether amides (PEI), polyetheretherketones (PEEK), and any combinations thereof; and (13) forming a frame with a crown opening, forming a crown insert from a thermoplastic composite material, and joining the crown insert to the body such that the crown insert overlies the crown opening.

In one embodiment the cup 304, and its variations and embodiments, and/or the front body portion 4602, and its variations and embodiments, comprises cast metal alloy, while further embodiments may be formed by forging, stamping, metal injection molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM. Metal additive manufacturing (metal AM) includes, but is not limited to, powder bed additive manufacturing, metal binder jetting manufacturing, sheet lamination manufacturing, direct energy deposition manufacturing, and bound powder extrusion. One such embodiment utilizes powder bed fusion (PBF) methods employing the use of either a laser or electron beam to melt and fuse the metal powder into a solid. This technique includes the following metal additive manufacturing methods: electron beam melting (EBM), direct metal laser sintering (DMLS), selective heat sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS). One such metal binder jetting manufacturing embodiment utilizes metal powders that are jetted onto a build platform to print objects using either a continuous or drop on demand (DOD) approach, followed by application of a liquid binder combine the powder layer by layer, building the desired object, followed by post-processing steps of sintering and/or infiltration to be strengthened. One such sheet lamination process includes the joining of sheets, or strips, of material together layer by layer through bonding, ultrasonic welding or ultrasonic additive manufacturing, or brazing to build an object. Sheet lamination methods are low-temperature processes and can bond different materials together. In a direct energy deposition manufacturing embodiment a focused energy source, such as a laser or electron beam, is directed at the building material to melt it while it is simultaneously being deposited layer by layer, and/or may incorporate use of a heated nozzle to deposit melted material onto the specified surface where it solidifies, which may include powder DED such as laser metal deposition (LMD) and/or laser engineering net shaping (LENS), as well as wire DED techniques such as electron beam additive manufacturing (EBAM).

Disclosed are various golf clubs as well as golf club heads including alignment features along with associated methods, systems, devices, and various apparatus. It would be understood by one of skill in the art that the disclosed golf clubs and golf club heads are described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

The sport of golf is fraught with many challenges. Enjoyment of the game is increased by addressing the need to hit the golf ball further, straighter, and with more skill. As one progresses in golfing ability, the ability to compete at golf becomes a source of enjoyment. However, one does not simply hit a golf ball straighter or further by mere desire. Like most things, skill is increased with practice—be it repetition or instruction-so that certain elements of the game become easier over time. But it may also be possible to improve one's level of play through technology.

Much technological progress in the past several decades of golf club design has emphasized the ability to hit the golf ball further. Some of these developments include increased coefficient of restitution (COR), larger golf club heads, lighter golf club heads, graphite shafts for faster club speed, and center of gravity manipulation to improve spin characteristics, among others. Other developments have addressed a golfer's variability from shot-to-shot, including larger golf club heads, higher moment of inertia (MOI), variable face thickness to increase COR for off-center shots, and more. Still further developments address a golfer's consistent miss-hits—of which the most common miss-hit is a slice-including flight control technology (FCT), such as loft and lie connection sleeves to adjust, inter alia, face angle), moveable weights, sliding weight technologies, and adjustable sole pieces (ASP). Such technologies aid golfers in fixing a consistent miss, such that a particular error can be addressed.

As such, modern technology has done much to improve the golfer's experience and to tailor the golf club to the needs of the particular player. However, some methods are more effective than others at achieving the desired playing results. For example, research suggests that—for a drive of about 280 yards-a 1° difference in face angle at impact may account for about 16 yards of lateral dispersion in the resultant shot. Similarly, for moveable weights, changes in balance of weight by 12 grams moving for about 50 mm may result in about 15 yards of lateral dispersion on the resultant shot. However, it is also understood that a change in lie angle of the golf club head affects the face angle, but at a much smaller degree. As such, simply by increasing lie angle by 1°, the face angle alignment of the golf club head may be adjusted by 0.1° open or closed. As such, for better players who are simply trying to tune their ball flight, adjusting lie angle may be much more finely tunable than adjusting face angle. However, for many golfers, slicing (a rightward-curving shot for a right-handed golfer, as understood in the art) is the primary miss, and correction of such shot is paramount to enjoyment of the game.

One of the major challenges in the game of golf involves the difference between perception and reality. Golf includes psychological challenges—as the player's confidence wanes, his or her ability to perform particular shots often wanes as well. Similarly, a player's perception of his or her own swing or game may be drastically different from the reality. Some technology may address the player's perception and help aid in understanding the misconceptions. For example, technology disclosed in U.S. Pat. No. 8,771,095 to Beach, et. al, entitled “CONTRAST-ENHANCED GOLF CLUB HEADS,” filed Mar. 18, 2011, provides a player with a clearer understanding of his or her alignment than some of the preexisting art at the time, which may improve that player's ability to repeat his or her shots. However, it may be more helpful to provide those players a method to address the misconceptions and provide correction for them.

We have now surprisingly found that alignment features that includes all or a portion of the interface region between the areas of contrasting shade or color on the crown of the club head and the face of the club head and/or all or a portion of the interface region between areas of contrasting shade or color on different portions on the crown of the club head allows for improved performance in the resulting clubs by accounting for not only the actual alignment of the club head by the golfer during the shot but also as modified by the perceived alignment of the club head by the golfer. One example of a combination of contrasting colors or shades would be for example a black or metallic grey or silver color contrasting with white, but also included are other combinations which provide at a minimum a “just noticeable difference” to the human eye. Although a “just noticeable difference” in terms of colors of a golf club head is to a degree somewhat subjective based on an individual's visual acuity, it can be quantified with reference to the CIELAB color system, a three dimensional system which defines a color space with respect to three channels or scales, one scale or axis for Luminance (lightness) (L) an “a” axis which extends from green (−a) to red (+a) and a “b” axis from blue (−b) to yellow (+b). This three dimensional axis is illustrated in FIG. 80.

A color difference between two colors can then be quantified using the following formula;

$Δ E_{ab}^{*} = \sqrt{{(L_{2}^{*} - L_{1}^{*})}^{2} + {(a_{2}^{*} - a_{1}^{*})}^{2} + {(b_{2}^{*} - b_{1}^{*})}^{2}}$

- where
- (L*₁, a*₁and b*₁) and (L*₂, a*₂and b*₂) represents two colors in the L,a,b space and where
- ΔE*_ab=2.3 sets the threshold for the “just noticeable difference” under illuminant conditions using the reference illuminant D65 (similar to outside day lighting) as described in CIE 15.2-1986.

Thus, for the alignment features of the golf clubs of the present invention, a contrasting color difference, ΔE*_ab, is greater than 2.3, preferably greater than 10, more preferably greater than 20, even more preferably greater than 40 and even more preferably greater than 60.

For general reference, a golf club head 100 is seen with reference to FIGS. 70A-70D. One embodiment of a golf club head 100 is disclosed and described with reference to FIGS. 70A-70D. As seen in FIG. 70A, the golf club head 100 includes a face 110, a crown 1120, a sole 130, a skirt 140, and a hosel 150. Major portions of the golf club head 100 not including the face 110 are considered to be the golf club body for the purposes of this disclosure.

The metal wood club head 100 has a volume, typically measured in cubic-centimeters (cm³), equal to the volumetric displacement of the club head 100, assuming any apertures are sealed by a substantially planar surface. (See United States Golf Association “Procedure for Measuring the Club Head Size of Wood Clubs,” Revision 1.0, Nov. 21, 2003). In other words, for a golf club head with one or more weight ports within the head, it is assumed that the weight ports are either not present or are “covered” by regular, imaginary surfaces, such that the club head volume is not affected by the presence or absence of ports. In several embodiments, a golf club head of the present application can be configured to have a head volume between about 110 cm³and about 600 cm³. In more particular embodiments, the head volume is between about 130 cm³and about 280 cm³, or between about 250 cm³and about 500 cm³. In yet more specific embodiments, the head volume is between about 300 cm³and about 500 cm³, between 300 cm³and about 360 cm³, between about 360 cm³and about 420 cm³, between about 390 cm³and about 500 cm³, or between about 420 cm³and about 500 cm³. In some embodiments, the head volume is between about 370 cm³and about 500 cm³.

In the case of a driver, the golf club head has a volume between approximately 300 cm³and approximately 460 cm³, and a total mass between approximately 145 g and approximately 245 g. In the case of a fairway wood, the golf club head 10 has a volume between approximately 100 cm³and approximately 250 cm³, and a total mass between approximately 145 g and approximately 260 g. In the case of a utility or hybrid club the golf club head 10 has a volume between approximately 60 cm³and approximately 150 cm³, and a total mass between approximately 145 g and approximately 280 g.

A three dimensional reference coordinate system 200 is shown. An origin 205, also referred to as face center and/or center face, (CF) of the coordinate system 200 is located at the center of the face (CF) of the golf club head 100. See U.S.G.A. “Procedure for Measuring the Flexibility of a Golf Clubhead,” Revision 2.0, Mar. 25, 2005, for the methodology to measure the center of the striking face of a golf club. The coordinate system 200 includes a z-axis 1206, a y-axis 207, and an x-axis 1208 (shown in FIG. 70B). Each axis 1206,207,1208 is orthogonal to each other axis 1206,207,1208. The x-axis 1208 is tangential to the face 110 and parallel to a ground plane (GP). The golf club head 100 includes a leading edge 1170 and a trailing edge 180. For the purposes of this disclosure, the leading edge 1170 is defined by a curve, the curve being defined by a series of forward most points, each forward most point being defined as the point on the golf club head 100 that is most forward as measured parallel to the y-axis 207 for any cross-section taken parallel to the plane formed by the y-axis 207 and the z-axis 1206. The face 110 may include grooves or score lines in various embodiments. In various embodiments, the leading edge 1170 may also be the edge at which the curvature of the particular section of the golf club head departs substantially from the roll and bulge radii.

As seen with reference to FIG. 70B, the x-axis 1208 is parallel to the GP onto which the golf club head 100 may be properly soled-arranged so that the sole 130 is in contact with the GP in the desired arrangement of the golf club head 100. The y-axis 207 is also parallel to the GP and is orthogonal to the x-axis 1208. The z-axis 1206 is orthogonal to the x-axis 1208, the y-axis 207, and the GP. The golf club head 100 includes a toe 1185 and a heel 190. The golf club head 100 includes a shaft axis (SA) defined along an axis of the hosel 150. When assembled as a golf club, the golf club head 100 is connected to a golf club shaft (not shown). Typically, the golf club shaft is inserted into a shaft bore 1245 defined in the hosel 150. As such, the arrangement of the SA with respect to the golf club head 100 can define how the golf club head 100 is used. The SA is aligned at an angle 198 with respect to the GP. The angle 198 (LA) is known in the art as the lie angle (LA) of the golf club head 100. A ground plane intersection point (GPIP) of the SA and the GP is shown for reference. In various embodiments, the GPIP may be used as a point of reference from which features of the golf club head 100 may be measured or referenced. As shown with reference to FIG. 70A, the SA is located away from the origin 205 such that the SA does not directly intersect the origin or any of the axes 1206,207,1208 in the current embodiment. In various embodiments, the SA may be arranged to intersect at least one axis 1206,207,1208 and/or the origin 205. A z-axis ground plane intersection point 1212 can be seen as the point that the z-axis intersects the GP. The top view seen in FIG. 70D shows another view of the golf club head 100. The shaft bore 1245 can be seen defined in the hosel 150.

Referring back to FIG. 70A, a crown height 2162 is shown and measured as the height from the GP to the highest point of the crown 1120 as measured parallel to the z-axis 1206. The golf club head 100 also has an effective face height 163 that is a height of the face 110 as measured parallel to the z-axis 1206. The effective face height 163 measures from a highest point on the face 110 to a lowest point on the face 110 proximate the leading edge 1170. A transition exists between the crown 1120 and the face 110 such that the highest point on the face 110 may be slightly variant from one embodiment to another. In the current embodiment, the highest point on the face 110 and the lowest point on the face 110 are points at which the curvature of the face 110 deviates substantially from a roll radius. In some embodiments, the deviation characterizing such point may be a 10% change in the radius of curvature. In various embodiments, the effective face height 163 may be 2-7 mm less than the crown height 2162. In various embodiments, the effective face height 163 may be 2-12 mm less than the crown height 2162. An effective face position height 1164 is a height from the GP to the lowest point on the face 110 as measured in the direction of the z-axis 1206. In various embodiments, the effective face position height 1164 may be 2-6 mm. In various embodiments, the effect face position height 1164 may be 0-10 mm. A distance 1177 of the golf club head 100 as measured in the direction of the y-axis 207 is seen as well with reference to FIG. 70A. The distance 1177 is a measurement of the length from the leading edge 1170 to the trailing edge 180. The distance 1177 may be dependent on the loft of the golf club head in various embodiments.

For the sake of the disclosure, portions and references disclosed above will remain consistent through the various embodiments of the disclosure unless modified. One of skill in the art would understand that references pertaining to one embodiment may be included with the various other embodiments.

As seen with reference to FIG. 71, a golf club head 500 includes a painted crown 1120 and unpainted face 110. Painted or otherwise contrast-enabled crowns have been utilized as described in U.S. Pat. No. 8,771,095 to Beach, et. al, entitled “CONTRAST-ENHANCED GOLF CLUB HEADS,” filed Mar. 18, 2011, to provide golfers with aided alignment. Typically the golfer employs the crown to face transition or top-line to align the club with the desired direction of the target line. The top-line transition is clearly delineated by a masking line between the painted crown and the unpainted face. While such features may have been described to some degree, use of the features to bias alignment has not been conceived in the art. With the golf club head 500 of the current embodiment, one of skill in the art would understand that the high-contrast described in U.S. Pat. No. 8,771,095 to Beach, et. al, entitled “CONTRAST-ENHANCED GOLF CLUB HEADS,” filed Mar. 18, 2011, may be beneficial for emphasizing various alignment features. As such, the disclosure is incorporated by reference herein in its entirety.

For reference, a face angle tangent 505 is seen in FIG. 71. The face angle tangent 505 indicates a tangent line to the center face 205. The face angle tangent 505 in the current embodiment is coincident with the x-axis 1208 (as seen with reference to prior FIGS.). Also seen in FIG. 71 is a top tangent 510. In the current embodiment, the top tangent 510 is a line made tangent to a top of the face 110 because, in the current embodiment, a joint between the face 110 and the crown 1120 is coincident with paint lines. The top tangent 510 in the several embodiments of the current disclosure will follow the contours of various paint lines of the crown 1120, and one of skill in the art would understand that the top tangent 510 need not necessarily be coincident with a tangent to the face 110. However, in the current embodiment, the top tangent 510 is parallel to the face angle tangent 505. As such, the paint of the crown 1120 can be described as appearing square with the face angle.

The purpose of highlighting such features of the golf club head 500 is to provide a basis for the discussion of alignment with respect to the current disclosure. Through variations in alignment patterns, it may be possible to influence the golfer such that the golfer alters his or her play because of the appearance of misalignment. If a player perceives that the golf club head is such that the face is open with reference to the intended target, he or she would be more likely to try to “square up” the face by manually closing it. Many golfers prefer not to perceive a metal wood golf club head as appearing closed, as such an appearance is difficult to correct. However, even if such a player were to perceive the metal wood head as being closed, such perception does not mean that the golf club head is aligned in a closed position relative to the intended target.

As seen with reference to FIG. 72, a golf club head 600 includes similar head geometries to golf club head 500. However, the golf club head 600 includes a feature to alter the perceived angle of the face 110 for the user. In the current embodiment, atop tangent 610 that is aligned at an angle 615 with respect to the face angle tangent 505 such that the perceived angle of the face (Perceived Face Angle, PFA) is different from the actual alignment of the face angle tangent 505. In the current embodiment, the angle 615 is about 4°. In various embodiments, the angle 615 may be 2°-6°. In various embodiments, the angle 615 may be less than 7°. In various embodiments, the angle 615 may be 5-10°. In various embodiments, the angle 615 may be less than 12°. In various embodiments, the angle 615 may be up to 15°. As indicated with respect to top tangent 510, the top tangent 610 is an indicator of the alignment of an edge of an area of contrasting paint or shading of the crown 1120 delineated by a masking line between the painted crown and the unpainted face relative to the color or shading of the face 110 and is the line that is tangent to an edge 614 of the contrasting crown paint or crown shading at a point 612 where the edge 614 intersects a line parallel to the y-axis 207.

In various embodiments, a perceived angle may be determined by finding a linear best-fit line of various points. For such approximation, a perceived angle tangent may be determined by best fitting points on the edge 614 at coordinates of the x-axis 1208 that are coincident with center face 205-point 612- and at points ±5 mm of CF 205 (points 622a,b), at points ±10 mm of CF 205 (points 624a,b), at points ±15 mm of CF 205 (points 626a,b), and at points ±20 mm of CF 205 (points 628a,b). As such, nine points are defined along the edge 614 for best fit of the top tangent 610. In the current embodiment, the perceived angle tangent is the same as the top tangent 610.

However, such method for determining the perceived angle tangent may be most useful in cases where the edge 614 of an area of contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110 includes different radii of relief along the toe portion and the heel portion. In such an embodiment, a line that is tangent to the edge 614 at point 612 may not adequately represent the appearance of the alignment of the golf club head 600. Such an example can be seen with reference to FIG. 73.

As seen in FIG. 73, a golf club head 700 includes an edge 714 of an area of contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110 that is more aggressively rounded proximate the toe 1185 than prior embodiments. As such, a line 711 that is literally tangent to the edge 714 at a point 712 that is coincident with the y-axis 207 may not adequately describe the perception. Such a line would be the top tangent 710. However as noted previously with reference to golf club head 600, points 712, 722a,b, 724a,b, 726a,b, and 728a,b, can be used to form a best fit line 730 that is aligned at a perceived angle 735 that is greater than an angle 715 of the top tangent 710. In various embodiments, the perceived angle 735 may be within the increments of angle 615, above, or may be up to 200 in various embodiments. In most embodiments, the perceived angle 735 may be 8-10°. In various embodiments, the perceived angle 735 may be 9-10°. In various embodiments, the perceived angle 735 may be 7-11®. In various embodiments, the perceived angle 735 may be 7-8.5°. In various embodiments, alignment may be influenced by the inclusion of an alignment feature that does not invoke an edge such as edges 614, 714. As seen with reference to FIG. 74, various embodiments of alignment features may be suggestive of the face angle and, as such, provide an appearance of alignment to the golfer without modifying paint lines.

A golf club head 1800, as seen in FIG. 74, includes an alignment feature 1805. The alignment feature 1805 of the current embodiment includes at least one elongate side- and in the current embodiment, two elongate sides 807a and 807b are included. The alignment feature 1805 of the current embodiment also includes two additional sides 808a and 808b. As can be seen, the alignment feature 1805 is arranged such that the at least one elongate side is aligned about parallel to the x-axis. As such, a golfer is able to use the alignment feature 1805 by aligning the direction of the elongate side in an orientation that is about perpendicular to the intended target. The alignment feature 1805 has a length 847 as measured parallel to the x-axis 1208. In the current embodiment, the length 847 is about the same as the diameter of a golf ball, or about 1.7 inches. However, in various embodiments, the length 847 may be 0.5 inches, 0.75 inches, 1 inch, 1.25 inches, 1.5 inches, 1.75 inches, 2 inches, 2.25 inches, 2.5 inches, or various lengths therein. If the length 847 of the dominant elongate side 807a or 807b is less than about 0.3 inches, the impact of the alignment feature 1805 on biasing the golfer's perception decreases substantially.

However, with sufficient use, the alignment feature 1805 can become the primary focus of the golfer's attention and, as such, modifications to the arrangement of the alignment feature 1805 with respect to the x-axis 1208 (which is coincident with the face angle tangent 505) may allow the golfer to bias his or her shots and thereby modify his or her outcome.

As seen with reference to FIG. 75, a golf club head 1900 includes an alignment feature 905. The alignment feature 905 of the current embodiment includes one elongate side 907a on a side of the alignment feature 905 that is proximate the face 110. The alignment feature 905 includes several potential rear portions. Similar to golf club head 1800, golf club head 1900 includes the alignment feature 905 having a potential second elongate side 907b in one embodiment. In another embodiment, an extended rear portion 907c may also be included or may be included separately from elongate side 907b. In the current embodiment, the elongate side 907b is oriented at an angle 915 with respect to the face angle tangent 505.

For the embodiment including second elongate side 907b, the second elongate side 907b is about parallel to the elongate side 907a. As such, the embodiment is similar to golf club head 1800 but is oriented at angle 915. With respect to extended rear portion 907c, the orientation of such an embodiment may appear less askew and, consequently, may be more effective at modifying the golfer's perception of the club's alignment. A perpendicular reference line 918 is seen as a reference for being orthogonal to the elongate side 907a. The perpendicular reference line 918 intersects the elongate side 907a at a point 919 that bisects the elongate side 907a. Further, the perpendicular reference line 918 intersects the x-axis 1208 at an intersection point 921 that is heelward of the center face 205. In the current embodiment, the intersection point 921 is heelward of center face 205 by about 2 mm. In various embodiments, the intersection point 921 may be about the same as center face 205. In various embodiments, the intersection point 921 may be up to 2 mm heelward of center face 205. In various embodiments, the intersection point 921 may be up to 5 mm heelward of center face 205. In various embodiments, the intersection point 921 may be somewhat toeward of center face 205. In various embodiments, the intersection point 921 may be ±2 mm of the center face 205.

Another embodiment of a golf club head 1100, shown in FIG. 76, includes an alignment feature 1105. The alignment feature has a first elongate side 1107a and a second elongate side 1107b. In the current embodiment, however, the first elongate side 1107a is about parallel with the face angle tangent 505 and the x-axis 1208. However, the second elongate side 1107b is oriented at an angle 1115 with respect to the face angle tangent 505 such that the golfer's perception of alignment may be altered.

A preferred method for measuring the perceived face angle observed by a golfer further takes into account the fact that most golfers have a dominant left eye and when they address the ball with the club head, a direct line between the left eye and center face would actually cross the topline heel ward of center face and thus this is where an alignment feature which includes an edge of an area of contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110 would exert the most effect on the golfer's perception of the face angle. This perceived face angle is thus called a Sight Adjusted Perceived Face Angle (SAPFA) and is measured using the apparatus shown in FIGS. 77A-77C.

The apparatus used is shown in FIGS. 77A, 77B and 77C and includes a frame 1203 which holds a fixture 1205 for holding and aligning a golf club shaft 1207 and attached golf club head 1209 at a Lie Angle of 45°. The face of the golf club head 1209 is also set at a face angle of 0° using a face angle gauge 1211. The face angle gauge may be any commonly used in the industry such as a De la Cruz face angle gauge). After setting the loft and lie angle the club is clamped in the fixture using a screw clamp 1213. The frame 1203 also includes an attachment point 1215 for mounting two cameras 1217 and 1219 and a Calpac Laser CP-TIM-230-9-1L-635 (Fine/Precise Red Line Laser Diode Module Class II. 1 mW/635 nm), 1221. The center of the lens of camera 1219 is situated at the x, y and z coordinates (namely 766 mm, 149 mm, 1411 mm) using the previously defined x y and z axes with USGA center face (as measured using the procedure in U.S.G.A. “Procedure for Measuring the Flexibility of a Golf Clubhead,” Revision 2.0, Mar. 25, 2005, “USGA Center Face”) as the origin, and where a positive x coordinate represents a position heel ward of center face, a positive y coordinate represent a position rearward of center face and a positive z coordinate represents a position above center face. The laser is situated between the two cameras.

As shown in FIG. 77C the laser produces a line 1223 having an axis parallel to the camera axis and projecting along the y axis which is adjusted such that the line intersects USGA Center Face 1225. The point 1227 at which the line then intersects the edge of an area of contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110 which in this case corresponds to the white paint line of the crown 1229 is then physically marked on the paint line using a marker and acts as the datum or reference point. A camera is then activated to take an image of the club head including the datum or reference point 1227 and the paint line 1229.

The image from the camera is then analyzed using an image analyzer software package (which can be any of these known in the art able to import an image and can fit a line to the image using a curve fitting function). A best fit line to the paint line is then determined. For most embodiments the best fit to the paint line results from fitting the line to a quadratic equation of the form y=ax²+bx+c. Two points are then selected on this best fit line at arc length between +/−0.25 mm from the datum point. A straight line is then drawn between the two points and a line perpendicular to this line is then drawn through the datum. The Sight Adjusted Perceived Face Angle (SAPFA) is then measured as the angle between the perpendicular line and the y axis.

Using this method the Sight Adjusted Perceived Face Angle (SAPFA) of the golf clubs of the present invention may be from −2 to 10, preferably from 0 to 6, more preferably from 0.5 to 4 even more preferably from 1 to 2.5 and most preferably from 1.5 to 2 degrees.

Examples

Four identical club heads were taken and the paint line edge of an area of contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110 was varied and the Sight Adjusted Perceived Face Angles (SAPFA) measured.

In addition to the Sight Adjusted Perceived Face Angles (SAPFA) four additional measurements were taken to describe the paint line edge alignment feature of the four clubs and these values are summarized in Table 1.

In addition to the SAPFA, three additional angles were measured at different points as measured from the datum along the best fit line to the paint line edge alignment feature determined as for the SAPFA. The first angle was obtained at a point along the best fit line at an arc length 25 mm heelward of the datum. Again as for the SAPFA measurement, two points at arc length between +/−0.25 mm from the 25 mm point were selected. A straight line is then drawn between these two points and a line perpendicular to this line is then drawn at the 25 mm point. The angle is then measured between this perpendicular line and the y axis. This angle is reported as the Sight Adjusted Perceived Face Angle 25 mm Heelward (“SAPFA_25H”).

The second angle was obtained at a point along the best fit line at an arc length 25 mm toeward of the datum. Again as for the SAPFA measurement, two points at arc length between +/−0.25 mm from the 25 mm point were selected. A straight line is then drawn between the two points and a line perpendicular to this line is then drawn at the 25 mm point. The angle is then measured between this perpendicular line and the y axis. This angle is reported as the Sight Adjusted Perceived Face Angle 25 mm Toeward (“SAPFA_25T”).

In addition, to capture any effect of greater rounding of the paint line edge alignment feature towards the toe of the golf club head, a third angle was obtained at a point along the best fit line at an arc length 50 mm toeward of the datum. Again as for the SAPFA measurement, two points at arc length between +/−0.25 mm from the 25 mm point were selected. A straight line is then drawn between the two points and a line perpendicular to this line is then drawn at the 50 mm point. The angle is then measured between this perpendicular line and the y axis. This angle is reported as the Sight Adjusted Perceived Face Angle 50 mm Toeward (“SAPFA_50T”).

Finally, in an attempt to describe more of the paint line edge alignment feature, the image of the paint line edge alignment feature imported into the image analyzer as for the SAPFA measurement was also fit to a circle using the formula (x-a)²+(y-b)²=r², and the radius of curvature of this circular fit line determined and reported in the table below as the Radius of Curvature (circle fit).

Sight

Adjusted

Perceived
Radius of
Angle
Angle
Angle

Face Angle
Curvature
25 mm
25 mm
50 mm

Example
(SAPFA)
(circle
Heelward
Toeward
Toeward

No.
(degrees)
fit, mm)
(degrees)
(degrees)
(degrees)

1
3.5722
570.47
1.1377
5.9453
8.2757

2
5.2813
419.53
1.7509
8.6871
11.9168

3
0.2927
781.02
−1.4461
2.0189
3.7129

4
−0.5925
568.21
−3.06
1.8533
4.245

Each club was then hit between 6 to 12 times by 10 different players into a blank screen with no trajectory or other feedback available to the player, and a Trackman 3e launch monitor and the TPS software package were used to calculate the total dispersion from a center target line with a positive total dispersion indicating the number of yards right of the center target line and a negative total dispersion indicating the number of yards left of the center target line. Thus, a player who has a tendency to slice the ball i.e. produce a ball flight right of the target line would be assisted in producing a shot closer to the target line if the golf club tended to yield a more negative dispersion.

The graph in FIG. 78 plots the Sight Adjusted Perceived Face Angle (SAPFA) versus the average total dispersion of each club when hit 6-12 times by each player. The data show that adjustment of the edge of an area of contrasting paint or shading of the crown relative to the color or shading of the face such that the Sight Adjusted Perceived Face Angle (SAPFA) of the golf club goes from −0.88 degrees through 0.5 degrees through 3.34 degrees to 5.55 degrees results in an overall change in total dispersion from 8.6 yards to the right of the target line to 24.2 yards to the left of the target i.e. an absolute change in total dispersion of 32.8 yards from the same club head by solely manipulating the appearance of the paint line comprising the primary alignment feature.

The golf club heads of the present invention have a Sight Adjusted Perceived Face Angle (SAPFA) of from about −2 to about 10, preferably of from about 0 to about 6, more preferably of from about 0.5 to about 4 even more preferably of from about 1 to about 2.5 and most preferably of from about 1.5 to about 2 degrees.

The golf club heads of the present invention also have a Sight Adjusted Perceived Face Angle 25 mm Heelward (“SAPFA_25H”) of from about −5 to about 2, more preferably of from about −3 to 0, even more preferably of from about −2 to about −1 degrees.

The golf club heads of the present invention also have a Sight Adjusted Perceived Face Angle 25 mm Toeward (“SAPFA_25T”) of from 0 to about 9, more preferably of from about 1 to about 4.5, even more preferably of from about 2 to about 4 degrees.

The golf club heads of the present invention also have a Sight Adjusted Perceived Face Angle 50 mm Toeward (“SAPFA_50T”) of from about 2 to about 9, more preferably of from about 3.5 to about 8, even more preferably of from about 4 to about 7 degrees.

The golf club heads of the present invention also have a Radius of Curvature (circle fit) of from about 300 to about 1000, more preferably of from about 400 to about 900, even more preferably of from about 500 to about 775 mm.

In other embodiments, the golf club head in addition to having a first or primary alignment feature as described earlier with reference to FIGS. 70-73, may also have a second or secondary alignment feature including the alignment features as described earlier with reference to FIGS. 74, 75 and 76.

In an embodiment shown in FIGS. 79A and 79B, the golf club head 1400 can have a crown having a first portion having a first surface characteristic including a first color, shade, texture, and/or visible surface feature and a second portion having a second surface characteristic including a second color, shade, texture, and/or visible surface feature, and a primary alignment feature consisting of a an edge 1402 of an area of contrasting surface characteristic of the first portion of the crown 1120 relative to a surface characteristic of the face 110 as described earlier and illustrated in FIGS. 72 and 73. In a further embodiment a contrast exists between a surface characteristic of a portion of the face and another portion of the face, or a portion of the face and a portion of the crown, and/or two different portions of the crown, may be achieve via a first portion having a first visible surface feature and a second portion having a second visible surface feature different from the first visible surface feature. For example in one embodiment the first visible surface feature is a first visible unidirectional pattern such as one associated with an outermost unidirectional prepreg ply layer, whereas the second visible surface feature is a second visible unidirectional pattern such as one associated with an outermost unidirectional prepreg ply layer and the second visible unidirectional pattern is oriented differently that the first visible unidirectional pattern. In one such embodiment the second visible unidirectional pattern has a second visible orientation direction, the first visible unidirectional pattern has a first visible orientation direction, and an angle between the first visible orientation direction and the second visible orientation direction is at least 30 degrees, and in further embodiments is at least 45 degrees, 60 degrees, 75 degrees, or 90 degrees. Thus, the first portion and the second portion may have the same color, shade, or texture, yet still be easily distinguishable via the different visible surface features. Further embodiments incorporate any combination of different visible surface features such as (a) a visible weave pattern versus a visible unidirectional pattern, (b) differing visible weave patterns such as a twill weave pattern versus a plain weave pattern, (c) the same visible weave pattern but oriented differently in the first portion and the second portion, such as differing by at least 30, 45, 60, 75, or 90 degrees, and/or (d) differing visible fiber content such as a first visible fiber content and a second visible fiber content, different from the first, which allows for situations such (i) a parallel visible unidirectional patterns but with the first portion having a greater density of visible fibers than the second portion, or vice versa, and/or (ii) situations having the same weave pattern and orientation, but different weave density, and/or (iii) chopped fiber materials wherein the first portion has a different fiber density than the second portion and therefore has a differing visible surface feature. Further, any of these examples may have the same texture, for example by having a smooth external clearcoat layer, but still have differing visible surface features, however in further embodiments they may also present different textures. Further embodiments incorporate other differing surface characteristics including, but not limited to, differences in gloss, reflectivity, iridescence, pearlescence, metamerism, and/or texture. Any of the disclosed differing surface characteristics may also be incorporated by attaching a separate component, such as a coating, sticker, decal, badge, or film, or by removing, texturing, or ablating a portion of a paint, coating, or finish by any known material removal, texturing, or ablating process, but with specific embodiments disclosed later herein. In one specific embodiment the separate component creating the alignment feature is located beneath and external transparent layer and is therefore positioned during manufacturing; while in another embodiment the separate component creating the alignment feature is externally attached to a finished club head.

As additionally seen in FIGS. 169-171, the club head may further incorporate a secondary alignment feature 1404 proximate the face but rearward of the primary alignment feature and delineated by a change in surface characteristic, again including a color, shade, texture, and/or visible surface feature, at a secondary feature delineation line which delineates the transition between the first portion of the crown having an area of contrasting first crown surface characteristic including a first color, shade, texture, and/or visible surface feature, with a second portion of the crown having a second crown surface characteristic including a second color, shade, texture, and/or visible surface feature. The secondary alignment feature a comprises an elongate side 1406 having a length of at least 10 mm, and in further embodiments at least 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, or 70 mm. The secondary alignment feature may also have a second and third elongate side 1408a and 1408b extending back from the face and at an angle to elongate side 1406 and rearward of elongate side 1406.

As seen in FIGS. 164-177, in another embodiment the club head may further incorporate a face secondary alignment feature 1404 located on a portion of the face and delineated by a change in surface characteristic, again including a color, shade, texture, and/or visible surface feature, at a secondary feature delineation line which delineates the transition between a first portion of the face having an area of contrasting first face surface characteristic including a first color, shade, texture, and/or visible surface feature, with a second portion of the face having a second face surface characteristic including a second color, shade, texture, and/or visible surface feature. All of the disclosure herein relating to the face secondary alignment feature 1404 also applies to the secondary alignment feature 1404 located on the crown. The face secondary alignment feature 1404 a comprises an upper elongate side 1407 having an upper side length 1510, and a lower elongate side 1409 having a lower side length 1610. As seen in FIG. 164, the upper side length 1510 and the lower side length 1610 are measured along the x-axis 1208 in the x-z vertical plane containing the x-axis 1208 and the z-axis 1206 based upon a projection of the face secondary alignment feature 1404 on the x-z plane. Similarly, the upper side length 1510 can be broken down into a toeward upper side length 1511 and a heelward upper side length 1512, with both measured in the same manner as the upper side length 1510 but from a vertical center face plane VCFP, which contains the y-axis 207 seen in FIGS. 70A-70D. Likewise, the lower side length 1610 can be broken down into a toeward lower side length 1611 and a heelward lower side length 1612, with both measured in the same manner as the lower side length 1610 but from the vertical center face plane VCFP. Similarly, the face secondary alignment feature 1404 has a face alignment feature height 1700, which is the distance between the upper elongate side 1407 and the lower elongate side 1409 in the z-axis 1206 direction, again based upon a projection of the face secondary alignment feature 1404 on the x-z plane. Additionally, each point along the upper elongate side 1407 has an upper elongate side elevation 1500, measured vertically down to the ground plane 317, and each point along the lower elongate side 1409 has a lower elongate side elevation 1600, measured vertically down to the ground plane 317. Similarly, as seen in FIG. 178, each point along the upper elongate side 1407 has an upper elongate apex-plane offset distance 1530, measured vertically upward to the apex plane 4623, and each point along the lower elongate side 1409 has a lower elongate apex-plane offset distance 1630, measured vertically upward to the apex plane 4623. The apex plane 4623 is a plane parallel to the ground plane 317 and contacting the crown apex 4621, and an apex height is the distance between the apex plane 4623 and the ground plane 317.

In one embodiment the upper side length 1510 and/or the lower side length 1610 is at least 75% of the apex height, and in further embodiments at least 85%, 95%, 105%, 115%, 125%, 135%, or 145%. In another embodiment the upper side length 1510 and/or the lower side length 1610 is no more than 250% of the apex height, and in further embodiments no more than 225%, 200%, 175%, or 150%. In one embodiment the upper side length 1510 and/or the lower side length 1610 is at least 35% of the club head depth, illustrated in FIG. 81, and in further embodiments at least 40%, 45%, 50%, or 55%. In another embodiment the upper side length 1510 and/or the lower side length 1610 is no more than 95% of the club head depth, and in further embodiments no more than 90%, 85%, 80%, or 75%. In one embodiment the upper side length 1510 and/or the lower side length 1610 is at least 100% of Zup, which is the elevation of the club head center of gravity above the ground plane 317, and in further embodiments at least 125%, 150%, 175%, 200%, 225%, 250%, 275%, or 300%. In another embodiment the upper side length 1510 and/or the lower side length 1610 is no more than 600% of Zup, and in further embodiments no more than 550%, 500%, 450%, 425%, or 400%. In one embodiment the upper side length 1510 and/or the lower side length 1610 is at least 8 times the greatest face alignment feature height 1700, and in further embodiments at least 11, 14, 17, 20, or 23 times. In another embodiment the upper side length 1510 and/or the lower side length 1610 is no more than 50 times the greatest face alignment feature height 1700, and in further embodiments no more than 47, 44, 41, 38, 35, or 33 times. In one embodiment the upper side length 1510 and/or the lower side length 1610 is at least 30 mm, and in further embodiments at least 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, or 100 mm. In another embodiment the upper side length 1510 and/or the lower side length 1610 is no more than 110 mm, and in further embodiments no more than 105 mm, 95 mm, 85 mm, 75 mm, or 65 mm.

In one embodiment the upper side length 1510 is greater than the lower side length 1610. In another embodiment the second elongate side 1408a and/or the third elongate side 1408b is not vertical when viewed in a front elevation view such as FIG. 164. Further, again when viewed in viewed in a front elevation view, the second elongate side 1408a and the third elongate side 1408b are both at an angle from the vertical center face plane and the angles are not equal; whereas in another embodiment an extension of the second elongate side 1408a and an extension the third elongate side 1408b intersect at a location below the ground plane 317. In one embodiment the upper side length 1510 decreases as the loft of the club head increases. For example in one embodiment a set of at least 2, 3, or 4 club heads having a volume of 400 cc or more, the upper side length 1510 is less in the higher lofted club head; while in another embodiment the decrease of the upper side length 1510, in millimeters, is at least β multiplied by the increase in loft, in degrees, between the 2 club heads, where in one embodiment β is 1, while in further embodiments β is 2, 3, 4, 5, or 6. For example in another embodiment a set of at least 2, 3, or 4 club heads having a volume of 150-250 cc, the upper side length 1510 is less in the higher lofted club head; while in another embodiment the decrease of the upper side length 1510, in millimeters, is at least β multiplied by the increase in loft, in degrees, between the 2 club heads, where in one embodiment β is 1, while in further embodiments β is 2, 3, 4, 5, or 6. For example in another embodiment a set of at least 2, 3, or 4 club heads having a volume of 75-145 cc, the upper side length 1510 is less in the higher lofted club head; while in another embodiment the decrease of the upper side length 1510, in millimeters, is at least β multiplied by the increase In loft, in degrees, between the 2 club heads, where in one embodiment β is 1, while in further embodiments β is 2, 3, 4, 5, or 6. In still another embodiment any of these relationships is true for a set having at least one club head with a volume of 400 cc or more, and at least one club head with a volume of 150-250 cc; while a further embodiment also add at least one club head with a volume of 75-145 cc.

In one embodiment the toeward upper side length 1511 is at least 105% of the heelward upper side length 1512, and in further embodiments at least 110%, 115%, or 120%. In another embodiment the toeward upper side length 1511 is no more than 170% of the heelward upper side length 1512, and in further embodiments no more than 160%, 150%, 140%, or 130%. Similarly, in one embodiment the toeward lower side length 1611 is at least 105% of the heelward lower side length 1612, and in further embodiments at least 110%, 115%, or 120%. In another embodiment the toeward lower side length 1611 is no more than 170% of the heelward lower side length 1612, and in further embodiments no more than 160%, 150%, 140%, or 130%. In a further embodiment the heelward upper side length 1512 and/or the heelward lower side length 1612 is at least 50% of Zup, and in additional embodiments at least 60%, 70%, 80%, 90%, or 100% In one embodiment the face alignment feature height 1700 varies. In the embodiment illustrated in FIG. 164 the face alignment feature height 1700 varies at a heelward end portion and/or a toeward end portion. In a further embodiment the face alignment feature height 1700 is constant throughout at least 50% of the upper side length 1510, and in further embodiment at least 60%, 70%, 80%, or 90%. As illustrated in FIG. 100, a center-face y-axis location is defined as the distance CFY measured in the y-axis direction 207 from the center-face location 3110 to the shaft axis plane. In one embodiment the greatest face alignment feature height 1700 is at least 10% of CFY, while in further embodiment it is at least 12.5%, 15%, or 17.5%. In another embodiment the greatest face alignment feature height 1700 is no more than 70% of CFY, and in additional embodiments no more than 60%, 50%, 45%, 40%, or 35%.

In one embodiment the face alignment feature height 1700 increases as the loft of the club head decreases. For example in one embodiment a set of at least 2, 3, or 4 club heads having a volume of 400 cc or more, the face alignment feature height 1700 is greater in the lower lofted club head; while in another embodiment the increase of the face alignment feature height 1700, in millimeters, is at least β multiplied by the decrease in loft, in degrees, between the 2 club heads, where in one embodiment β is 0.1, while in further embodiments β is 0.15, 0.2, or 0.25. For example in one embodiment a set of at least 2, 3, or 4 club heads having a volume of 150-250 cc, the face alignment feature height 1700 is greater in the lower lofted club head; while in another embodiment the increase of the face alignment feature height 1700, in millimeters, is at least β multiplied by the decrease in loft, in degrees, between the 2 club heads, where in one embodiment β is 0.1, while in further embodiments β is 0.15, 0.2, or 0.25. For example in one embodiment a set of at least 2, 3, or 4 club heads having a volume of 75-145 cc, the face alignment feature height 1700 is greater in the lower lofted club head; while in another embodiment the increase of the face alignment feature height 1700, in millimeters, is at least β multiplied by the decrease in loft, in degrees, between the 2 club heads, where in one embodiment β is 0.1, while in further embodiments β is 0.15, 0.2, or 0.25. In still another embodiment any of these relationships is true for a set having at least one club head with a volume of 400 cc or more, and at least one club head with a volume of 150-250 cc; while a further embodiment also add at least one club head with a volume of 75-145 cc.

In the embodiment seen in FIGS. 118, 121, 125, and 175, and discussed in more detail later, a forwardmost point on the constant diameter portion of the external hosel surface 3251 defines a vertical forward hosel plane 3252, which is parallel to the shaft axis plane. A secondary offset vertical forward hosel plane 3254 is shown in FIG. 175 and is parallel to the vertical forward hosel plane 3252 and located an offset hosel plane distance in front of the vertical forward hosel plane 3252. In one embodiment the offset hosel plane distance is 3 mm, while in further embodiments it is 2 mm, or 1 mm. In one embodiment at least a portion of the upper elongate side 1407 is behind the secondary offset vertical forward hosel plane 3254 and a portion of the upper elongate side 1407 is forward of the secondary offset vertical forward hosel plane 3254.

A further embodiment has an upper elongate side elevation 1500 that varies by at least 2.5% of a minimum upper elongate side elevation 1500, and in further embodiments at least 5%, 7.5%, or 10%. An additional embodiment has an upper elongate side elevation 1500 that varies by no more than 25% of the minimum upper elongate side elevation 1500, and in further embodiments no more than 22.5%, 20%, 17.5%, 15%, or 12.5%. Similarly, a further embodiment has a lower elongate side elevation 1600 that varies by at least 2.5% of a minimum lower elongate side elevation 1600, and in further embodiments at least 5%, 7.5%, or 10%. An additional embodiment has a lower elongate side elevation 1600 that varies by no more than 25% of the minimum lower elongate side elevation 1600, and in further embodiments no more than 22.5%, 20%, 17.5%, 15%, or 12.5%.

In one embodiment, seen in FIG. 165, the face 110 includes a face plate 4610 welded in a face opening in the face 110 and creating a fusion zone 9000 and establishing a center of fusion perimeter 9010 around the perimeter of the face plate 4610. In one embodiment the portion of the face surrounding the face opening is formed of a stainless steel alloy, which in a further embodiment is a martensitic type stainless steel alloy, precipitation hardening stainless steel alloy, austenitic type stainless steel alloy, duplex stainless steel alloy, or ferritic stainless steel alloy. In another embodiment the portion of the face surrounding the face opening is formed of a martensitic stainless steel alloy, which in a further embodiment is selected from the group of 410, 420, 431, 440, or 450, and in a further embodiment is an age hardened martensitic stainless steel alloy. In another embodiment the face plate 4610 is formed of a maraging steel alloy, which in a further embodiment is selected from the group of grade 200, grade 250, grade 300, and grade 350, while in another embodiment it is C300 steel alloy. In one embodiment the face secondary alignment feature 1404 is located entirely on the stainless steel alloy portion of the face.

In one embodiment, illustrated in FIGS. 172-174, the face 110 has a face coating 111, having a coating thickness 2113, applied to the face substrate 2112 through any number of processes including, but not limited to, physical vapor deposition (PVD) and chemical vapor deposition (CVD). In one embodiment the coating thickness 2113 is 0.3-15 microns. In one embodiment the face secondary alignment feature 1404 is formed by removing a portion of the face coating 111. In one such embodiment seen in FIG. 172 the face coating 111 is entirely removed in face secondary alignment feature 1404 leaving an exposed portion of the face substrate 2112, which in one embodiment is stainless steel alloy. While in another embodiment seen in FIG. 173 only a portion of the face coating 111 is removed and thus the face secondary alignment feature 1404 is created by the formation of a recess in the face coating 111 that does not extend through the entire coating thickness 2113, which may alone create the contrasting face surface characteristic when compared to the adjacent face coating 111 that has not been removed. While in still a further embodiment seen in FIG. 174 the face secondary alignment feature 1404 is formed by removing the full coating thickness 2113 and a portion of the face substrate 2112 leaving a recess in the face substrate 2112.

Further, in any of the embodiments in which the entire coating thickness 2113 is removed, the face substrate 2112 may be left raw and exposed to the environment in the finished club head as sold and played, and the raw exposed face substrate 2112 creates the contrasting face surface characteristic when compared to the adjacent face coating 111 and/or crown. This is why in some embodiments the face secondary alignment feature 1404 is strategically placed on the portion of the face 111 formed of stainless steel alloy and at least a safety zone distance away from the center of fusion perimeter 9010, seen in FIG. 165, around a portion of the perimeter of the face plate 4610. In one embodiment the safety zone distance is at least 50% of maximum thickness of the face plate 4610, and at least 60%, 70%, or 80% in further embodiments. In another embodiment the safety zone distance is at least 0.5 mm, while in further embodiments it is at least 1.0 mm, 1.5 mm, or 2.0 mm. Thus, in some embodiments of face secondary alignment feature 1404 is delineated from the other portion of the face 110 by the change in surface characteristics between the exposed face substrate 2112 and the adjacent portion of the face 110 where the face coating 111 has not been removed.

In another embodiment the upper elongate side 1407 is within a predefined proximity distance of the crown leading edge 4625, disclosed in great detail later herein, utilizing the disclosed simple proximity method with the first end of the string is placed at a point on the upper elongate side 1407. Then if a portion of the crown leading edge 4625 is contacted by the second end of the string, the upper elongate side 1407 is within the predefined proximity distance to the crown leading edge 4625. In one embodiment the predefined proximity distance is 4 mm, while in further embodiments it is 3 mm, 2 mm, 1 mm, or 0.75 mm. Further, the upper elongate side 1407 may be recessed in relation to the crown leading edge 4625, or alternatively stated the crown leading edge 4625 may be proud of the upper elongate side 1407, as disclosed later in great detail regarding the proud relationship of the crown leading edge 4625 with respect to the face perimeter, and all of that later disclosure applies equally to the relationship of the crown leading edge 4625 to the upper elongate side 1407, as well as the gap therebetween.

With reference again to FIG. 176, in another embodiment at least a portion of the face secondary alignment feature 1404 has an upper elongate apex-plane offset distance 1530 that is least 30% of Zup, while in further embodiments it is at least 35%, 40%, 45%, 50%, 55%, 60%, 65%, or 70%. However, in another embodiment a maximum upper elongate apex-plane offset distance 1530 is no more than 120% of Zup, while in further embodiments it is no more than 110%, 100%, 90%, 85%, 80%, or 75%. In another embodiment a minimum upper elongate apex-plane offset distance 1530 is at least 10% of Zup, while in further embodiments it is at least 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 32%, or 34%. However, in another embodiment the minimum upper elongate apex-plane offset distance 1530 is no more than 35% of Zup, while in further embodiments it is no more than 32.5%, 30%, 29%, 28%, 27%, 26%, 25%, 24%, 23%, or 22%. In a further embodiment the maximum upper elongate apex-plane offset distance 1530 is at least 100% greater than the minimum upper elongate apex-plane offset distance 1530, and in further embodiments at least 125%, 150%, 175%, or 200%. In one embodiment the maximum upper elongate apex-plane offset distance 1530 occurs at a point located between the vertical center face plane and hosel portion 4604, and the minimum upper elongate apex-plane offset distance 1530 occurs at a point located between the vertical center face plane and the toe 1185. In still a further embodiment the minimum upper elongate apex-plane offset distance 1530 occurs at a point located between the vertical center face plane and a parallel plane containing the crown apex 4621.

In some embodiments the face secondary alignment feature 1404 is composed of multiple sections, which in one embodiment includes a central face secondary alignment portion 1404A, a toeward face secondary alignment portion 1404B, and a heelward face secondary alignment portion 1404C, as seen in FIG. 166, separated by breaks 1405. In one embodiment the breaks 1405 separate the portions 1404A, 1404B, 1404C by a distance of less than 5 mm, and in further embodiments less than 4 mm, 3 mm, or 2 mm. Any of the disclosure with respect to the second elongate side 1408a and/or the third elongate side 1408b, as well as their angles, also applies to the breaks 1405. In one embodiment the length of the central face secondary alignment portion 1404A is greater than the length of the toeward face secondary alignment portion 1404B and/or the length of the heelward face secondary alignment portion 1404C. In one embodiment the length of the central face secondary alignment portion 1404A is at least 2 times greater than the length of the toeward face secondary alignment portion 1404B and/or the length of the heelward face secondary alignment portion 1404C; and in further embodiments at least 3, 4, 5, or 6 times greater. In a further embodiment seen in FIG. 167, the face secondary alignment feature 1404 may include at least one gradient region 1411, although the face secondary alignment feature 1404 may be a gradient provided the disclosed contrast is achieved. In the embodiment of FIG. 167 the face secondary alignment feature 1404 has a uniform central region, flanked by two gradient regions 1411.

Another embodiment may incorporate a tertiary alignment feature having a face portion, located on a portion of the face, and a crown portion, located on a portion of the crown; in other words the teriary alignment feature continues from a portion of the face to a portion of the crown. All of the disclosure relating to the primary and secondary alignment features applies equally to the tertiary alignment feature, which may exist in conjunction with the primary alignment feature and/or secondary alignment feature, or may be present independent of primary alignment feature and/or secondary alignment feature.

Any of the alignment features may also incorporate a color changing paint in which the color of the material changes with the angle of observance. Thus, in one embodiment when viewed from the address position, the color is high contrast with respect to the face and/or crown, while when viewing the golf club head face-on the color is medium to low contrast with respect to the face and/or crown. In further embodiments any of the alignment features may incorporate paint, ink, coatings, and/or films that have hydrophilic and/or hydrophobic attributes. Accordingly, the alignment feature may have a higher level of hydrophilicity than the level of hydrophilicity of other areas of the face and/or crown. Hydrophilic means attracting water and hydrophobic means repelling water.

As one skilled in the art will understand, the face of every golf club head has a face surface roughness and a face area. Further, the alignment feature has an alignment feature surface roughness. In one embodiment the alignment feature surface roughness is less than the face surface roughness, while conversely in another embodiment the face surface roughness is less than the alignment feature surface roughness. In a further embodiment the alignment feature surface roughness of at least 10 in greater than the adjacent face surface roughness, and in some embodiments with very low face surface roughness the alignment feature surface roughness may be at least twice the adjacent face surface roughness. In a further low face surface roughness face embodiment it is preferred to have an alignment feature surface roughness of less than fifteen times the adjacent face surface roughness. In one particular embodiment a polished PVD face of the golf club head may have a face surface roughness of 5-20 μin, whereas the alignment feature surface roughness may be about 60-90 μin. In another embodiment the face surface roughness is preferably 5-70 μin when measured in a parallel direction to the grooves, and the alignment feature surface roughness is preferably 50-90 μin when measured in a parallel direction to the grooves.

As disclosed throughout, numerous methods and/or components may be used to create the alignment features. Such techniques include etching methods, oxidation techniques, peening methods, engraving techniques, media blasting processes, machining methods, cutting processes, painting, and/or application of durable inks and/or coatings. For example, etching techniques using laser processing, chemical processing, or through the use of a photosensitive light-activated coating process may be used. Further, lasers also can be configured to produce markings that do not remove material to alter the thickness of the face or face coating; instead, the laser energy oxidizes the material of the face or face coating, resulting in a visible change. This change leads to a marking that is visible without impacting the spin of a golf ball. One such laser type used is a Yttrium-Aluminum-Garnet (YAG) laser, such as the HM 1400 marketed by GSI Lumionics of Ottawa, Canada. Preferably, a 6-inch diameter lens having a 254 mm focal length is used.

The Sight Adjusted Perceived Face Angle Secondary Alignment Feature, (“SAPFA_SAF”) of the secondary alignment feature constituting elongate side 1406 and the second and third elongate sides 1408a and 1408b may be measured by importing the image of the club head obtained as per the measurement for the SAPFA. Points 1410b and 1410a are selected which are the innermost ends of the radii connecting lines 1408b and 1408 a with elongate side 1406 as shown in FIG. 79B. A best fit quadratic line is then fit for the secondary alignment feature between point 1410 a and 1410b and then a datum 1412 is determined as the center point along the arc length of the best fit line, again as for the SAPFA measurement, two points at arc length between +/−0.25 mm from the datum were selected. A straight line is then drawn between these two points and a line perpendicular to this line is then drawn at the datum. The Sight Adjusted Perceived Face Angle Secondary Alignment Feature, (“SAPFA_SAF”) is then measured as the angle between this perpendicular line and the y axis.

In some embodiments, the golf club heads of the present invention also have a Sight Adjusted Perceived Face Angle Secondary Alignment Feature, (“SAPFA_SAF”) of from about −2 to about 6, more preferably of from 0 to about 5, even more preferably of from about 1.5 to about 4 degrees.

The primary and secondary alignment features as described herein typically utilize paint lines which demark the edge of an area of contrasting paint or shading of the crown relative to the color or shading of the face. Preferably the contrasting colors are white in the crown area and black in the face area. Typically painting or shading of golf club heads is performed at the time of manufacture and thus are fixed for the lifetime of the club absent some additional painting performed after purchase by the owner. It would be highly advantageous if the profile of the alignment feature could be adjusted by the user using a simple method which would allow adjustment of the perceived face angle by the user in response to the golfer's observed ball direction tendency on any given day.

In some embodiments of the golf club heads of the present invention the crown comprises a rotatable or otherwise movable portion, with one side of said portion including the edge of an area of contrasting paint or shading of the crown relative to the color or shading of the face or the color or shading of the second portion of the crown which can be rotated or moved sufficient to yield the desired Perceived Face Angle, PFA and/or Sight Adjusted Perceived Face Angle (SAPFA) and/or Sight Adjusted Perceived Face Angle Secondary Alignment Feature, (“SAPFA_SAF”) to produce the desired ball flight. The movable portion of the crown is held in position by a fastening device such as a screw or bolt which is loosened to allow for rotation or movement and then subsequently tightened to fix the position of the crown after adjustment.

In addition to a portion of the crown being movable other embodiments include a movable layer or cover on top of the crown with one side of said movable layer or cover including the edge of an area of contrasting paint or shading of the crown relative to the color or shading of the face or the color or shading of the second portion of the crown which can be rotated or moved sufficient to yield the desired Perceived Face Angle, PFA and/or Sight Adjusted Perceived Face Angle (SAPFA) and/or Sight Adjusted Perceived Face Angle Secondary Alignment Feature, (“SAPFA_SAF”). The movable portion of the layer or cover is again held in position by a fastening device such as a screw or bolt or other fastening means which is loosened to allow for rotation or movement and then subsequently tightened to fix the position of the movable layer or cover after adjustment.

In other embodiments a portion of the crown may comprise electronic features which can be selectively activated to generate the required appearance including but not limited to light emitting diodes (LED), organic LED's (OLED), printed electronics with illumination devices, embedded electronics with illumination devices, electroluminescent devices, and so called quantum dots.

In other embodiments, a portion of the crown may comprise a coating that alters its characteristics when exposed to external conditions including but not limited to thermochromic coatings, photochromic coatings, electrochromic coatings and paramagnetic paint.

In one preferred embodiment, at least a portion of the crown of the golf club head or a layer covering at least a portion of the crown of the golf club head comprises an electronic graphic display. The display provides active color and graphic control for either the entire top portion of the crown or layer covering at least a portion of the crown or a portion thereof. The display may be constructed from flexible organic light-emitting diodes (OLED) displays, e-ink technology, digital fabrics, or other known means of active electronic color and graphic display means. For example, an organic light emitting diode (OLED) (e.g., a light emitting polymer (LEP), and organic electro luminescence (OEL)) is a light-emitting diode (LED) whose emissive electroluminescent layer is composed of a film of organic compounds. The layer usually contains a polymer substance that allows suitable organic compounds to be deposited in rows and columns onto a carrier substrate such as the at least a portion of the crown of the golf club head or a layer covering at least a portion of the crown of the golf club head, by a simple “printing” process. The resulting matrix of pixels can emit light of different colors.

In some embodiments, the at least a portion of the crown of the golf club head or a layer covering at least a portion of the crown of the golf club head is segmented into portions which may be controlled differently from each other. For example, one side of the alignment feature has a static surface color and the other side a second static and contrasting surface color display capability.

The display is operatively connected to a microprocessor disposed in the golf club head (e.g., via wires). The microprocessor is further operatively connected to a data port, for example a universal serial bus (USB) port (e.g., via wires). The data port allows transfer and retrieval of data to and from the microprocessor. Data ports and data transfer protocols are well known to one of ordinary skill in the art. The data port (USB port) may be disposed in the rearward area of the golf club head.

Data can be obtained from a variety of sources. In some embodiments, an Internet website is dedicated to support of the golf club head of the present invention. For example, the website may contain downloadable data and protocols (e.g., colors, color patterns, images, video content, logos, etc.) that can be uploaded into the microprocessor of the golf club head (via the data port, via a cable, via a computer). As an example, the website may have a gallery for choosing colors to be displayed, as well as patterns of the colors

In some embodiments, data can be uploaded from other sources, for example DVDs, CDs, memory devices (e.g., flash memory), and the like. Sources may also include cellular phones, smart phones, personal digital assistants (PDAs), digital vending kiosks, and the like. In some embodiments, the data can be uploaded and downloaded via other mechanisms, for example wired or wireless mechanisms. Such mechanisms may include Bluetooth™, infrared datalink (IrDa), Wi-Fi, UWB, and the like.

In some embodiments, one or more control buttons are disposed on the golf club head allowing a user to manipulate the display as desired. The control buttons are operatively connected to the microprocessor. The microprocessor is configured to receive input signals from the control buttons and further send output commands to manipulate the. The control buttons may be operatively connected to the display and/or the microprocessor via one or more wires.

The microprocessor and/or display are operatively selected to a power source, for example a battery. The battery may be rechargeable. In some embodiments, the battery comprises a control means for turning on and off the device. All wires and data ports and other electronic systems are adapted to sustain the impact forces incurred when a golfer hits a golf ball with the golf club head.

In other embodiments of the golf club heads of the present invention a method to accomplish user adjustably of the alignment feature would involve at least a portion of the crown of the golf club head or a layer covering at least a portion of the crown of the golf club head being covered by a dielectric electroluminescent coating system using as one example the materials and methods as described in U.S. Pat. No. 6,926,972 by M. Jakobi et al., issuing on Aug. 9, 2005 and assigned to the BASF Corporation, the entire contents of which are incorporated by reference herein. Using this technology an electric current (provided by a small battery fixed securely in the golf club head cavity) could be selectively employed to use electroluminescence to highlight (or eliminate) a particular color thereby adjusting the alignment feature orientation.

In some embodiments, the golf club head may include sensors, such as described in U.S. patent application Ser. No. 15/996,854, filed Jun. 4, 2018, which is incorporated herein by reference. For example, the golf club may include one or more sensors for measuring swing speed, face angle, lie angle, tempo, swing path, face angle to swing path relationships, dynamic loft, and shaft lean. Other measurements may include back stroke time, forward stroke time, total stroke time, tempo, impact stroke speed, impact location, back stroke length, back stroke rotation, forward stroke rotation, rotation change, lie, and loft. Further measurements may include golf shot locations during play and golf shot distance data. Additional and different measurements may also be captured. The measurements may be captured during a full swing, short game, putting, or during other golf swings.

The one or more sensors may include motion sensors, accelerometers, gyro sensors, magnetometers, global positioning system (GPS) sensors, optical markers, or other sensors. The one or more sensors may be attached to the golf club head, integrated into a display of the golf club, attached to or integrated into the shaft of the golf club (e.g., proximate to the butt end of golf club grip, along the shaft, or at another location), housed within the golf club grip, and/or attached to or integrated into another portion of the golf club. In an embodiment, multiple sensors are provided on the golf club, such as at the same or different portions of the golf club. For example, a first sensor may be attached to or integrated into the golf club head and a second sensor housed within the grip of the golf club or attached to the golf club shaft. Additional and different multiple sensor arrangements may be used.

In an embodiment, a display or another electronic feature of the golf club may display one or more of the measured values on the crown or another portion of the golf club head. For example, the display or another electronic feature may be a removable display device, or may integrated into user device, such as a PDA, smart phone, iPhone, iPad, iPod, or other computing device. The one or more measured values may be displayed using an application running on the display device or using a device associated with the display or other electronic feature of the golf club head. In some embodiments, the sensors may be configured to communicate with an external device, such as a computing device (e.g., personal computer (PC), laptop computer, tablet, smart phone, cell phone, iPhone, iPad, Personal Digital Assistant (PDA), server computer, or another computing device), a launch monitor, a club fitting platform, or another device. In these embodiments, the one or more measured values may be displayed using an application running on the external device. In some embodiments, the one or more sensors interact with an external device, such as a video camera, to capture one or more measured values.

Referring back to FIG. 70B, a coordinate system for measuring a center of gravity (CG) location is located at the face center 205. In one embodiment, the positive x-axis 1208 is projecting toward the heel side of the club head and the negative x-axis 1208 is projecting toward the toe side of the golf club head. Further, the positive z-axis 1206 is projecting toward the crown side of the club head and the negative z-axis 1206 is projecting toward the sole side of the golf club head. Finally, the positive y-axis 207 is projecting toward the rear of the club head parallel to a ground plane. Unless noted otherwise, as used herein a first location is forward of a second location when the first location is nearer face center 205 along the y-axis 207 than is the second location; and likewise the first location is behind the second location when the first location is further from face center 205 along the y-axis 207 than is the second location. Unless noted otherwise, as used herein a first location is toeward of a second location when the first location is further from the hosel portion along the x-axis 1208 than is the second location; and likewise the first location is heelward of the second location when the first location is closer to the hosel portion along the x-axis 1208 than is the second location.

In exemplary embodiments, a projected CG location on the striking face is considered the “sweet spot” of the club head. The projected CG location is found by balancing the clubhead on a point. The projected CG location is generally projected along a line that is perpendicular to the face of the club head. In some embodiments, the projected CGy (y-axis coordinate) location is less than 2 mm above the center face location, less than 1 mm above the center face, or up to 1 mm or 2 mm below the center face location 205. In some embodiments, the golf club head has a CG with a CGx (x-axis) coordinate between about −10 mm and about 10 mm from the center face location 205, a CGy between about 15 mm and about 50 mm, and a CGz (z-axis coordinate) between about −10 mm and about 5 mm. In some embodiments, the CGy is between about 20 mm and about 50 mm.

The golf club head also has moments of inertia defined about three axes extending through the golf club head CG orientation, including: a CGz extending through the CG in a generally vertical direction relative to the ground plane when the club head is at address position, a CGx extending through the CG in a heel-to-toe direction generally parallel to the striking face 110 and generally perpendicular to the CGz, and a CGy extending through the CG in a front-to-back direction and generally perpendicular to the CGx and the CGz. The CGx and the CGy both extend in a generally horizontal direction relative to the ground plane when the club head 100 is at the address position.

The club head and many of its physical characteristics disclosed herein will be described using “normal address positio” as the club head reference position, unless otherwise indicated. At normal address position, the club head rests on a flat ground plane. Unless noted otherwise, as used herein, “normal address position” means the club head position wherein a vector normal to a center face 205 substantially lies in a first vertical plane (i.e., a vertical plane is perpendicular to the ground plane), a centerline axis of a hosel bore establishes a shaft axis that lies in a second vertical plane, and the first vertical plane and the second vertical plane substantially perpendicularly intersect.

The moment of inertia about the golf club head CGx is calculated by the following equation:

$I_{CGx} = \int (y^{2} + z^{2}) dm$

In the above equation, y is the distance from a golf club head CG xz-plane to an infinitesimal mass dm and z is the distance from a golf club head CG xy-plane to the infinitesimal mass dm. The golf club head CG xz-plane is a plane defined by the CGx and the CGz. The CG xy-plane is a plane defined by the CGx and the CGy.

The moment of inertia about the golf club head CGy is calculated by the following equation:

$I_{CGy} = \int (x^{2} + z^{2}) dm$

In the above equation, x is the distance from a golf club head CG yz-plane to an infinitesimal mass dm and z is the distance from a golf club head CG xy-plane to the infinitesimal mass dm. The golf club head CG yz-plane is a plane defined by the CGy and the CGz. The CG yx-plane is a plane defined by the CGy and the CGx.

Moreover, a moment of inertia about the golf club head CGz is calculated by the following equation:

$I_{CGz} = \int (x^{2} + y^{2}) dm$

In the equation above, x is the distance from a golf club head CG yz-plane to an infinitesimal mass dm and y is the distance from the golf club head CG xz-plane to the infinitesimal mass dm. The golf club head CG yz-plane is a plane defined by the CGy and the CGz.

In certain implementations, the club head can have a moment of inertia about the CGz between about 450 kg·mm²and about 650 kg·mm², and a moment of inertia about the CGx between about 300 kg·mm²and about 500 kg·mm², and a moment of inertia about the CGy between about 300 kg·mm²and about 500 kg·mm².

For a variety of reasons, it may be advantageous to orient the center of gravity (CG) of the golf club head toward the toe. For example, users often strike the golf ball high (e.g., +3 to +4 mm on the z-axis) and toeward (e.g., −5 to −7 mm on the x-axis) on the striking face. Striking the ball off-center (i.e., in a location different from the projected CG location on the striking face) generally decreases ball-speed, and as a result, decreases the distance traveled by the golf ball.

Further, as discussed above, striking the face toeward also produces a gear effect, producing hook spin. Increasing the negative CGx orientation (i.e., from −2 to −10 mm on the x-axis) may alter the gear effect by decreasing the counter-clockwise spin (i.e., for a right-handed golfer) which ultimately results in the golf ball curving to the left.

Additionally, in order to maximize the moment of inertia (MOI) about a z-axis extending through the CGz, a negative CGx orientation may be provided. Working in conjunction with the weight of the hosel of the golf club, a negative CGx orientation allows for greater MOI about the z-axis by strategically distributing club head weight on the x-axis at corresponding positive and negative orientations.

Alternatively, it may be advantageous to orient the CG of the golf club head toward the heel. For example, by increasing positive CGx orientation (i.e., from +2 mm to 0 mm on the x-axis), the club head may close faster (i.e., at 400-500 rpm), increasing local club head speed and producing more ball-speed, and as a result, increasing the distance traveled by the golf ball.

In certain implementations, the golf club head can have a CGx between about +2 and about −10 mm. For example, the CGx for a golf club head with adjustable weights (discussed below) is between about −3 mm to about −4 mm. In certain implementations, the club head can have a low CGz of less than 0, such as between 0 and about −4 mm. In certain implementations, the club head can have a CGz positioned below a geometric center of the face. In certain implementations, the club head can have a moment of inertia about the CGz (also referred to as “Izz”) above 400 kg·mm², above 460 kg·mm²or above 480 kg·mm². A moment of inertia about the CGx (also referred to as “Ixx”) can be above 300 kg·mm². The moments of inertia of the golf club head can also be expressed as a ratio, such as a ratio of Ixx to Izz. For example, in some embodiments, a ratio of Ixx to Izz is at most 0.6, or 60%. In an example, the golf club head can have an Ixx above 300 kg·mm²and an Izz above 500 kg·mm², such that Ixx/Izz is less than or equal to 0.6. In another example, the Ixx is greater than 280 kg·mm²and the Izz is greater than 465 kg·mm².

In certain implementations, the golf club head can have a Zup less than 30 mm. For example, above ground, an alternative club head coordinate system places the head origin at the intersection of the z-axis and the ground plane, providing positive z-axis coordinates for every club head feature. As used herein, “Zup” means the CG z-axis location determined according to this above ground coordinate system. Zup generally refers to the height of the CG above the ground plane as measured along the z-axis.

In certain implementations, the golf club head can have a Delta 1 (i.e., measure of how far rearward in the golf club head body the CG is located) greater than 20, such as greater than 26 in certain implementations. More specifically, Delta 1 is the distance between the CG and the hosel axis along the y axis (in the direction straight toward the back of the body of the golf club face from the geometric center of the striking face). It has been observed that smaller values of Delta 1 result in lower projected CGs on the golf club head face. Thus, for embodiments of the disclosed golf club heads in which the projected CG on the ball striking club face is lower than the geometric center, reducing Delta 1 can lower the projected CG and increase the distance between the geometric center and the projected CG. Note also that a lower projected CG can promote a higher launch and a reduction in backspin due to the z-axis gear effect. Thus, for particular embodiments of the disclosed golf club heads, in some cases the Delta 1 values are relatively low, thereby reducing the amount of backspin on the golf ball helping the golf ball obtain the desired high launch, low spin trajectory.

The United States Golf Association (USGA) regulations constrain golf club head shapes, sizes, and moments of inertia. Due to these constraints, golf club manufacturers and designers struggle to produce golf club heads having maximum size and moment of inertia characteristics while maintaining all other golf club head characteristics. For example, one such constraint is a volume limitation of 460 cm³. In general, volume is measured using the water displacement method. However, the USGA will fill any significant cavities in the sole or series of cavities which have a collective volume of greater than 15 cm³.

In some embodiments, as in the case of a fairway wood, the golf club head may have a volume between about 100 cm³and about 300 cm³, such as between about 150 cm³and about 250 cm³, or between about 130 cm³and about 190 cm³, or between about 125 cm³and about 240 cm³, and a total mass between about 125 g and about 260 g, or between about 200 g and about 250 g. In the case of a utility or hybrid club, the golf club head may have a volume between about 60 cm³and about 150 cm³, or between about 85 cm³and about 120 cm³, and a total mass between about 125 g and about 280 g, or between about 200 g and about 250 g. In the case of a driver, the golf club head may have a volume between about 300 cm³and about 600 cm³, between about 350 cm³and about 600 cm³, and/or between about 350 cm³and about 500 cm³, and can have a total mass between about 175 g and about 215 g, such as between about 195 g and about 205 g.

Historically, CG_xlocations were heelward about 4-6 mm. More recently, CG_xlocations have been moved toeward to about −1 mm. CG_xlocations will likely continue to be toeward, such as in the example CG_xlocations described in U.S. patent application Ser. No. 16/171,237, filed Oct. 25, 2018, which is incorporated herein by reference. For example, club head has a center of gravity (CG), the location of which may be defined in terms of the coordinate system described above and shown in FIGS. 70A, 70B and 70D, and in some embodiments, the club head has a CG_xtoeward of center face as, for example, no more than −2 mm toeward. In some embodiments the club head has a CG_xof 0 to −4 mm. In some embodiments the club head has a moment of inertia about the z-axis (I_zz) of 480 to 600 Kg·mm²or in some embodiments greater than 490 Kg·mm², a moment of inertia about the x-axis (I_xx) of about 280 to 420 Kg·mm²or in some embodiments greater than 280 Kg·mm².

There are a variety of ways to position the CG orientations of the golf club head. For example, in some embodiments, a composite crown and/or sole is provided to help overcome manufacturing challenges associated with conventional golf club heads having normal continuous crowns made of titanium or other metals, and can replace a relatively heavy component of the crown with a lighter material, freeing up discretionary mass which can be strategically allocated elsewhere within the golf club head. In certain embodiments, the crown may comprise a composite material, such as those described herein and in the incorporated disclosures, having a density of less than 2 grams per cubic centimeter. In still further embodiments, the composite material has a density of no more than 1.5 grams per cubic centimeter, or a density between 1 gram per cubic centimeter and 2 grams per cubic centimeter. Providing a lighter crown further provides the golf club head with additional discretionary mass, which can be used elsewhere within the golf club head to serve the purposes of the designer. For example, with the discretionary mass, additional weight can be strategically added to the hollow interior of the golf club head, or strategically located on the exterior of the golf club head, to shift the effective CG fore or aft, toeward or heelward or both (apart from any further CG adjustments made possible by adjustable weight features), and/or to improve desirable MOI characteristics, as described above.

In some embodiments, the crown and/or sole may be formed in whole or in part from a composite material, such as a carbon composite, made of a composite including multiple plies or layers of a fibrous material (e.g., graphite, or carbon fiber including turbostratic or graphitic carbon fiber or a hybrid structure with both graphitic and turbostratic parts present. Examples of some of these composite materials for use in the metalwood golf clubs and their fabrication procedures are described in U.S. patent application Ser. No. 10/442,348 (now U.S. Pat. No. 7,267,620), Ser. No. 10/831,496 (now U.S. Pat. No. 7,140,974), U.S. Ser. Nos. 11/642,310, 11/825,138, 11/998,436, 11/895,195, 11/823,638, 12/004,386, 12,004,387, 11/960,609, 11/960,610, and 12/156,947, which are incorporated herein by reference.

Alternatively, the crown and/or sole may be formed from short or long fiber-reinforced formulations of the previously referenced polymers. Exemplary formulations include a Nylon 6/6 polyamide formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 285. The material has a Tensile Strength of 35000 psi (241 mPa) as measured by ASTM D 638; a Tensile Elongation of 2.0-3.0% as measured by ASTM D 638; a Tensile Modulus of 3.30×10⁶psi (22754 Mpa) as measured by ASTM D 638; a Flexural Strength of 50000 psi (345 Mpa) as measured by ASTM D 790; and a Flexural Modulus of 2.60×10⁶psi (17927 Mpa) as measured by ASTM D 790.

Also included is a polyphthalamide (PPA) formulation which is 40% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 4087 UP. This material has a Tensile Strength of 360 Mpa as measured by ISO 527; a Tensile Elongation of 1.4% as measured by ISO 527; a Tensile Modulus of 41500 Mpa as measured by ISO 527; a Flexural Strength of 580 Mpa as measured by ISO 178; and a Flexural Modulus of 34500 Mpa as measured by ISO 178.

Also included is a polyphenylene sulfide (PPS) formulation which is 30% Carbon Fiber Filled and available commercially from RTP Company under the trade name RTP 1385 UP. This material has a Tensile Strength of 255 Mpa as measured by ISO 527; a Tensile Elongation of 1.3% as measured by ISO 527; a Tensile Modulus of 28500 Mpa as measured by ISO 527; a Flexural Strength of 385 Mpa as measured by ISO 178; and a Flexural Modulus of 23,000 Mpa as measured by ISO 178.

In other embodiments, the crown and/or sole is formed as a two layered structure comprising an injection molded inner layer and an outer layer comprising a thermoplastic composite laminate. The injection molded inner layer may be prepared from the thermoplastic polymers, with preferred materials including a polyamide (PA), or thermoplastic urethane (TPU) or a polyphenylene sulfide (PPS). Typically the thermoplastic composite laminate structures used to prepare the outer layer are continuous fiber reinforced thermoplastic resins. The continuous fibers include glass fibers (both roving glass and filament glass) as well as aramid fibers and carbon fibers. The thermoplastic resins which are impregnated into these fibers to make the laminate materials include polyamides (including but not limited to PA, PA6, PA12 and PA6), polypropylene (PP), thermoplastic polyurethane or polyureas (TPU) and polyphenylene sulfide (PPS).

The laminates may be formed in a continuous process in which the thermoplastic matrix polymer and the individual fiber structure layers are fused together under high pressure into a single consolidated laminate, which can vary in both the number of layers fused to form the final laminate and the thickness of the final laminate. Typically the laminate sheets are consolidated in a double-belt laminating press, resulting in products with less than 2 percent void content and fiber volumes ranging anywhere between 35 and 55 percent, in thicknesses as thin as 0.5 mm to as thick as 6.0 mm, and may include up to 20 layers. Further information on the structure and method of preparation of such laminate structures is disclosed in European patent No. EP1923420B1 issued on Feb. 25, 2009 to Bond Laminates GMBH, the entire contents of which are incorporated by reference herein.

The composite laminates structure of the outer layer may also be formed from the TEPEX® family of resin laminates available from Bond Laminates which preferred examples are TEPEX® dynalite 201, a PA66 polyamide formulation with reinforcing carbon fiber, which has a density of 1.4 g/cm³, a fiber content of 45 vol %, a Tensile Strength of 785 mPa as measured by ASTM D 638; a Tensile Modulus of 53 gPa as measured by ASTM D 638; a Flexural Strength of 760 mPa as measured by ASTM D 790; and a Flexural Modulus of 45 GPa) as measured by ASTM D 790.

Another preferred example is TEPEX® dynalite 208, a thermoplastic polyurethane (TPU)-based formulation with reinforcing carbon fiber, which has a density of 1.5 g/cm³, a fiber content of, 45 vol %, a Tensile Strength of 710 mPa as measured by ASTM D 638; a Tensile Modulus of 48 gPa as measured by ASTM D 638; a Flexural Strength of 745 mPa as measured by ASTM D 790; and a Flexural Modulus of 41 gPa as measured by ASTM D 790.

Another preferred example is TEPEX® dynalite 207, a polyphenylene sulfide (PPS)-based formulation with reinforcing carbon fiber, which has a density of 1.6 g/cm³, a fiber content of 45 vol %, a Tensile Strength of 710 mPa as measured by ASTM D 638; a Tensile Modulus of 55 gPa as measured by ASTM D 638; a Flexural Strength of 650 mPa as measured by ASTM D 790; and a Flexural Modulus of 40 gPa as measured by ASTM D 790.

There are various ways in which the multilayered composite crown may be formed. In some embodiments the outer layer, is formed separately and discretely from the forming of the injection molded inner layer. The outer layer may be formed using known techniques for shaping thermoplastic composite laminates into parts including but not limited to compression molding or rubber and matched metal press forming or diaphragm forming.

The inner layer may be injection molded using conventional techniques and secured to the outer crown layer by bonding methods known in the art including but not limited to adhesive bonding, including gluing, welding (preferable welding processes are ultrasonic welding, hot element welding, vibration welding, rotary friction welding or high frequency welding (Plastics Handbook, Vol.¾ 4, pages 106-107, Carl Hanser Verlag Munich & Vienna 1998)) or calendaring or mechanical fastening including riveting, or threaded interactions.

Before the inner layer is secured to the outer layer, the outer surface of the inner layer and/or the inner of the outer layer may be pretreated by means of one or more of the following processes (disclosed in more detail in Ehrenstein, “Handbuch Kunststoff-Verbindungstechnik”, Carl Hanser Verlag Munich 2004, pages 494-504):

- Mechanical treatment, preferably by brushing or grinding,
- Cleaning with liquids, preferably with aqueous solutions or organics solvents for removal of surface deposits
- Flame treatment, preferably with propane gas, natural gas, town gas or butane
- Corona treatment (potential-loaded atmospheric pressure plasma)
- Potential-free atmospheric pressure plasma treatment
- Low pressure plasma treatment (air and 02 atmosphere)
- UV light treatment
- Chemical pretreatment, e.g. by wet chemistry by gas phase pretreatment
- Primers and coupling agents

In an especially preferred method of preparation a so called hybrid molding process may be used in which the composite laminate outer layer is insert molded to the injection molded inner layer to provide additional strength. Typically the composite laminate structure is introduced into an injection mold as a heated flat sheet or, preferably, as a preformed part. During injection molding, the thermoplastic material of the inner layer is then molded to the inner surface of the composite laminate structure the materials fuse together to form the crown as a highly integrated part. Typically the injection molded inner layer is prepared from the same polymer family as the matrix material used in the formation of the composite laminate structures used to form the outer layer so as to ensure a good weld bond.

In addition to being formed in the desired shape for the aft body of the club head, a thermoplastic inner layer may also be formed with additional features including one or more stiffening ribs to impart strength and/or desirable acoustical properties as well as one or more weight ports to allow placement of additional tungsten (or other metal) weights.

The thickness of the inner layer is typically of from about 0.25 to about 2 mm, preferably of from about 0.5 to about 1.25 mm.

The thickness of the composite laminate structure used to form the outer layer, is typically of from about 0.25 to about 2 mm, preferably of from about 0.5 to about 1.25 mm, even more preferably from 0.5 to 1 mm.

As described in detail in U.S. Pat. No. 6,623,378, filed Jun. 11, 2001, entitled “METHOD FOR MANUFACTURING AND GOLF CLUB HEAD” and incorporated by reference herein in its entirety, the crown or outer shell (or sole) may be made of a composite material, such as, for example, a carbon fiber reinforced epoxy, carbon fiber reinforced polymer, or a polymer. Furthermore, U.S. patent application Ser. No. 12/974,437 (now U.S. Pat. No. 8,608,591) describes golf club heads with lightweight crowns and soles.

Composite materials used to construct the crown and/or sole should exhibit high strength and rigidity over a broad temperature range as well as good wear and abrasion behavior and be resistant to stress cracking.

Such properties include,

- a) a Tensile Strength at room temperature of from about 7 ksi to about 330 ksi, preferably of from about 8 ksi to about 305 ksi, more preferably of from about 200 ksi to about 300 ksi, even more preferably of from about 250 ksi to about 300 ksi (as measured by ASTM D 638 and/or ASTM D 3039);
- b) a Tensile Modulus at room temperature of from about 0.4 Msi to about 23 Msi, preferably of from about 0.46 Msi to about 21 Msi, more preferably of from about 0.46 Msi to about 19 Msi (as measured by ASTM D 638 and/or ASTM D 3039);
- c) a Flexural Strength at room temperature of from about 13 ksi to about 300 ksi, from about 14 ksi to about 290 ksi, more preferably of from about 50 ksi to about 285 ksi, even more preferably of from about 100 ksi to about 280 ksi (as measured by ASTM D 790);
- d) a Flexural Modulus at room temperature of from about 0.4 Msi to about 21 Msi, from about 0.5 Msi to about 20 Msi, more preferably of from about 10 Msi to about 19 Msi (as measured by ASTM D 790);

Composite materials that are useful for making club-head components comprise a fiber portion and a resin portion. In general the resin portion serves as a “matrix” in which the fibers are embedded in a defined manner. In a composite for club-heads, the fiber portion is configured as multiple fibrous layers or plies that are impregnated with the resin component. The fibers in each layer have a respective orientation, which is typically different from one layer to the next and precisely controlled. The usual number of layers for a striking face is substantial, e.g., forty or more. However for a sole or crown, the number of layers can be substantially decreased to, e.g., three or more, four or more, five or more, six or more, examples of which will be provided below. During fabrication of the composite material, the layers (each comprising respectively oriented fibers impregnated in uncured or partially cured resin; each such layer being called a “prepreg” layer) are placed superposedly in a “lay-up” manner. After forming the prepreg lay-up, the resin is cured to a rigid condition. If interested a specific strength may be calculated by dividing the tensile strength by the density of the material. This is also known as the strength-to-weight ratio or strength/weight ratio.

In tests involving certain club-head configurations, composite portions formed of prepreg plies having a relatively low fiber areal weight (FAW) have been found to provide superior attributes in several areas, such as impact resistance, durability, and overall club performance. (FAW is the weight of the fiber portion of a given quantity of prepreg, in units of g/m², also abbreviated gsm). FAW values at or below 120 g/m², at or below 100 g/m², or at or below 70 g/m², can be particularly effective. A particularly suitable fibrous material for use in making prepreg plies is carbon fiber, as noted. More than one fibrous material can be used. In other embodiments, however, prepreg plies having FAW values below 70 g/m²and above 100 g/m²may be used. Generally, cost is the primary prohibitive factor in prepreg plies having FAW values below 70 g/m².

In particular embodiments, multiple low-FAW prepreg plies can be stacked and still have a relatively uniform distribution of fiber across the thickness of the stacked plies. In contrast, at comparable resin-content (R/C, in units of percent) levels, stacked plies of prepreg materials having a higher FAW tend to have more significant resin-rich regions, particularly at the interfaces of adjacent plies, than stacked plies of low-FAW materials. Resin-rich regions tend to reduce the efficacy of the fiber reinforcement, particularly since the force resulting from golf-ball impact is generally transverse to the orientation of the fibers of the fiber reinforcement. The prepreg plies used to form the panels desirably comprise carbon fibers impregnated with a suitable resin, such as epoxy. An example carbon fiber is “34-700” carbon fiber (available from Grafil, Sacramento, Calif), having a tensile modulus of 234 Gpa (34 Msi) and a tensile strength of 4500 Mpa (650 Ksi). Another Grafil fiber that can be used is “TR50S” carbon fiber, which has a tensile modulus of 240 Gpa (35 Msi) and a tensile strength of 4900 Mpa (710 ksi). Suitable epoxy resins are types “301” and “350” (available from Newport Adhesives and Composites, Irvine, Calif). An exemplary resin content (R/C) is between 33% and 40%, preferably between 35% and 40%, more preferably between 36% and 38%.

Each of the golf club heads discussed throughout this application may include a separate crown, sole, and/or face that may be a composite, such as, for example, a carbon fiber reinforced epoxy, carbon fiber reinforced polymer, or a polymer crown, sole and/or face.

In some embodiments, the CGx, CGy and CGz magnitudes of the golf club head may be adjustable. For example, in an embodiment, the golf club head is provided with one or more adjustable weight features, such as weight ports, tracks, and/or slots in conjunction with one or more adjustable weights located in the weight port(s), track(s), and/or slot(s). For example, U.S. Pat. No. 9,868,036, which is incorporated herein by reference, describes weight tracks with slidable weights for adjusting the CG orientations of the golf club head. Other adjustable weight features may be used to adjust the CG orientations.

In some embodiments, the magnitures of the CGx, cGy and CGz values of the golf club head are positioned in conjunction with the aerodynamic properties of the golf club head. In some implementations, aerodynamic drag forces on the golf club head are reduced by the shape of the striking face. For example, aerodynamic drag forces can be reduced by providing a striking face that is shorter along the positive x-axis 1208 projecting toward the heel side of the club head and taller on the negative x-axis 1208 is projecting toward the toe side of the golf club head. In other words, the striking face may be provided with bulge oriented in the portion of the face in the negative x-axis. For example, as discussed below, the golf club head may have a crown height to face height ratio of at least 1.12. As a result of this configuration, more material and mass is provided along the negative x-axis of the striking face than along the positive x-axis, which may orient the CGx on the negative x-axis. This aerodynamic shape tends to move CGx toeward naturally.

In addition to the features described above, additional aerodynamic shapes are described in U.S. Pat. Nos. 8,858,359 and 9,861,864. For example, various properties may be modified to improve the aerodynamic aspects of the golf club head. In various embodiments, the volume of the golf club head may be 430 cc to 500 cc. In various embodiments, there may be no inversions, indentations, or concave shaping elements on the crown of the golf club head, and, as such, the crown remains convex over its body, although the curvature of the crown may be variable in various embodiments.

For example, in an embodiment, the golf club head a face height of about 59.1 mm and a crown height of about 69.4 mm. As can be seen, a ratio of the crown height to the face height is 69.4/59.1, or about 1.17. In other embodiments, the golf club head may have a crown height to face height ratio of at least 1.12. Other crown height to face height ratios may be used. For example, a face height of about 58.7 mm may be provided in an embodiment. The corresponding crown height is about 69.4 mm in the current embodiment. A ratio of the crown height to the face height is 69.4/58.7, or about 1.18. Alternatively, a face height of about 58.7 mm may be provided in another embodiment. The crown height is about 69.4 mm in the current embodiment. A ratio of the crown height to the face height is 69.4/58.7, or about 1.18. As such, the ratio of crown height to face height134 elatioen about 1 and about 2, depending on the embodiment.

In another example, the golf club head may have a minimum and/or a maximum face area. For example, the larger the face area, the more drag is produced (i.e., lowers aerodynamic features of the golf club head. In addition to aerodynamic features, the minimum and/or maximum face areas may be dictated by other golf club head properties, such as mass savings and ball speed benefits. Accordingly, in one embodiment, the golf club head has a minimum face area of 3300 mm². In other embodiments, the golf club head has a face area between about 3700 mm²and about 4000 mm². In other embodiments, the golf club head has a face area between about 3500 mm²and about 4200 mm². In other embodiments, the golf club head has a face area between about 4100 mm²and about 4400 mm², preferably between 4200 mm²and 4300 mm². In yet another embodiment, the golf club head has a maximum face area of about 4500 mm². Other face areas may be used.

In some implementations, discretionary mass is strategically positioned at an angle with respect to the striking face 110, such as in the same plane as the golf club head as the club is designed to travel on the downswing. In some embodiments, the discretionary mass is strategically provided low (along the negative z-axis), rearward (along the positive y-axis 207), and toeward (along the negative x-axis 1208), orienting the mass in the location where air is flowing, thereby reducing aerodynamic drag forces and orienting CGx on the negative x-axis.

Examples of strategically positioned discretionary masses are described in U.S. provisional patent application Ser. No. 62/755,319, which is incorporated herein by reference. For example, as illustrated in FIGS. 81, 82, 83A, 84-88, golf club head 300 comprises an inertia generator 360, which may comprise an elongate center sole portion 362 that extends in a generally Y-direction—though as illustrated, and as further described below, is also angled toewardly—from a position proximate the golf club head center of gravity 350 to the rear portion of the body.

In one or more embodiments, golf club head 300 includes a hollow body 310 defining a crown portion 312, a sole portion 314, a skirt portion 316, and a striking surface 318. The striking surface 318 can be integrally formed with the body 310 or attached to the body. The body 310 further includes a hosel 320, which defines a hosel bore 324 adapted to receive a golf club shaft. The body 310 further includes a heel portion 326, a toe portion 328, a front portion 330, and a rear portion 332. Included are a number of features that may improve playability, including at least an inertia generator 360, front channel 390, a slot or channel insert 395, one or more front channel support ribs 396, an additional rib 397 that connects to front channel support ribs 396, as well as composite panels on the sole 344, 348 and on the crown 335, along with discretionary mass elements and other additional features, as will be further described herein. The front channel 390 may have a certain length L (which may be measured as the distance between its toeward end and heelward end), width W (e.g., the measurement from a forward edge to a rearward edge of the front channel 390), and offset distance OS from the front end, or striking surface 318 (e.g., the distance between the face 318 and the forward edge of front channel 390. During development, it was discovered that the COR feature length L and the offset distance OS from the face play an important role in managing the stress which impacts durability, the sound or first mode frequency of the club head, and the COR value of the club head. All of these parameters play an important role in the overall club head performance and user perception.

A front plane 331 that extends from a forwardmost point of the golf club head, and a rear plane 333 that extends from a rearward most point of the golf club head. Each of these planes extends from its respective point and is perpendicular to the ground plane 317. Together, the planes may be used to measure the front to back depth of the golf club head (“club head depth”), as illustrated in FIG. 81. A midpoint plane 334 extends perpendicular to the ground plane 317 halfway between the front plane 331 and the rear plane 333. As illustrated in FIG. 82, a center 323 is disposed on the striking surface 318. Also shown on the face is the projected CG point 325. Golf club head 300 also has a skirt height 315, which may measure the lowest point above the ground plane at which the skirt meets the crown. In some embodiments, the skirt height 315 may be between 25 mm and 40 mm, such as between 30 mm and 40 mm, or between 30 mm and 35 mm.

As best illustrated in FIGS. 81 and 82, the center sole portion 362 comprises an elongate and substantially planar surface that is closer to the ground plane 317 than the surrounding portions of the sole 314 that are toeward and heelward of the inertia generator 360. In certain embodiments, the inertia generator 360 is angled so that a rear end of the inertia generator is toeward of a front end. An angle of the inertia generator relative to the y-axis may be in the range of 10 to 25 degrees, such as between 15 and 25 degrees, such as between 17 and 22 degrees. As illustrated in FIGS. 73A and 74, an aperture 366 may be provided within the center sole portion 362, which aperture may be used for introducing hot melt into the inner cavity of the golf club head. Also provided is an inertia generator support rib 368, which may run along the inside of the golf club head under inertia generator 360. A cross-section of the inertia generator may be taken along line 24-24. Inertia generator support rib 368 may not only help provide structural support for the inertia generator, it may also help constrain any hot melt that is injected using aperture 366.

As best illustrated in FIGS. 81 and 84, the inertia generator further comprises a heelward sole surface 361 and a toeward sole surface 363 that slope upwardly from the center sole portion 362 to the sole 314 when viewed in the normal address position. The heelward sole surface 361 may have a generally triangular shape, with: a base that faces generally forward and heelward (and may be substantially parallel to the heel sole insert 344, a first edge adjacent the center sole portion 362 that extends rearwardly from the toeward end of the base generally parallel to the center sole portion, and a second edge that extends from the heelward end of the base at a position on the sole 314 to a position that is “raised up” from the sole at or proximate to the heelward side of the center sole portion 362 at the rear 332 of the golf club head. The toeward sole surface 363 may likewise have a generally triangular shape, with: a base that faces generally forward and toeward (and may be substantially parallel to the toe sole insert 348, a first edge adjacent the center sole portion 362 that extends rearwardly from the heelward end of the base generally parallel to the center sole portion, and a second edge that extends from the toeward end of the base at a position on the sole 314 to a position that is “raised up” from the sole at or proximate to the toeward side of the center sole portion 362 at the rear 332 of the golf club head. The inertia generator is configured so that a center of gravity 365 may in certain embodiments be positioned toeward of the x axis and lower (or closer to the ground plane 317) than the z-axis. In other words, the inertia generator may help to move the club's overall center of gravity 350 toeward, while also lowering its center of gravity, reducing Zup, as described above.

Example values for the inertia generator's center of gravity 365 are set forth below. In certain embodiments, the inertia generator may have a center of gravity 365 relative to the center 323 of the striking surface 318 as measured on the:

- x-axis (CG_x) of between −10 mm and −25 mm, such as between −15 mm and −20 mm;
- y-axis (CG_y) of between 80 and 110 mm, such as between 90 and 100 mm; and
- z-axis (CG_z) of between 0 and −20 mm, such as between −10 mm and −20 mm.

Additionally, due to its shape and orientation, the inertia generator is configured to generally align with a typical swing path, permitting increased inertia generated during a golf swing. Example moments of inertia for golf club head 300 are set forth below.

As best illustrated in FIG. 83A, the crown can be formed to have a recessed peripheral ledge or seat 338 to receive the crown insert 335, such that the crown insert is either flush with the adjacent surfaces of the body to provide a smooth seamless outer surface or, alternatively, slightly recessed below the body surfaces. The crown insert 335 may cover a large opening 340 (illustrated in FIG. 83A) at the top and rear of the body, forming part of the crown 312 of the golf club head. Heel sole insert 344 and toe sole insert 348 may be secured to the body 310 to cover heel sole opening 342 and toe sole opening 346, respectively, in the sole rearward of the hosel (illustrated in FIG. 85). Heel sole opening 342 has a heel sole ledge 1343 for supporting heel sole insert 344. Similarly, toe sole opening 346 has a toe sole ledge 1347 for supporting toe sole insert 348. The golf club head may comprise a forward mass pad 380 positioned heelward and forward on the sole 314.

As best illustrated in FIG. 86, a plurality of characteristic time (“CT”) tuning screws 1375 may be inserted through apertures 374 in the striking surface. Dampening material such as tuning foam 376 may be inserted through one or both of these apertures into the inner cavity 394 of the golf club head 300 to adjust the characteristic time. For example, a dampening material may be added that, upon hardening, may lower the CT time. Additional details about providing tuning of the characteristic time are provided in U.S. patent application Ser. No. 15/857,407, filed Dec. 28, 2017, the entire contents are hereby incorporated by reference herein.

Positioned on a rear side of the inertia generator 360 is inertia generator mass element 385, which may comprise a steel or tungsten weight member or other suitable material. Inertia generator mass element 385 may be removably affixed to the rear of the inertia generator 360 using a fastener port 386 that is positioned in the rear of the inertia generator 360 and configured to receive a fastener 388, which may be removably inserted through an aperture 387 in the inertia generator mass element 385 and into the fastener port 386. Fastener port 386 and aperture 387 may be threaded so that fastener 388 can be loosened or tightened either to allow movement of, or to secure in position, inertia generator mass element 385. The fastener may comprise a head with which a tool (not shown) may be used to tighten or loosen the fastener, and a body that may, e.g., be threaded to interact with corresponding threads on the fastener port 386 and aperture 387 to facilitate tightening or loosening the fastener 388.

The fastener port 386 can have any of a number of various configurations to receive and/or retain any of a number of fasteners, which may comprise simple threaded fasteners, such as described herein, or which may comprise removable weights or weight assemblies, such as described in U.S. Pat. Nos. 6,773,360, 7,166,040, 7,452,285, 7,628,707, 7,186,190, 7,591,738, 7,963,861, 7,621,823, 7,448,963, 7,568,985, 7,578,753, 7,717,804, 7,717,805, 7,530,904, 7,540,811, 7,407,447, 7,632,194, 7,846,041, 7,419,441, 7,713,142, 7,744,484, 7,223,180, 7,410,425 and 7,410,426, the entire contents of each of which are incorporated by reference herein.

As illustrated in FIG. 86, the golf club head's hosel 320 has a hosel bore 324 that may accommodate a shaft connection assembly 355 that allows the shaft to be easily disconnected from the golf club head, and that may provide the ability for the user to selectively adjust a and/or lie-angle of the golf club. The shaft connection assembly 355 may comprise a shaft sleeve that can be mounted on the lower end portion of a shaft (not pictured), as described in U.S. Pat. No. 8,303,431. A recessed port 378 is provided on the sole 314, and extends from the sole 314 toward the hosel 320, and in particular the hosel bore 324. The hosel bore 324 extends from the hosel 320 through the golf club head 300 and opens within the recessed port 378 at the sole 314 of the golf club head 300. The hosel bore may contain threads that are configured to interact with a fastener such as a screw. The golf club head is removably attached to the shaft by shaft connection assembly 355 (which is mounted to the lower end portion of a golf club shaft (not shown)) by inserting one end of the shaft connection assembly 355 into the hosel bore 324, and inserting a screw 379 (or other suitable fixation device) upwardly through the recessed port 378 in the sole 314 and, in the illustrated embodiment, tightening the screw 379 into a threaded opening of the shaft connection assembly 355, thereby securing the golf club head to the shaft sleeve 302. A screw capturing device, such as in the form of an O-ring or washer 381, can be placed on the shaft of the screw 379 to retain the screw in place within the golf club head when the screw is loosened to permit removal of the shaft from the golf club head. For embodiments having a shaft connection assembly 355 the club head mass and mass properties, including but not limited to the CG location, associated measurements utilizing the CG location, and moments of inertia are determined with all components of the shaft connection assembly 355 installed. The shaft connection assembly 355 may include an internal connection assembly sleeve 356 fixed to, or formed in, the club head.

Illustrated in FIG. 88 are dashed lines surrounding golf club head 300. Each of these dashed lines represents a fixed distance above a ground plane when golf club head 300 is in normal address position, so that a cross-section of the golf club head taken at one of the respective lines would be positioned at a consistent height above the ground plane. For example, 10 mm cross-section line 1302 represents the cross-section of golf club head 300 at a position 10 mm above the ground plane. In turn:

- 15 mm cross-section line 1303 represents the cross-section of golf club head 300 at a position 15 mm above the ground plane;
- 20 mm cross-section line 1304 represents the cross-section of golf club head 300 at a position 20 mm above the ground plane;
- 25 mm cross-section line 1305 represents the cross-section of golf club head 300 at a position 25 mm above the ground plane;
- 30 mm cross-section line 1306 represents the cross-section of golf club head 300 at a position 30 mm above the ground plane;
- 35 mm cross-section line 1307 represents the cross-section of golf club head 300 at a position 35 mm above the ground plane; and
- 40 mm cross-section line 1308 represents the cross-section of golf club head 300 at a position 40 mm above the ground plane.

As discussed above, the CGx orientation of the golf club head may be moved toeward (along the negative x-axis) or heelward (along the positive x-axis) to provide to generate specific properties of the golf club head, such as increasing MOI, increasing ball speed and reducing “gear effect.” However, orientating the CGx toeward may result in the striking face of the golf club head remaining open at impact with the golf ball. In this example, when the CGx is oriented along the negative x-axis, it may be more difficult for the user to square (e.g., release) the club head in the downswing, resulting in users hitting the ball right (i.e., a “slice” or “blocked” shot). Conversely, when the orientating the CGx heelward may result in the striking face of the golf club head to be closed at impact with the golf ball. In this example, when the CGx is oriented along the positive x-axis, the club head may release early, making it more difficult for the user to keep the striking face from closing too quickly in the downswing, resulting in the user hitting the ball left (i.e., a “hook” or “pulled” shot). To overcome the missed shots resulting from the negative or positive CGx orientations, visual cues may be provided to offset the CGx orientation (i.e., altering the perceived angle of the face 110 for the user), allowing the user to hit the ball straighter with fewer misses.

As discussed above, in some embodiments, one or more features of the golf club head may be provided to alter the perceived angle of the face for the user. For example, referring back to FIG. 72, the golf club head 600 includes an alignment feature to alter the perceived angle of the face 110 for the user. In implementations with a negative CGx orientation, an alignment feature is provided to alter the perceived top line relative to striking face, with the perceived top line appearing to be square while the actual face angle is closed relative to the perceived top line. By closing the actual face angle relative to the perceived top line, the user counteracts the miss right by closing the club head in the downswing to square the striking face at impact with the golf ball. Conversely, in implementations with a positive CGx orientation, a different alignment feature is provided to alter the perceived top line relative to striking face, with the perceived top line appearing to be square while the actual face angle is open relative to the perceived top line. By opening the actual face angle relative to the perceived top line, the user counteracts the miss left by opening the club head in the downswing to square the striking face at impact with the golf ball.

For example, the alignment feature may be provided as a contrasting paint or shading of the crown 1120 relative to the color or shading of the face 110. In this example, users tend to focus on the perceived top line produced by the contrasting paint, such as via white or another color paint contrasting with the metal striking face, even when the actual face angle is visible to the user. The user tends to ignore the actual face angle when contrasting paint of shading is provided. Further, the alignment feature may also provide for unconscious correction during the swing. Specifically, by perceiving the club to be square when the actual face angle is closed or open relative to the perceived top line, the user will naturally and unconsciously attempt to square the perceived top line at impact with the golf ball, correcting for the misses caused by the CGx orientation.

In some implementations, the alignment feature may alter the perceived top line from about 2 to about 4 degrees open or closed relative to the actual face angle. In some implementations, for each 5 percent change in negative or positive CGx orientation, the perceived top line is 1 degree open or closed, respectively, with respect to the actual face angle (i.e., opening or closing the perceived top line relative to the actual face angle), causing the user to close or open the actual face angle at the address position. Depending on the golf club, each degree of perceived top line change may affect lateral dispersion in a resultant shot by a set amount. For example, changing the perceived top line of a driver by one degree may reduce dispersion by approximately five yards. In another example, changing the perceived top line of a fairway wood by one degree may reduce dispersion by approximately three yards.

In some implementations, the alignment feature may be provided as a parabola defined relative to the striking face. For example, a point on parabola relative to the striking face is provided from about 2 to about 4 degrees open or closed relative to the angle of the striking face. Depending on the golf club, the radius of the alignment feature may affect lateral dispersion in a resultant shot by a set amount. For example, changing the radius of the parabola defining the topline of a driver by one degree may reduce dispersion by approximately five yards. In another example, changing the radius of the parabola defining the topline of a fairway wood by one degree may reduce dispersion by approximately three yards.

In some embodiments, grooves and/or score lines of the golf club head may be provided to alter the address position for the user, aligning the address position with the CG orientations. Referring back to FIG. 70B, grooves and/or score lines are located on the striking face 110, traditionally positioned at the center of face (CF) located at the origin 205 of the coordinate system 200. Orientating the CGx along the positive or negative x-axis, without moving scorelines from the CF, may cause the user to address the golf club head to the golf ball without aligning the CGx with the golf ball. If the user does not align the golf ball with the CGx, the user may strike the golf ball at a location on the striking face that does not correspond with the CGx location, decreasing ball speed and the accuracy of the golf shot. For example, for a positive CGx, striking the club at the CF does not correspond with the positive CGx orientation. Further, if the user strikes the ball at a location on the striking face corresponding to the positive CGx (i.e., toewardly of the score lines provided at CF), the user may believe that the shot was mishit, resulting in the user misaligning future shots. In some implementations, score lines and/or grooves are provided offset from CF at a location on the striking face corresponding the CGx, CGy and CGz orientations. The score lines and grooves also serve as an alignment aid at address. For example, in the example of a negative CGx, the score lines and/or grooves are positioned toewardly of CF to encourage the user to address and strike the ball more toewardly (i.e., aligned with the negative CGx). In this example, the score lines and/or grooves are positioned toeward of a geometric center of the face. Thus, the score lines and/or grooves are aligned for maximum performance (i.e., maximum ball speed, reducing gear effect, reducing dispersion, and the like).

Further, golf club designs are provided to counteract the left and right tendency that a player encounters when the ball impacts a high, low, heelward and/or toeward position on the club head striking face. One such golf club design incorporates a “twisted” bulge and roll contour, such as discussed in U.S. Pat. Nos. 9,814,944 and 10,265,586 and U.S. Patent Pub. No. 2019/0076705, which are incorporated herein by reference in their entireties.

In some embodiments, an alignment feature is provided to alter the perceived angle of the face for the user to appear closed with respect to the upper toe quadrant 514 of the striking face. In other embodiments, an alignment feature is provided to alter the perceived angle of the face for the user to appear closed with respect to the actual face angle. In the aforementioned embodiments, the alignment feature counteracts the open appearance of “twisted” bulge and roll contour. In some embodiments, the alignment feature may be provided as a contrasting color or shading of the crown 1120 relative to the color or shading of the face 110, which may further be implemented through the use of a decal attached to either the crown 1120 or the face 110, or even via material removal processes removing, or texturing, a coating, such as paint, PVD, CPVD, or the like, from either the crown 1120 or the face 110, which may further include the use of a laser to remove, or texture, said coating. In some embodiments, the contrasting paint or shading extends from the crown 1120 onto the face 110. In some implementations, a negative CGx is provided along with a “twisted” bulge and roll contour on the striking face. In some implementations, the negative CGx counteracts some of the alignment issues caused by the “twisted” bulge contour, and vice versa. For example, the “twisted” bulge and roll contour on the striking face may be combined with one or more adjustable weights and/or a discretionary mass strategically positioned at an angle with respect to the striking face. Other combinations of the present embodiments may be provided.

In an embodiment, an alignment feature is provided to alter the perceived angle of the face of a golf club head with a “twisted” bulge and roll contour on the striking face. In this embodiment, the performance of the golf club had can be improved by decreasing lateral dispersion of the golf club head. For example, in the case of a right-handed golfer, lateral dispersion is measured indicating that the golf club has a dispersion tendency for a right miss. The right miss may be the result of the “twisted” bulge and roll contour causing the perceived angle of the face of the golf club head to appear open. The alignment feature may be altered to counteract for the right miss, such as by altering the perceived face angle to appear closed with respect to the closed with respect to the actual face angle. The amount that the alignment feature may be altered may be based on the amount of the lateral dispersion, such as by altering the alignment feature about 1 degree with respect to the intended target line for about every 3-5 yards of lateral dispersion from the intended target line. In the case of a left-handed golfer, if the lateral dispersion is measured indicating that the golf club has a dispersion tendency for a left miss, the alignment feature may be altered to counteract for the left miss by altering the perceived face angle to appear closed with respect to the closed with respect to the actual face angle.

In another embodiment, a different alignment feature is provided to alter the perceived angle of the face of a golf club head with a “twisted” bulge and roll contour on the striking face. In this embodiment, the performance of the golf club had can also be improved by decreasing lateral dispersion of the golf club head. For example, in the case of a right-handed golfer, lateral dispersion is measured indicating that the golf club has a dispersion tendency for a left miss. The left miss may be the result of the “twisted” bulge and roll contour causing the perceived angle of the face of the golf club head to appear closed. The alignment feature may be altered to counteract for the left miss, such as by altering the perceived face angle to appear open with respect to the closed with respect to the actual face angle. The amount that the alignment feature may be altered may be based on the amount of the lateral dispersion, such as by altering the alignment feature about 1 degree with respect to the intended target line for about every 3-5 yards of lateral dispersion from the intended target line. In the case of a left-handed golfer, if the lateral dispersion is measured indicating that the golf club has a dispersion tendency for a right miss, the alignment feature may be altered to counteract for the right miss by altering the perceived face angle to appear closed with respect to the closed with respect to the actual face angle.

In an embodiment, a method 2400 is provided for determining an alignment feature for a golf club head, such as in a head with a negative CGx, a “twisted” bulge and roll, or another design. This method may be performed using one or more of the golf club head embodiments discussed above.

At 2410, a golf club head is provided with an alignment feature. In an embodiment, the golf club head is a new design to be tested prior to large scale manufacturing. In this embodiment, the golf club head may have one or more alignment features. The one or more alignment features may be based on previous designs, such as retained topline properties from a previous design, or may a new alignment feature, such as based on a computer aided design (CAD) model or another club head design. For example, the golf club head may have undergone a complete remodel, such as incorporating a substantial golf club head shape change, or may have been slightly redesigned based on a previous golf club head design. In another embodiment, The golf club head may have only minor differences from another golf club head design, such as a different loft that may result in differences between golf club head designs.

In FIG. 89, at 2420, the alignment feature is measured. For example, in an embodiment using a top line as an alignment feature, a top line radius is measured. Other alignment features may be measured. Additionally or alternatively, a Sight Adjusted Perceived Face Angle (SAPFA) or other metric of the golf club head may also be measured.

At 2430, the golf club head is tested. For example, a prototype of the new golf club head design are provided for player testing. In this example, one or more players may test the golf club head. Based on the testing, a lateral dispersion of the golf club head may be measured. Other performance metrics may also be measured. Lateral dispersion may be indicative that a different alignment feature may provide better performance, such as less lateral dispersion. In another example, an impression of the alignment feature on the user may also be measured. In this example, if the golf club head face appears too open or too closed during the test, a different alignment feature may improve appeal or confidence in the golf club head to the testers.

At 2440, the alignment feature is adjusted. For example, based on the testing, the one or more alignment features may be adjusted to increase performance and/or appeal of the golf club head. In this example, a top line radius may be adjusted. Based on the lateral dispersion measured during testing, a top line radius may be adjusted one degree for every five yards of lateral dispersion with a driver and adjusted one degree for every three yards of lateral dispersion with a fairway wood. Other adjustment amounts may be provided. Further, additional and different adjustments to the one or more alignment features may be provided.

After the alignment feature is adjusted, one or more of acts 2430 and 2440 may be repeated for additional testing and/or adjustment. In some embodiments, individual player testing may also be performed, such as for individual tour players. At 2450, the adjusted alignment feature is provided for manufacturing. For example, after testing and adjusting one or more alignment features, the golf club head design is manufactured.

Discretionary mass generally refers to the mass of material that can be removed from various structures providing mass that can be distributed elsewhere for tuning one or more mass moments of inertia and/or locating the golf club head center-of-gravity. Golf club head walls provide one source of discretionary mass. In other words, a reduction in wall thickness reduces the wall mass and provides mass that can be distributed elsewhere. Thin walls, particularly a thin crown, provide significant discretionary mass compared to conventional golf club heads. For example, a golf club head made from an alloy of steel can achieve about 4 grams of discretionary mass for each 0.1 mm reduction in average crown thickness. Similarly, a golf club head made from an alloy of titanium can achieve about 2.5 grams of discretionary mass for each 0.1 mm reduction in average crown thickness. Discretionary mass achieved using a thin crown, e.g., less than about 0.65 mm, can be used to tune one or more mass moments of inertia and/or center-of-gravity location.

To achieve a thin wall on a golf club head body, such as a thin crown, a golf club head body can be formed from an alloy of steel or an alloy of titanium. Some examples of titanium alloys that can be used to form any of the striking faces and/or club heads described herein can comprise titanium, aluminum, molybdenum, chromium, vanadium, and/or iron. For example, in one representative embodiment the alloy may be an alpha-beta titanium alloy comprising 6.5% to 10% Al by weight, 0.5% to 3.25% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti (one example is sometimes referred to as “1300” titanium alloy). In another representative embodiment, the alloy may comprise 6.75% to 9.75% Al by weight, 0.75% to 3.25% or 2.75% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti. In another representative embodiment, the alloy may comprise 7% to 9% Al by weight, 1.75% to 3.25% Mo by weight, 1.25% to 2.75% Cr by weight, 0.5% to 1.5% V by weight, and/or 0.25% to 0.75% Fe by weight, with the balance comprising Ti. In another representative embodiment, the alloy may comprise 7.5% to 8.5% Al by weight, 2.0% to 3.0% Mo by weight, 1.5% to 2.5% Cr by weight, 0.75% to 1.25% V by weight, and/or 0.375% to 0.625% Fe by weight, with the balance comprising Ti. In another representative embodiment, the alloy may comprise 8% Al by weight, 2.5% Mo by weight, 2% Cr by weight, 1% V by weight, and/or 0.5% Fe by weight, with the balance comprising Ti. Such titanium alloys can have the formula Ti-8Al-2.5Mo-2Cr-1V-0.5Fe. As used herein, reference to “Ti-8Al-2.5Mo-2Cr-1V-0.5Fe” refers to a titanium alloy including the referenced elements in any of the proportions given above. Certain embodiments may also comprise trace quantities of K, Mn, and/or Zr, and/or various impurities.

Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have minimum mechanical properties of 1150 mPa yield strength, 1180 mPa ultimate tensile strength, and 8% elongation. These minimum properties can be significantly superior to other cast titanium alloys, including 6-4 Ti and 9-1-1 Ti, which can have the minimum mechanical properties noted above. In some embodiments, Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have a tensile strength of from about 1180 mPa to about 1460 mPa, a yield strength of from about 1150 mPa to about 1415 mPa, an elongation of from about 8% to about 12%, a modulus of elasticity of about 110 gPa, a density of about 4.45 g/cm³, and a hardness of about 43 on the Rockwell C scale (43 HRC). In particular embodiments, the Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy can have a tensile strength of about 1320 mPa, a yield strength of about 1284 mPa, and an elongation of about 10%.

In some embodiments, striking faces and/or club head bodies can be cast from Ti-8Al-2.5Mo-2Cr-1V-0.5Fe. In some embodiments, striking surfaces and club head bodies can be integrally formed or cast together from Ti-8Al-2.5Mo-2Cr-1V-0.5Fe, depending upon the particular characteristics desired. The mechanical parameters of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe given above can provide surprisingly superior performance compared to other existing titanium alloys. For example, due to the relatively high tensile strength of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe, cast striking faces comprising this alloy can exhibit less deflection per unit thickness compared to other alloys when striking a golf ball. This can be especially beneficial for metalwood-type clubs configured for striking a ball at high speed, as the higher tensile strength of Ti-8Al-2.5Mo-2Cr-1V-0.5Fe results in less deflection of the striking face, and reduces the tendency of the striking face to flatten with repeated use. This allows the striking face to retain its original bulge, roll, and “twist” dimensions over prolonged use, including by advanced and/or professional golfers who tend to strike the ball at particularly high club velocities. For further details concerning titanium casting, please refer to U.S. Pat. No. 7,513,296, incorporated herein by reference. Additionally, the thickness of a club hosel may be varied to provide for additional discretionary mass, as described in U.S. Pat. No. 9,731,176, the entire contents of which are hereby incorporated by reference.

As discussed above, the location and characteristics of golf club head alignment features, such as a golf club head topline, may be important to the golf club's performance and aesthetics. For example, a 1-degree change in perceived face angle of the golf club head may cause a lateral dispersion of up to about 5 yards. Likewise, providing an alignment feature changing the perceived face angle of the golf club head may correct for lateral dispersion caused by other characteristics of the golf club.

One or more of the present embodiments provide for hard tooling the location and characteristics of one or more alignment features into the golf club head. For example, instead of masking and painting a topline onto the golf club head, a topline is hard tooled at the intersection between the casted club head body and a face insert. The club head body, such as a casted club head body, may be painted separately from the face insert, requiring no special masking to provide for an alignment feature. In some embodiments, a transition zone between the face and the crown may be painted the same color as other portions of the casted club head body, eliminating the need to use a masking line between the transition zone and other portions of the casted club head body. After painting the casted club head body, the face may be bonded or otherwise attached to the casting. A contrast in color, difference in finishes, and/or difference in texture between the casted club head body and the face defines the necessary visual cue. For example, the face insert may be a single color, or multicolored. Likewise, the club head body and/or the crown may also be a single color, or multicolored, providing for one or more alignment features by contrasting with the one or more color of the face insert. In another example, the club head body and/or the crown may have one finish, such as gloss, and the face insert may be a different finish, such as matte. In yet another example, the club head body and/or the crown may have one texture, such a visible composite weave, and the face insert may be a different texture, such as a texture that appears uniform or smooth. Additionally or alternatively, a crown insert may be bonded or otherwise attached to the casted club head body to provide for a visual cue. Accordingly, the topline may not be subject to the manufacturing variability resulting from user error and the manufactured golf club heads may be more consistent from part to part.

In some embodiments, the face insert is made of a composite that includes multiple plies or layers of a fibrous material (e.g., graphite, or carbon, fiber) embedded in a cured resin (e.g., epoxy), such as those described in U.S. patent application Ser. No. 18/913,535, filed Oct. 11, 2024, the entire contents of which are hereby incorporated by reference. Composite face plates for use in the metalwood golf clubs may be fabricated using the procedures described in U.S. Pat. Nos. RE43801, issued Nov. 13, 2012, U.S. Pat. No. 8,163,119, issued Apr. 24, 2012, U.S. Pat. No. 8,777,776, issued Jul. 15, 2014, U.S. Pat. No. 9,409,066, issued Aug. 9, 2016, U.S. Pat. No. 8,303,435, issued Nov. 6, 2012, and U.S. patent application Ser. No. 10/442,348 (now U.S. Pat. No. 7,267,620, issued Sep. 11, 2007), Ser. No. 11/642,310, filed Dec. 19, 2006, which are all incorporated herein by reference in their entirety. The composite material can be manufactured according to the methods described at least in U.S. patent application Ser. No. 11/825,138, the entire contents of which is herein incorporated by reference in its entirety. In some embodiments, the face insert has a variable thickness, such as those described in U.S. Pat. No. 8,163,119, issued Apr. 24, 2012, the entire contents of which are hereby incorporated by reference.

In some embodiments, the face is tunable (e.g., for CT, COR, or another characteristic), such as described in U.S. patent application Ser. No. 18/743,971, filed Jun. 14, 2024, the entire contents of which are hereby incorporated by reference.

FIG. 90 is a top view of a golf club head having at least one tooled alignment feature. The golf club head 2500 includes a face 110, a crown 1120, a sole 130 (not depicted), a skirt 140, and a hosel 150. As depicted in FIG. 90, a primary alignment feature 2514 is provided on the golf club head. The primary alignment feature 2514 may be provided as a topline that is hard tooled at the intersection of the face 110 and the casting of the golf club head 2500. The topline may delineate the transition between at least a portion of the crown 1120 having a shade, color, finish, and/or texture that contrasts and/or is different from the shade, color, finish, and/or texture of the face 110. The topline may also delineate a transition between the face 110 with another portion of the golf club body. In some embodiments, the casting of the golf club head 2500, including a portion of the crown 1120, are painted in a shade or color prior to attaching the face 110. The face 110 may define the characteristics of the primary alignment feature 2514. For example, the size and shape of the face 110 may change the location of the topline, curvature of the topline, Sight Adjusted Perceived Face Angle (SAPFA) of the golf club head 2500, and other characteristics of the golf club head 2500 and/or primary alignment feature 2514.

In some embodiments, the face 110 is provided at least in part as a composite material. Other materials may also be used. The face 110 may be bonded to the golf club head 2500. Any bonding methods known in the art may be utilized, including but not limited to adhesive bonding, including gluing, welding (preferable welding processes are ultrasonic welding, hot element welding, vibration welding, rotary friction welding or high frequency welding (Plastics Handbook, Vol.¾ 4, pages 106-107, Carl Hanser Verlag Munich & Vienna 1998)) or calendaring or mechanical fastening including riveting, or threaded interactions. Alternatively, the face 110 may be attached to the golf club head in another manner, such as with screws, fasteners, epoxy, welding, or with another attaching or bonding means. In some embodiments, the face may be welded from the back of the face (i.e., from inside the cavity of a golf club head). The welding may not fully penetrate the face (e.g., less than 100% weld penetration). Past club head designs have provided for an intersection location of the face 110 and golf club body casting at a location that is undesirable for a primary alignment feature 2514. For example, past intersection locations do not provide for aesthetic and visual cue performance due to durability constraints. One or more of the present embodiments provide for a bonded face design allowing for a tooled topline location with aesthetic and performance characteristics while maintaining durability of the golf club head. For example, the tooled topline location may follow the shape of the face insert. If testing the club head shows a lateral dispersion that goes right and/or appears closed, the shape of the face insert may be changed to minimize the lateral dispersion and to make the club head appear more open. Likewise, if testing the club head shows a lateral dispersion that goes left and/or appears open, the shape of the face insert may be changed to minimize the lateral dispersion and to make the club head appear more closed. To maximize performance, the face insert may not be a uniform shape (e.g., not an elliptical face insert). For example, in some embodiments, a portion of the face insert extends upward and heelward toward the hosel. A portion of the face insert may also extend upward and toeward.

In some embodiments, the golf club head includes a secondary alignment feature. Referring back to FIG. 90, the secondary alignment feature 2516 may delineate a transition between the first portion of the crown 2518 and a second portion of the crown 2520. In an example, the first portion of the crown 2518 may have a contrasting shade or color with the shade or color of the face 110 and the second portion of the crown 2520 may have a contrasting shade or color with the shade or color of the first portion of the crown 2520. Secondary alignment 2516 feature may also be hard tooled into the club head, such as with a crown insert. In some embodiments, the crown insert may be as a composite material. Examples of some of these composite materials for use in the metalwood golf clubs and their fabrication procedures are discussed herein and described in U.S. patent application Ser. Nos. 10/442,348 (now U.S. Pat. No. 7,267,620), 10/831,496 (now U.S. Pat. No. 7,140,974), 11/642,310, 11/825,138, 11/998,436, 11/895,195, 11/823,638, 12/004,386, 12,004,387, 11/960,609, 11/960,610, and 12/156,947, which are incorporated herein by reference.

FIG. 91 is a perspective view of a golf club head having at least one tooled alignment feature, without a face insert installed. In this embodiment, the golf club head 2500, or any of the disclosed components, may be cast, milled, or formed in any other fashion included metal injection molded and additive manufacturing techniques, to create a ledge 2622 for receiving a face insert 110 (not depicted). The face insert 110 may be provided as a composite material or as another material. For example, the face insert 110 may be a molded composite to be bonded to the ledge 2622 of golf club head. By bonding the face insert 110 to the ledge 2622, the transition between the face 110 and the crown 1120 provide for a noticeable topline as the primary alignment feature 2514. In some embodiments, the face 110 is bonded to the ledge 2622 with a seamless transition between the face 110 and crown 1120, such to promote desired aerodynamic and aesthetic characteristics.

The characteristics of the primary alignment feature 2514 may be defined by the face insert 110. For example, a larger face insert 110 may position the alignment feature 2514 higher on the golf club head 2500. Likewise, a smaller face insert 110 may position the alignment feature 2514 lower on the golf club head 2500. The shape of the face insert 110 may also provide for a desired curvature and/or radius of the topline. Once the desired characteristics of the primary alignment feature 2514 are established, the alignment feature 2514 is hard tooled into the golf club head 2500. Hard tooling the alignment feature allows for the alignment feature to be permanent, non-deformable, and not prone to manufacturing errors associated with painted alignment features that use stickers or other maskings during manufacturing. As such, the primary alignment feature may be determined by the club head casting, or a feature milled, stamped, molded, or forged into the club head, and integrated in the golf club head using the face insert.

FIG. 92 is a perspective view of a golf club head having at least one tooled alignment feature, with a face insert installed. In this embodiment, the golf club head 2500 is provided with the face insert 110 bonded to the ledge 2622 (not depicted). As depicted in FIG. 92, the primary alignment feature 2514 is a hard tooled topline at the intersection of the face 110 with the casting body, such as a first portion of the crown 2518. In the case of a bonded face, the joint between the face 110 and the crown 1120 determines the topline 2514. Other ways of installing the face insert may be used, such as with screws, fasteners, or another method of installation.

Additional features of the golf club head 2500 may be facilitated by using a face insert 110. For example, including a notch in the back of the face insert 110 allows for the golf club head 2500 to utilize flight control technology (FCT) in the hosel 150 to include a loft and lie connection sleeve to adjust, inter alia, face angle. Other characteristics of the face insert may provide for performance benefits. In an embodiment, the face insert 110 may provide for more accurate and uniform face thicknesses between manufactured golf club heads and provide for the precise face thickness variabilities incorporated in the golf club head design. In an embodiment, a molded composite face insert allows for variable thickness across locations of the face. In an embodiment, the center of gravity about the x-axis (CGx) may be more accurately positioned using the face insert, such as by using a variable thickness face. Further, characteristic time (CT) and coefficient of restitution (COR) requirements may be attained precisely by molding the composite face and bonding the face to the golf club head. The composite face may also be tunable after installation. In an embodiment, the face insert may provide for a CT above about 255 and a COR of about 0.835. In an embodiment, different bulge and roll characteristics may be prescribed for a user and provided using the face insert. For example, the different bulge and roll characteristics, including twisted bulge and roll characteristics, may be provided by selecting from different face inserts. One of the different face inserts may be selected prior to bonding the face to the golf club head, or alternatively the face inserts may be interchangeable by a user or club fitter. In yet another embodiment, changing the face characteristics requires the club head casting to change to accommodate the new face insert.

In some embodiments, the face insert may be provided as a dark face insert surface area having a CIELab brightness (L) of less than about 40 and a bright surface area of the casted club head body and/or the crown of the club head has a CIELab brightness of between about 50 and about 100. In some embodiments, the difference in brightness (ΔL) between the face insert and the club head body and/or the crown is at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, or another difference greater than about 20.

In some embodiments, the face insert may be provided with a dark face insert surface area having a CIELab brightness (L) of less than about 40 and the club head body and/or the crown of the club head is provided with a dark surface area having a CIELab brightness of less than about 40. For example, the difference in brightness (ΔL) between the face insert and the club head body and/or the crown is at least 5, at least 10, at least 15, at least 20, or in another series of embodiments the difference less than about 20, or less than about 15, or less than about 10, or less than about 5.

In some embodiments, the face insert may be provided as a matte, semigloss, or low gloss face insert surface area having a gloss value of less than about 60, about 50, or about 40 gloss units and a semigloss surface area of the club head body and/or the crown of the club head has a CIELab gloss value of greater than about 40, about 50, about 60, and about 70 gloss units. For example, a matte or low gloss face insert may have gloss values of less than 10, 8, 5, 4, or 2 gloss units.

Any difference in appearance between the face insert and the club head body and/or the crown may be used as an alignment feature. The club head body and/or the crown may be different in appearance with the face insert by color, brightness, texture, finish, or another visual difference. For example, different finishes may be used, such gloss, semigloss, low gloss, matte, or another finish. Different textures may also be used, such textures manufactured into the club head components, ridges, valleys, patterns of material, composite weaves, and other textures.

FIG. 93 is a flowchart of a method 2800 for counteracting a lateral dispersion tendency of a golf club head. For example, the method may be used to determine an alignment feature for a golf club head. This method may be performed using one or more of the golf club head embodiments discussed herein or with another golf club head having a face, a crown and a sole.

At 2810, a primary alignment feature is provided. For example, the primary alignment feature may include a line delineating a transition between a portion of the crown and the face. The portion of the crown may have an area with a shade or color that contrasts the shade or color of the face. The primary alignment feature may be hard tooled into the golf club head using the face of the golf club body. For example, the face may be bonded or otherwise attached to a painted golf club body. The face may be painted or provided with a different shade or color from the crown, or may be unpainted. In an embodiment, the face is provided in a composite material of a shade or color that contrasts with the crown.

At 2820, the lateral dispersion tendency of the golf club head is measured. The lateral dispersion tendency indicates an average dispersion from a center target line. For example, a positive lateral dispersion tendency is the average dispersion right of the center target line and a negative lateral dispersion tendency is the average dispersion left of the center target line. For example, a prototype of the new golf club head design is provided for player testing. In this example, one or more players may test the golf club head. Based on the testing, a lateral dispersion of the golf club head may be measured. Other performance metrics may also be measured. Lateral dispersion may be indicative that a different alignment feature may provide better performance, such as less lateral dispersion. In another example, an impression of the alignment feature on the user may also be measured. In this example, if the golf club head face appears too open or too closed during the test, a different alignment feature may improve appeal or confidence in the golf club head to the testers.

At 2830, the primary alignment feature is adjusted to provide an adjusted primary alignment feature, such as to counteract the lateral dispersion tendency of the golf club head. The primary alignment feature may also be adjusted in conjunction with changing face characteristics of the golf club head, such as when providing for different bulge and roll characteristics, tuning CT, and prescribing other face characteristics. In an embodiment, based on the testing, the primary alignment feature may be adjusted to increase performance and/or appeal of the golf club head. In this example, a top line radius may be adjusted. Based on the lateral dispersion measured during testing, a top line radius may be adjusted one degree for every five yards of lateral dispersion with a driver and adjusted one degree for every three yards of lateral dispersion with a fairway wood. Other adjustment amounts may be provided. Furthermore, additional and different adjustments to the one or more alignment features may be provided.

After the alignment feature is adjusted, one or more of acts 2820 and 2830 may be repeated for additional testing and/or adjustment. In some embodiments, individual player testing may also be performed, such as for individual tour players. In some embodiments, a secondary alignment feature is tested and adjusted.

At 2840, the adjusted primary alignment feature is incorporated into the golf club head. In an embodiment, the adjusted primary alignment feature is incorporated into the golf club head by retooling the golf club head. The adjusted alignment feature may also be provided for manufacturing the golf club heads. For example, after testing and adjusting one or more alignment features, the golf club head design is manufactured. Therefore, as-cast with the golf club head, the one or more alignment features are integrally formed into the golf club head, such as with an integrally formed topline alignment feature.

FIG. 94 is a section view of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed. In some embodiments, the transition from a portion of the crown 1120 to the face insert (not depicted in FIG. 94) provides for a primary alignment feature. For example, FIG. 94 shows a front portion 330 of a golf club head, such as golf club head 2500 or another golf club head. The front portion 330 is configured to receive a face insert (not depicted in FIG. 29), such as face insert 110 or another face insert. The front portion 330 includes a face insert support structures 2928A, 2928B. An upper face insert support structure 2928A is adjacent or immediately next to the crown 1120. A lower face insert support structure 2928B is adjacent or immediately next to the sole 130.

In some embodiments, when installed to the face insert support structures 2928A, 2928B, the face insert forms a part of the transition region from the face to the crown 1120 and/or the sole 130. For example, at least a portion of the transition region may be painted the same color or shade as at least a portion of the crown prior to installing the face insert, which when installed provides a contrasting color or shade of the face insert with respect to the painted portion of the transition region and/or crown. In other embodiments, the face insert eliminates the need for a transition region from the face to the crown 1120 and/or the sole 130. In some embodiments, the face insert includes at least a portion of the radius of the transition from the face insert to the crown. By forming part of the radius of the transition from the face to the crown, aerodynamics of the club head may be improved by decreasing turbulence of the air passing from the face to the crown and increasing annular flow.

FIG. 95A is a section view of an upper lip of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed. FIG. 95A depicts an upper face insert support structure 2928A that is adjacent or immediately next to the crown 1120. The upper face insert support structure 2928A includes an upper rear support member 3046A and an upper peripheral member 3048A. The upper rear support member 3046A and the upper peripheral member 3048A create an upper undercut recess 3006A forming a lip for receiving the face insert and connecting a portion of the crown 1120 to the upper face insert support structure 2928A.

In some embodiments, the upper face insert support structure 2928A is provided in a shape that flexes in a similar manner as the face insert when the golf club head strikes a golf ball. For example, in some golf club head designs, the face insert material, such as a composite material, is more flexible or compliant than the golf club body material, such as an aluminum or titanium alloy. In this example, a slot or recess 3008A may be provided within the upper peripheral member 3048A to increase flexibility or compliance of the upper face insert support structure 2928A, allowing the face to flex more uniformly. Additional and different shapes may be provided to increase or decrease flexibility and compliance of one or more components of the golf club body. By flexing in a similar manner, the golf club head may be more durable, substantially preventing the face insert from decoupling, or de-bonding, from the golf club body.

FIG. 95B is a section view of a lower lip of a golf club head in accord with one embodiment of the current disclosure, without a face insert installed. FIG. 95B depicts a lower face insert support structure 2928B that is adjacent or immediately next to the sole 130. The lower face insert support structure 2928B includes a lower rear support member 3046B and a lower peripheral member 3048B. The lower rear support member 3046B and the lower peripheral member 3048B create a lower undercut recess 3006B forming a lip for receiving the face insert and connecting a portion of the sole 130 to the lower face insert support structure 2928B.

In some embodiments, the lower face insert support structure 2928B is provided in a shape that flexes in a similar manner as the face insert when the golf club head strikes a golf ball. In the example discussed above, the face insert material is more flexible or compliant than the golf club body material. In this example, a slot or recess 3008B may be provided within the lower peripheral member 3048B to increase flexibility or compliance of the upper face insert support structure 2928B, allowing the face to flex more uniformly. Additional and different shapes may be provided to increase or decrease flexibility and compliance of one or more components of the golf club body. By flexing in a similar manner, the golf club head may be more durable, substantially preventing the face insert from decoupling, or de-bonding, from the golf club body.

FIG. 96 is a top view of a golf club head in accord with one embodiment of the current disclosure. FIG. 96 depicts club head 3100 with hosel 150, face 110 and a center-face location 3110. A center-face y-axis location (CFY) is defined using the center-face location 3110 of face 110 and a center point location 3150 of the hosel 150. A positive CFY produces onset of the golf club head and extends from center point location 3150 of hosel 150 toward the front portion of the golf club head to the center-face location 3110. For example, onset may cause lateral dispersion and the face to appear too far forward of the hosel. A negative CFY produces offset of the golf club head and extends from center point location 3150 of hosel 150 toward the rear portion of the golf club head to the center-face location 3110. A face progression (FP) is defined using the leading-edge location 3120 of face 110 and a center point location 3150 of the hosel 150. Face progression is related to face location, loft and face height. CFY, face progression, and alignment features all influence performance of a golf club head, such as lateral dispersion. For example, if the CFY and/or face progression of the golf club head is changed, one or more alignment features may be provided to counteract the lateral dispersion created or reduced by the CFY and/or face progression.

In some embodiments, a high CFY (e.g., greater than about 15 mm, 14 mm, 13 mm, or another CFY) may produce lateral dispersion right of the intended target line. In other embodiments, a low CFY (e.g., less than about 15 mm, 14 mm, 13 mm, or another CFY) may produce lateral dispersion left of the intended target line. In some embodiments, CFY is between about 13 mm and about 15 mm.

In some embodiments, a high face progression (e.g., greater than about 20 mm, 19 mm, 18 mm, or another face progression) may produce lateral dispersion right of the intended target line. In other embodiments, a low face progression (e.g., less than about 19 mm, 18 mm, 17 mm, or another face progression) may produce lateral dispersion left of the intended target line. In some embodiments, face progression is between about 15 mm and about 20 mm.

In some embodiments, a golf club head is provided with at least one of. CFY no more than 15.5 mm; CFY no more than 15 mm; CFY no more than 14.5 mm; CFY no more than 14 mm; CFY no more than 13.5; CFY no more than 13 mm; face progression no more than 20 mm; face progression no more than 19 mm; face progression no more than 18 mm; face progression no more than 17 mm; and face progression no more than 16 mm. In some embodiments, a golf club head is provided with a CFY no more than 17.5 mm. In another series of embodiments CFY is at least 8 mm, 9 mm, 10 mm, 11 mm, or 12 mm. Likewise, in another series of embodiments face progression is at least 10 mm, 11 mm, 12 mm, 13 mm, or 14 mm.

FIG. 32 is a perspective view from a toe side of a golf club head 3200. In this embodiment, the golf club head 3200 includes a hollow body 3210. The hollow body 3210 includes a hosel 150, a crown 1120 (not depicted), and a sole 130. In some embodiments, the hollow body 3210 has openings to receive the face insert 110 (not depicted), a crown insert 3220, and/or a sole insert 3230. In some embodiments, the hollow body is a metal or composite material frame, and the face insert 110 (not depicted), a crown insert 3220, and/or a sole insert 3230 are at least in part composite materials. The hollow body 3210 is cast with a ledge 2622 for receiving a face insert 110 (not depicted). By bonding the face insert 110 to the ledge 2622, the transition between the face 110 and the crown 1120 provide for a primary alignment feature 2514, such as a topline or another alignment feature. For example, the hollow body 3210 may be cast from a titanium alloy, an aluminum alloy, another alloy, or a combination thereof. The hollow body 3210 is painted prior to bonding a face insert 110 (not depicted), a crown insert 3220 (not depicted), and/or a sole insert 3230. By bonding the face insert and/or the crown insert, one or more alignment features are hard tooled into the golf club head 3200. The face insert 110, a crown insert 3220, and/or a sole insert 3230 may be bonded to the hollow body 3210 after the hollow body 3210 is painted, such as by bonding the face insert 110 first, then boding the crown insert 3220. Alternatively, the crown insert 3220 is bonded first, followed by the face insert 110. By bonding the inserts after the hollow body 3210 is painted, the one or more alignment features are hard tooled into the golf club head during casting and bonding. In some embodiments, at least a portion of the crown and sole inserts 3220, 3230 are manufactured from a composite material.

In other embodiments, one or more alignment features are hard tooled into the golf club head by casting one or more witness lines into the golf club head. For example, one or more positive witness lines may be cast into the hollow body 3210, such as by casting a protrusion, ridge, or other raised feature in the hollow body 3210. In another example, one or more negative witness lines may be cast into the hollow body 3210, such as an indentation, valley, or other depressed feature into the hollow body 3210. In some embodiments, a combination of positive and negative witness lines may be provided. The one or more witness line may be painted with the hollow body 3210 to provide one or more alignment features. Alternatively or additionally, the witness lines may be used as a guide for painting one or more alignment features on the golf club head. By casting the witness lines in the golf club head during manufacturing, the subsequent painting of the one or more alignment features may be more accurate from part to part.

Referring back to FIG. 97, in some embodiments, the hosel 150 may be adjustable, such as using flight control technology (FCT) in the hosel 150. For example, FCT may include a loft and lie connection sleeve to adjust, inter alia, face angle. The FCT may be adjustable with a screw 3255 or another connector. The hosel 150 also includes an external hosel surface 3251 and an internal hosel surface 3253. The internal hosel surface 3253 may occupy at least a portion of the face opening or region for receiving the face insert 110 (not depicted). To accommodate the internal hosel surface 3253, a notch or other feature is provided in face insert 110 for accepting at least a portion of the hosel within the face insert 110. As discussed herein, the notch may reduce CFY and accommodates at least a portion of the hosel within the face insert. Further, by accommodating for a portion of the hosel within the face insert, a portion of the face insert may extend high on the heel and follow the natural shape of the crown and/or other features of the club head. In some embodiments, the face insert 110 ties directly into the hosel 150. By accommodating at least a portion of the internal hosel surface 3253 within the face insert 110, a center-face location 3110 (not depicted) of the face insert 110 may be located closer to a center point location 3150 (not depicted) of the hosel 150, reducing CFY and increasing performance of the golf club head.

In some embodiments, the golf club head 3200 includes a slot 3295 and a weight track 3245. For example, the slot 3295 and/or the weight track 3245 may be cast into the hollow body 3210. As will be discussed below, the slot 3295 may increase the durability of the golf club head by allowing at least a portion of the hollow body 3210 to flex similarly to the face insert 110, increasing performance of the golf club head and increasing the durability of the golf club head by preventing the face insert 110 from decoupling from the hollow body 3210. In some embodiments, the golf club head 3200 includes one or more characteristic time (CT) tuning ports. Referring to FIG. 97, a CT tuning port 3275 is provided in the toe portion of the hollow body 3210. Another CT tuning port (not depicted) may be provided in the heel portion of the hollow body 3210. The one or more CT tuning ports may be provided in additional and different locations on the golf club head 3200, such in the face insert 110 or in another location. Using the CT tuning port(s), an adhesive or another material may be injected into the golf club head 3200 to reduce or increase the CT of the golf club head. For example, the golf club head 3200 may be manufactured with a CT that does not conform to the United States Golf Association (USGA) regulations that constrain CT of golf club heads. By injecting an adhesive into the CT tuning port 3275, the CT of the golf club head is detuned to conform to the USGA regulations.

In some embodiments, the golf club head includes one or more foam inserts. For example, a foam insert 3276 is positioned within the hollow body 3210. An additional foam insert is also provided proximate to the toe portion (not depicted). The one or more foam inserts aid in CT tuning the golf club head by restraining the adhesive or other material to locations within the golf club head while the material solidifies. Additionally, a rear wall may also be provided to further restrain the material while it solidifies. Accordingly, the foam inserts and the rear wall prevent the adhesive injected into the tuning port 3275 from moving too far toeward, heelward, and backward, allowing the golf club head to be CT tuned more precisely. Additional and different structures may be provided to restrain the injected materials during CT tuning.

In some embodiments, the golf club head includes a multi-material inertia generator. An inertia generator, as discussed herein, may also be referred to as an aft winglet and a center of gravity (CG) lowering platform. The inertia generator 3285 moves discretionary mass rearward to increase inertia and to move the CG projection lower on the face of the golf club head. For example, the golf club head 3200 includes an inertia generator 3285 extending rearwardly and angled toewardly from the front portion of the golf club head 3200 to the rear portion of the golf club head 3200. A multi-material inertia generator may include two or more materials of different densities. For example, the inertia generator 3285 includes one or more of a low density portion 3286, a medium density portion 3287, and a high density portion 3288.

The low density portion 3286 may be a composite or another material, such as a portion of the composite sole panel 3230 or as another component. The low density portion 3286 has a density of less than about 2 g/cc, such as between about 1 g/cc and about 2 g/cc. The medium density portion 3287 may be an aluminum alloy, a titanium alloy, another alloy, another material, or a combination of multiple alloys or materials, such as a portion of the hollow body 3210 or as another component. The medium density portion 3287 has a density greater than about 2.7 g/cc, such as between about 1 g/cc and about 5 g/cc, between about 2.0 g/cc and about 5.0 g/cc, and between about 2.5 g/cc and about 4.5 g/cc. The high density portion 3288 may be a steel alloy, a tungsten alloy, another alloy, another material, or a combination of multiple alloys or materials, such as a rear weight affixed to the inertia generator 3285 or as another component. The high density portion 3288 has a density greater than about 7 g/cc. For example, an aluminum alloy is often about 2.7 g/cc, a titanium alloy is often about 4.5 g/cc, a steel alloy is often about 7.8 g/cc, and tungsten alloy a tungsten alloy is often about 19 g/cc.

FIG. 98 is a perspective view from a toe side of a golf club head 3200. FIG. 98 provides another view of the sole 130 with the insert 3230, the inertia generator 3285, the slot 3295, the weight track 3245 and the screw 3255. The inertia generator 3285 is provided as a multi-material inertia generator, with a low density portion 3286, medium density portion 3287, and high density portion 3288.

FIG. 99 is a perspective view of a portion of a golf club head 3200. FIG. 99 shows the hosel 150 with the external hosel surface 3251 and the internal hosel surface 3253. As depicted in FIG. 99, the ledge 2622 for receiving a face insert 110 (not depicted) is joined to the internal hosel surface 3253 within an intersection region 3257. The face support, such as including ledge 2622, intersects and joins with the internal hosel surface 3253 allowing the internal hosel surface 3253 to interact with and/or be at least partially within the face insert 110. The face support may intersect and/or join the internal hosel surface 3253 proximate to the crown, proximate to the sole, or proximate to the crown and the sole.

FIG. 100 is a perspective view from the rear portion of a golf club head 3200, without a crown insert 3220 installed. FIG. 100 shows a club head 3200 with hosel 150, internal hosel surface 3253, foam inserts 3276, and high density portion 3288. A ledge 3224 is provided for bonding a crown insert 3220 (not depicted). The ledge 3224 is wider proximate to the front portion and the face of the club head to provide for additional CT tuning. For example, in addition to supporting the crown insert 3220, a width of the ledge 3224 is increased to decrease the CT of the club head. In an embodiment, the ledge 3224 width is increased from about 10 mm to about 15 mm proximate the face. During or after manufacture, material can be removed from the ledge 3224 to increase the CT of the club head, such as increasing the CT by about 8 to about 10 points. As discussed above, CT tuning is typically used to reduce CT of a club head to meet the USGA constraints. If the CT of a club head is determined to be too far under the USGA constraints, the club head can tuned using the ledge 3224 to increase CT to approach or exceed the USGA constraints.

In some embodiments, the golf club head 3200 includes support ribs 3296, 3297. For example, support ribs 3296 provide for additional support for the hollow body 3210, the weight track 3245 and/or slot 3295. The support ribs 3296 may be provided over the weight track 3245 and in other areas within the hollow body 3210. Support rib 3297 may be provided to support supports the hollow body 3210 and inertia generator 3285. As depicted in FIG. 100, the hollow body 3210 includes a platform of material extending in the direction of the inertia generator 3285 that includes the support rib 3297. Additional and different support ribs may be provided.

FIGS. 101-102 are views of portions of a golf club head 3200. FIG. 101 shows internal hosel surface 3253 occupying at least a portion of the face opening or region for receiving the face insert 110 (not depicted). By occupying at least a portion of the face opening or region for receiving the face insert 110, face progression and onset may be reduced, increasing performance of the golf club head 3200.

In some embodiments, the golf club head 3200 includes a mass pad 3290 in the heel portion of the golf club head. Mass pad 3290 positions discretionary mass of the golf club head 3200 heelward, and may lower the CG and move CG forward to modify the CG projection. In some embodiments, a removable and/or adjustable weight may be provided in the heel portion in lieu of or in addition to the mass pad 3290.

FIGS. 103-104 are views of portions of a golf club head 3200. As depicted in FIGS. 103-104, the ledge 2622 extends around the entire periphery of the face opening to support the face insert 110 (not depicted). By extending around the entire periphery, the ledge 2622 supports the entire face insert 110. In other embodiments, the ledge 3224 supports the face insert 110 in the heel portion, toe portion, crown portion and sole portion. For example, the ledge 2622 supports the face insert 110 in a region defined by about a 10 mm band about the geometric center of the face insert 110. Other bands about the geometric center of the face insert may be used, such as about 15 mm and about 20 mm. (prior art only had support in the heel and toe regions). Additional and different structures may be used to support the face around the entire periphery of the face or in regions about the geometric center of the face.

FIG. 105 is a view of a portion of a golf club head 3200. FIG. 105 shows the upper face insert support structure 2928A and the lower face insert support structure 2928B provided so that at least a portion of the hollow body 3210 flexes in a similar manner as the face insert 110 (not depicted) when the golf club head strikes a golf ball. Different materials (e.g., metal alloys and composites) have different flex characteristics and typically flex differently from each other. For example, the slot or recess 3008A and the slot or recess 3008B allow a composite face to flex more uniformly with the cast hollow body 3210. Additional and different geometries within the hollow body 3210 may be provided. By flexing in a similar manner, the golf club head may be more durable, substantially preventing the face insert from decoupling, or de-bonding, from the golf club body.

FIG. 106 is a perspective view from a toe side of two golf club heads 3200, 4100. The golf club head 3200 is an embodiment of the present disclosures and golf club head 4100 is an embodiment of a prior art club head design. The golf club head 3200 includes features that improve the aerodynamic features of the club head. For example, the prior art club head 4100 has a peak crown height that is located approximately in line with a center shaft axis of the hosel, referred to as an acute crown. To promote better aerodynamic properties of the golf club head 3200, the peak crown height is located rearward of the hosel, referred to as an obtuse crown. Referring to FIG. 106, the peak crown height of the golf club head 4100 is located a distance C2 forward of the rear-most edge of the hosel. To promote better aerodynamics, the peak crown height of the golf club head 3200 is located a distance C1 rearward of the rear-most edge of the hosel. In an embodiment, the peak crown height of the golf club head 3200 is located at least about 15 mm rearward of the rear-most edge of the hosel. Moving the peak crown height rearward allows aero flow to be attached to the club head longer, promoting better aerodynamic properties.

The skirt height of golf club 3200 may also improve aerodynamic features of the golf club head. Golf club head 3200 has a skirt height S1, which may measure the lowest point above the ground plane at which the skirt meets the crown. Golf club head 4100 has a skirt height S2. In some embodiments, the skirt height S1 is at least 20 mm, and in some embodiments may be between about 25 mm and about 40 mm, such as between 30 mm and 40 mm, or between 30 mm and 35 mm. Increasing the skirt height S1 of golf club head 3200 likewise improves the aerodynamic properties of the golf club head. The golf club body has a total body height from defined from a bottom most portion of the golf club body, or the ground plane, to a top most portion of the crown, or the peak crown height, such as vertically or along a z-axis. In some embodiments, the total body height is no less than 48 mm, no less than 52 mm, no less than 53 mm, no less than 54 mm, no less than 55 mm, no less than 56 mm, no less than 57 mm, no less than 58 mm, no less than 59 mm, or no less than 60 mm. In further embodiments the total body height is no more than 72 mm, no more than 70 mm, no more than 68 mm, no more than 66 mm, or no more than 64 mm. The golf club body also has a body length defined from a leading edge of the golf club body, or the leading-edge location, to a rearward most portion of golf club head, or the rearward most portion of the skirt, such as horizontally or along a y-axis. In some embodiments, the body length is no less than 98 mm, no less than 102 mm, no less than 106 mm, no less than 109 mm, no less than 112 mm, no less than 115 mm, or no less than 118 mm. In further embodiments the body length is no more than 133 mm, no more than 130 mm, no more than 127 mm, no more than 126 mm, no more than 125 mm, no more than 124 mm, no more than 123 mm, or no more than 122 mm.

FIG. 107 is an elevation view of a face insert 110. The composite face plate is attached to an insert support structure located at the opening at the front portion of the club head. Further details concerning the insert support structure are described in U.S. Pat. No. RE43,801, issued Nov. 13, 2012, which is incorporated by reference in the entirety.

In some embodiments, the face insert 110 can be machined from a composite plaque, and it should be noted that face insert and face plate are used interchangeably throughout, however the face insert 110 may be formed of metal alloy In an example, the composite plaque can be substantially rectangular with a length between about 90 mm and about 130 mm or between about 100 mm and about 120 mm, preferably about 110 mm±1.0 mm, and a width between about 50 mm and about 90 mm or between about 6 mm and about 80 mm, preferably about 70 mm±1.0 mm plaque size and dimensions. The face insert 110 is then trimmed from the plaque to create a desired face profile. For example, the face profile length 4212 can be between about 80 mm and about 120 mm, or between about 90 mm and about 110 mm, or between about 94 mm and about 106 mm, or between about 98 mm and about 104 mm, preferably about 102 mm. The face profile width 4211 can be between about 40 mm and about 65 mm, or between about 42 mm and about 63 mm, or between about 44 mm and about 61 mm, or between about 46 mm and about 59 mm, or between about 48 mm and about 57 mm, or between about 50 mm and about 55 mm, preferably about 53 mm. The ideal striking location width 4213 can be between about 25 mm and about 50 mm or between about 30 mm and about 40 mm, preferably about 34 mm. The ideal striking location length 4214 can be between about 40 mm and about 70 mm or between about 45 mm and about 65 mm, preferably about 55.5 mm. With continued reference to FIG. 107, the face insert 110 has a face topline perimeter edge 4215, a face lower portion perimeter edge 4216, a face toe transition region 4217, and a face heel transition region 4218. In one embodiment the face toe transition region 4217 is defined by that portion of the perimeter at the toe having a radius of curvature of less than 10 mm, and in further embodiments less than 9 mm, 8 mm, 7 mm, or 6 mm. Similarly, in one embodiment the face heel transition region 4218 is defined by that portion of the perimeter at the heel having a radius of curvature of less than 10 mm, and in further embodiments less than 9 mm, 8 mm, 7 mm, or 6 mm. Alternatively, the face insert 110 can be molded to provide the desired face dimensions and profile.

In embodiments where the face insert 110 is machined from a composite plaque, the face insert 110 can be machined in one or more operations, such as computer numerical control (CNC) or other operations. For example, starting with the composite plaque, a notch 4220 can be first machined from the plaque. Next, a perimeter chamfer can be machined around the perimeter of the face insert 110. Finally, a face profile can be machined from the plaque. In some embodiments, each of the notch 4220, perimeter chamfer, and face profile can be machined in a single operation, such as a single CNC operation without removing the plaque from the CNC fixture. In other embodiments, multiple operations can be performed, such as machining one or more of the notch 4220, perimeter chamfer, or face profile being machined separately from the other features of the face. Other orders of machining features can be provided, such as machining the notch after the face profile and chamfer, as well as machining additional features into the face insert 110, such as bond gap bumps and other features. The notch 4220 is not limited to nonmetallic face plates, or inserts, and all associated disclosure applies equally to metallic face plates, or inserts.

Additional features can be machined, molded, or cast into face the insert 110 to create the desired face profile. For example, a notch 4220 can be machined or molded into the backside of a heel portion of the face insert 110. For example, the notch 4220 in the back of the face insert 110 allows for the golf club head 2500 to utilize flight control technology (FCT) in the hosel 150. The notch 4220 can be configured to accept at least a portion of the hosel within the face insert 110. Alternatively or additionally, the notch 4220 can be configured to accept at least a portion of the club head body within the face insert 110.

In some embodiments, the notch 4220, or another relief portion, defines a transition region on the face insert. For example, the notch 4220 or relief portion is proximate to a heel portion of the face and can have an area of at least about 50 mm²and no more than about 300 mm², preferably less than about 200 mm², more preferably between about 75 mm²and about 150 mm². Preferably, the notch area is about 1.5% to about 6% of the external area of the face insert (e.g., the outward facing portion of the face configured for striking the golf ball), more preferably the notch area is about 2% to about 3% of the external face insert.

The notch may allow for the reduction of CFY by accommodating at least a portion of the hosel and/or at least a portion of the club body within the face insert, allowing the ideal striking location of the face insert to be closer to a plane passing through a center point location of the hosel. The face insert 110 can be configured to provide a CFY no more than about 18 mm and no less than about 9 mm, preferably between about 11.0 mm and about 16.0 mm, and more preferably no more than about 15.5 mm and no less than about 11.5 mm. The face insert 110 can be configured to provide face progression no more than about 21 mm and no less than about 12 mm, preferably no more than about 19.5 mm and no less than about 13 mm and more preferably no more than about 18 mm and no less than about 14.5 mm. In some embodiments, a difference between CFY and face progression is at least 2 mm and no more than 12 mm, preferably between at least 3 mm and 8 mm. In other embodiments, a difference between CFY and face progression is at least 2 mm and no more than 4 mm.

In another example, backside bumps 4230A, 4230B, 4230C, 4230D may be machined or molded into the backside of the face insert. The backside bumps 4230A, 4230B, 4230C, 4230D can be configured to provide for a bond gap. A bond gap is an empty space between the club head body and the face insert that is filled with adhesive during manufacturing. The backside bumps 4230A, 4230B, 4230C, 4230D protrude to separate the face from the club head body when bonding the face insert to the club head body during manufacturing. In some instances, too large or too small of a bond gap may lead to durability issues of the club head, the face insert, or both. Further, too large of a bond gap can allow too much adhesive to be used during manufacturing, adding unwanted additional mass to the club head. The backside bumps 4230A, 4230B, 4230C, 4230D can protrude between about 0.1 mm and 0.5 mm, preferably about 0.25 mm. In some embodiments, the backside bumps are configured to provide for a minimum bond gap, such as a minimum bond gap of about 0.25 mm and a maximum bond gap of about 0.45 mm.

Further, one or more of the edges of the face insert 110 can be machined or molded with a chamfer. In an example, the face insert 110 includes a chamfer substantially around the inside perimeter edge of the face insert, such as a chamfer between about 0.5 mm and about 1.1 mm, preferably 0.8 mm. In some embodiments, the perimeter chamfer is provided to avoid the face insert 110 bottoming out on an internal radius of the recessed face opening of the golf club head configured to receive the face insert 110. By providing the perimeter chamfer, the face insert 110 can fit properly within recessed face opening despite manufacturing variances and other characteristics of the golf club head created during the casting process.

FIG. 43 is a is a bottom perspective view of a face insert 110. The face insert has a heel portion 4341 and a toe portion 4342. The notch 4220 is machined or molded into the heel portion 4341. In this example, the face insert 110 has a variable thickness, such as with a peak thickness 4343. The peak thickness 4343 can be between about 2 mm and about 7.5 mm or between about 3.8 mm and about 4.8 mm, preferably 4.1 mm±0.1 mm, 4.25 mm±0.1 mm, or 4.5 mm±0.1 mm.

In some embodiments, the face insert 110 is manufactured from multiple layers of composite materials. Exemplary composite materials and methods for making the same are described in U.S. patent application Ser. No. 13/452,370 (published as U.S. Pat. App. Pub. No. 2012/0199282), which is incorporated by reference. In some embodiments, an inner and outer surface of the composite face can include a scrim layer, such as to reinforce the face insert 110 with glass fibers making up a scrim weave. Multiple quasi-isotropic panels (Q's) can also be included, with each Q panel using multiple plies of unidirectional composite panels offset from each other. In an exemplary four-ply Q panel, the unidirectional composite panels are oriented at 90°, −45°, 0°, and 45°, which provide for structural stability in each direction. Clusters of unidirectional strips (C's) can also be included, with each C using multiple unidirectional composite strips. In an exemplary four-strip C, four 27 mm strips are oriented at 0°, 125°, 90°, and 55°. C's can be provided to increase thickness of the face insert 110 in a localized area, such as in the center face at the ideal striking location. Some Q's and C's can have additional or fewer plies (e.g., three-ply rather than four-ply), such as to fine tune the thickness, mass, localized thickness, and provide for other properties of the face insert 110, such as to increase or decrease COR of the face insert 110.

The tables below provide examples of possible layups. These layups show possible unidirectional plies unless noted as woven plies. The construction shown is for a quasi-isotropic layup. A single layer ply has a thickness of ranging from about 0.065 mm to about 0.080 mm for a standard FAW of 70 gsm (grams per square meter) with about 36% to about 40% resin content. The thickness of each individual ply may be altered by adjusting either the FAW or the resin content, and therefore the thickness of the entire layup may be altered by adjusting these parameters.

In an example, a first face insert can have a peak thickness of 4.1 mm and an edge thickness of 3.65 mm, including 12 Q's and 2 C's, resulting in a mass of 24.7 g. In another example, a second face insert can have a peak thickness of 4.25 mm and an edge thickness of 3.8 mm, including 12 Q's and 2 C's, resulting in a mass of 25.6 g. The additional thickness and mass is provided by including additional plies in one or more of the Q's or C's, such as by using two 4-ply Q's instead of two 3-ply Q's. In yet another example, a third face insert can have a peak thickness of 4.5 mm and an edge thickness of 3.9 mm, including 12 Q's and 3 C's, resulting in a mass of 26.2 g. Additional and different combinations of Q's and C's can be provided for a face insert 110 with a mass between about 20 g and about 30 g, or between about 15 g and about 35 g. In one series of embodiments the mass of the face insert 110 is no more than 30 g, while in further embodiments it is no more than 28 g, 26 g, 25 g, and 24 g. In a further series of embodiments the mass of the face insert 110 is at least 16 g, while in further embodiments it is at least 18 g, 19 g, 20 g, 21 g, 22 g, and 23 g.

FIG. 109A is a section view of a heel portion 4341 of a face insert 110. The heel portion 4341 can include a notch 4220. In embodiments with a chamfer on an inside edge of the face insert 110, no chamfer 4450 can be provided on the notch 4220. The notch 4420 can have a notch edge thickness 4444 less than the non-notch edge thickness 4445 of the face insert 110. Thus, the face plate perimeter has a face perimeter thickness that may vary from the non-notch edge thickness 4445, to the notch edge thickness 4444. In one embodiment the notch edge thickness 4444 is at least 10% less than the non-notch edge thickness 4445, and in further embodiments at least 15%, 20%, 25%, 30%, or 35% less. In another embodiment the notch edge thickness 4444 is at least 25% of the non-notch edge thickness 4445, and at least 30%, 35%, 40%, 45%, 50%, or 55% in further embodiments. For example, in one embodiment the notch edge thickness 4444 can be between 1.5 mm and 2.1 mm, while in further embodiments the notch edge thickness 4444 is no more than 3.0 mm, no more than 2.8 mm, no more than 2.6 mm, no more than 2.4 mm, no more than 2.2 mm, no more than 2.0 mm, and in one embodiment is preferably 1.8 mm. In a further series of embodiments the notch edge thickness 4444 is at least 0.9 mm, and at least 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, and 1.6 mm in further embodiments. In one embodiment the reduced notch edge thickness 4444 extends over at least 5 mm of the perimeter of the face insert 110, while in further embodiments it extends over at least 7.5 mm, 10 mm, 12.5 mm, 15 mm, and 17.5 mm. In another embodiment the reduced notch edge thickness 4444 extends over no more than 70 mm of the perimeter of the face insert 110, while in further embodiments it extends over no more than 60 mm, 50 mm, 45 mm, 40 mm, and 35 mm. In one embodiment the non-notch edge thickness 4445 is constant throughout at least 90 mm of the perimeter of the face insert 110, while in further embodiments it constant throughout at least 110 mm, 130 mm, 150 mm, or 170 mm. In another embodiment, with reference to the front elevation view coordinate system of FIG. 126, the non-notch edge thickness 4445 is constant throughout at least 90 degrees of the perimeter of the face insert 110, and in further embodiments at least 135 degrees, 180 degrees, 225 degrees, 270 degrees, or 315 degrees. The non-notch edge thickness 4445 is at least 3.1 mm in an embodiment, and is at least 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, or 3.8 mm in further embodiments. In a still further series of embodiments the non-notch edge thickness 4445 is no more than 4.9 mm in an embodiment, and no more than 4.8 mm, 4.7 mm, 4.6 mm, 4.5 mm, 4.4 mm, 4.3 mm, 4.2 mm, or 4.1 mm in further embodiments. The peak thickness 4343 is greater than the non-notch edge thickness 4445 in one embodiment, while in further embodiments the peak thickness 4343 is at least 5%, 10%, or 15% greater than the non-notch edge thickness 4445. The peak thickness 4343 is 100% greater than the reduced notch edge thickness 4444 in one embodiment, while in further embodiments the peak thickness 4343 is at least 110%, 120%, or 130% greater than the reduced notch edge thickness 4444. The peak thickness 4343 is less than 200% of the non-notch edge thickness 4445 in one embodiment, while in further embodiments the peak thickness 4343 is less than 190%, 180%, 170%, 160%, 150%, 140%, or 130% of the non-notch edge thickness 4445. The peak thickness 4343 is less than 310% of the reduced notch edge thickness 4444 in one embodiment, while in further embodiments the peak thickness 4343 is less than 300%, 290%, 280%, or 270% of the reduced notch edge thickness 4444. The peak thickness 4343 is at least 3.9 mm in an embodiment, and is at least 4.0 mm, 4.1 mm, 4.2 mm, 4.3 mm, 4.4 mm, 4.5 mm, 4.6 mm, 4.7 mm, or 4.8 mm in further embodiments. In a still further series of embodiments the peak thickness 4343 is no more than 6.0 mm in an embodiment, and no more than 5.9 mm, 5.8 mm, 5.7 mm, 5.6 mm, 5.5 mm, 5.4 mm, 5.3 mm, 5.2 mm, 5.1 mm, or 5.0 mm in further embodiments.

FIG. 109B is a section view of a toe portion 4342 of a face insert 110. The toe portion 4342 includes a chamfer 4451 on the inside edge of the face insert 110. The chamfer 4451 has an internal angle from the chamfer surface to the face insert sidewall surface that is at least 110 degrees in one embodiment, and at least 120 degrees, 130 degrees, or 140 degrees in further embodiments. Further, the chamfer 4451 has a chamfer length of at least 0.5 mm in one embodiment, and at least 0.6 mm, 0.7 mm, 0.8 mm, or 0.9 mm in further embodiments. In a further embodiment the chamfer length is no more than 60% of the non-notch edge thickness 4445, and no more than 50%, 40%, 35%, 30%, or 25% in additional embodiments. In one embodiment the chamfer 4452 is present throughout at least 90 mm of the perimeter of the face insert 110, while in further embodiments it present throughout at least 110 mm, 130 mm, 150 mm, or 170 mm. In another embodiment, with reference to the front elevation view coordinate system of FIG. 126, the chamfer 4452 is present throughout at least 90 degrees of the perimeter of the face insert 110, and in further embodiments at least 135 degrees, 180 degrees, 225 degrees, 270 degrees, or 315 degrees. In a further embodiment the face insert perimeter adjacent the reduced notch edge thickness 4444 does not have the chamfer 4452. In still a further embodiment the notch 4220 has a radius of curvature of no more than 25 mm, and no more than 22 mm, 19 mm, and 16 mm in additional embodiments. At least a portion of the notch 4220 has an acute angle between the notch surface and the face insert sidewall surface, in one embodiment. In some embodiments, the edge thickness 4445 can be between about 3.35 mm and about 4.2 mm, preferably 3.65 mm±0.1 mm, 3.8 mm±0.1 mm, or 3.9 mm±0.1 mm.

FIG. 110 is a section view of a polymer layer 4500 of a face insert 110. The polymer layer 4500 can be provided on the outer surface of the face insert 110 to provide for better performance of the face insert 110, such as in wet conditions. Exemplary polymer layers are described in U.S. Pat. No. 9,694,253, issued Jul. 4, 2017, which is incorporated by reference. The polymer layer 4500 may include polyurethane and/or other polymer materials. The polymer layer may have a polymer maximum thickness 4560 between about 0.2 mm and 0.7 mm or about 0.3 mm and about 0.5 mm, preferably 0.40 mm±0.05 mm. The polymer layer may have a polymer minimum thickness 4570 between about 0.05 mm and 0.15 mm, preferably 0.09 mm±0.02 mm. The polymer layer can be configured with alternating maximum thicknesses 4560 and minimum thicknesses 4570 to create score lines on the face insert 100. Further, in some embodiments, teeth and/or another texture may be provided on the thicker areas of the polymer layer 4500 between the score lines.

In some embodiments, a method of assembling a golf club is provided. For example, the method includes providing a golf club head having a face opening with an internal hosel surface intruding into the face opening (e.g., forming a portion of the face opening). The golf club head can also include at least one of a crown opening and/or a sole opening. The method also includes attaching a composite face insert to the golf club body, where the face insert is machined from a composite plaque with a larger area than the finished face insert. For example, the composite face insert includes a machined perimeter chamfer and a machined in notch. The method further includes enclosing the face opening with the face insert, such as by attaching the face insert to the club head. In some embodiments, the internal hosel surface is received by the notch in the face insert. The method also includes enclosing one or more of the crown opening and/or sole opening with a crown insert and/or a sole insert. The method may further include attaching a golf club shaft having a shaft sleeve, and tightening a screw to attach the golf club shaft to the golf club head to form a golf club assembly. In some examples, the golf club head has a face progression less between 10 and 20 mm and a CFY between 9 and 18 mm, preferably less than 16 mm.

In some embodiments, the x-axis of the golf club head is tangential to the face and parallel to a ground plane, negative locations on the x-axis extend from the center face to the toe portion, and positive locations on the x-axis extend from the center face to the heel portion. In these embodiments, a center of gravity of the golf club body with respect to the x-axis (CGx) can be oriented from about 0 mm to about −10 mm.

In some embodiments, a method of counteracting a lateral dispersion tendency of a golf club head is provided. For example, the golf club head can have a face, a crown and a sole together defining an interior cavity, a body of the golf club head including a heel and a toe portion and having x, y and z axes which are orthogonal to each other and have their origin at USGA center face. The method can include providing a primary alignment feature comprising a line delineating a transition between at least a first portion of the crown having an area of contrasting shade or color with a shade or color of the face. The primary alignment feature can be hard tooled into the golf club head with the face of the golf club body, and the golf club head can have a first Sight Adjusted Perceived Face Angle (SAPFA) with respect to the primary alignment feature. The method also includes measuring the lateral dispersion tendency of the golf club head. The lateral dispersion tendency indicates an average dispersion from a center target line, where a positive lateral dispersion tendency is the average dispersion right of the center target line and a negative lateral dispersion tendency is the average dispersion left of the center target line. The method further includes adjusting the primary alignment feature to provide an adjusted primary alignment feature to counteract the lateral dispersion tendency of the golf club head and incorporating the adjusted primary alignment feature into the golf club head. The adjusted primary alignment feature can have a second Sight Adjusted Perceived Face Angle (SAPFA) of from about −2 to about 10 degrees and a second Radius of Curvature (circle fit) of from about 300 to about 1000 mm.

In some embodiments, the method can also include incorporating the adjusted primary alignment feature into the golf club head comprises retooling the golf club head. In some embodiments, adjusting the primary alignment feature counteracts the lateral dispersion tendency of the golf club head by providing for a positive lateral dispersion tendency for the golf club head. In some embodiments, adjusting the primary alignment feature counteracts the lateral dispersion tendency of the golf club head by providing for a negative lateral dispersion tendency for the golf club head. In some embodiments, adjusting the primary alignment feature counteracts the lateral dispersion tendency of the golf club head by reducing average dispersion from the center target line. In some embodiments, the primary alignment feature is hard tooled into the golf club head by bonding the face to the golf club body. In some embodiments, the golf club body is painted prior to bonding the face to the golf club body. In some embodiments, the adjusted primary alignment feature includes: a second Sight Adjusted Perceived Face Angle 25 mm Heelward (SAPFA_25H) of from about −5 to about 2 degrees; a second Sight Adjusted Perceived Face Angle 25 mm Toeward (SAPFA_25T) of from 0 to about 9 degrees; and a second Sight Adjusted Perceived Face Angle 50 mm Toeward (SAPFA_50T) of from about 2 to about 9 degrees.

Additional Exemplary Golf Club Heads

FIGS. 111-224 illustrate additional exemplary golf club heads 4600 that includes a face plate 4610 and an oversized crown 4620, also referred to as a crown panel, that extends to the front of the club head adjacent to the upper side of the face plate 4610, and in some embodiments forms a topline and/or rear perimeter portion of the club head. The crown 4620 and face plate 4610 can comprise nonmetallic composite materials, in some embodiments, such that the topline is formed where a portion of the composite material of the crown extends to be adjacent to a portion of the face plate. While much of this disclosure is related to relationships of the crown 4620, the face plate 4610, and the associated support structure, it is important to appreciate at the outset that the disclosure and relationships also apply to a sole plate 4640 having a portion wrapping around the front of the club head to be adjacent the face plate 4610, which may occur at the toe of the face plate 4610, as seen in FIGS. 142-146, at the heel of the face plate 4610, as seen in FIGS. 142-144, at the lower portion of the face plate 4610, as seen in FIGS. 141 and 145, and any combinations thereof. Similarly, the disclosure and relationships also apply to individual plates that may form only a portion of the skirt, and may be located at the toe or heel, and may not constitute a portion of the sole.

The club head include a body 4602 that includes a hosel portion 4604 and provides a primary structural support for the club head, and various other components are coupled to the body, which may include the face plate 4610 and the crown 4620, and in some embodiments a sole plate 4640, one or more weights (e.g., weights 4650, 4640), and/or other features. In some embodiments, the body includes a front body portion (labeled as 4602) and a rear ring portion 4630 attached together (e.g., welded, bonded, or mechanically attached) at the heel and toe ends, or integrally formed. Whether attached together or integrally formed, the front body portion 4602 and the rear ring portion 4630 compose a frame that serves as the supporting structure for the attachment of other components, which may include the crown 4620, the face plate 4610, and/or the sole plate 4640. Further, as disclosed later in detail, the face plate 4610 may be attached to, or integrally formed with the frame and/or front body portion 4602 and therefore the use of the term plate is not to imply a separate component, although it may be a separate component as disclosed in more detail later. Similarly, the sole plate 4640 may be attached to, or integrally formed with the frame, front body portion 4602, and/or rear ring portion 4630, and therefore the use of the term plate is not to imply a separate component, although it may be as disclosed in more detail later. Thus, in one simple embodiment the frame is created by the front body portion 4602 and the rear ring portion 4630, whether joined together or formed together, and form an upper crown opening 340 in the frame. The front body portion 4602 includes a hosel portion 4604 having a hosel bore, the center of which defines a shaft axis (SA).

The rear ring portion 4630 can in some embodiments comprise a different material than the front body portion 4602. In other embodiments, the front body portion and the rear ring portion are a unitary component of a common material. In one embodiment the front body portion 4602 and/or the rear ring portion 4630 is formed of a metal alloy, while in a further embodiment the front body portion 4602 and/or the rear ring portion 4630 is formed of nonmetallic material, including any of those disclosed herein.

The crown 4620 can have a large external surface area that extends greater extents compared to conventional crowns. The perimeter of the crown 4620 can be bonded to recessed ledges of the body such that the crown 4620 covers an upper opening in the body. For example, as shown in FIGS. 127 and 128, the crown 4620 can comprise a front portion 4622 that is bonded to a front, or forward, ledge 4680 of the body via body panel adhesive 4684. The front portion 4622 extends over and around an upper front portion of the body 4694 and is adjacent to to an upper portion 4612 of the face plate 4610. The body can also include a front opening 4696 that is covered by the face plate, with perimeter portions of the face plate 4610 being bonded to perimeter walls 4690, also referred to as the ledge wall 4690 or face support ledge wall 4690, and/or 4692, also referred to as the insert recess wall 4692, as seen in FIG. 128, of the body via face insert adhesive 4616. As seen in FIG. 128, the face support ledge wall 4690 has a ledge wall length 4691, measured from a ledge wall interior perimeter edge 4695 to the insert recess wall 4692. Similarly, the insert recess wall 4692 has an insert recess wall length 4693, which along the upper portion is measured from a recess wall leading edge 6100 to the face support ledge wall 4690, while in other portions, such as the illustrated lower portion, as seen in FIG. 132, is measured from forwardmost point of the insert recess wall 4692 to the face support ledge wall 4690. Referring again to FIG. 128, the face support ledge wall 4690 also has a ledge wall thickness 4699, which may vary slightly along the ledge wall length 4691, however unless noted otherwise references herein to the ledge wall thickness 4699 are the average ledge wall thickness 4699 from the ledge wall interior perimeter edge 4695 to the beginning of the fillet transitioning to the insert recess wall 4692. While the face support ledge wall 4690 is illustrated as continuous around the perimeter of the face plate 4610, in one embodiment it is discontinuous with at least X ledge gaps between adjacent and distinct ledge wall segments, wherein X represents a number from one to ten. Further, the face support ledge wall 4690 may be formed of a single material around the perimeter of the face plate 4610, however in one embodiment the face support ledge wall 4690 is constructed of at least 2 distinct portions formed of different material.

In one embodiment, the upper front portion of the body 4694, namely the front body portion 4602, is completely covered and not visible between the crown 4620 and the face plate 4610. This allows the topline of the club head to formed by the juncture of the crown 4620 and the face plate 4610, which can allow for a very precisely defined topline (the benefits of which are described in detail elsewhere herein). By contrast, in conventional club heads, the topline of the club head is often painted by hand and susceptible to variance due to human error. The exact orientation and position of the topline can be defined by precisely manufacturing the mating shapes of the front portion of the crown and the top portion of the face plate. This also allows for the intentional creation of custom topline orientations that are slightly different in different club heads, such as to influence a draw bias for instance.

Another advantage is that there is not a need to paint a visible upper front portion of the body, as in a conventional club head, which eliminates the problem of the painted surfaces chipping or otherwise being damaged from ball strikes or other impacts. Unexpectedly, it was discovered that the composite material of the crown is more durable and resistant to chipping and cracking than a conventional painted surface on a metallic body. This may be because the composite material of the crown 4620 is adhered to itself, which is a stronger bond than a paint layer adhered to a metallic body. In addition, the composite crown material overlapping a forward surface of the body appears to provide a very robust and damage resistant surface at the upper front region of the club head.

At the toe side of the club head, a toe portion 4624 of the crown 4620 can extend all the way to a toeward-most extent of the club head, or further, and be bonded to the ledge 4680 of the body. As shown in FIG. 129, some embodiments include the rear ring portion 4630 of the body, which may have a complementary ledge 4636 that is continuous with the ledge 4680, and the toe portion 4624 of the crown 4620 can be bonded to one, or both. A toe end of the crown 4620 can contact and/or be bonded to a wall 4688, 4638 where the body steps down to the recessed ledge. The wall 4688 of FIG. 129 is also known as the toe-side stepped down wall 4688 shown in FIG. 131. As seen in FIGS. 129 and 130, wall 4638, also referred to as the intermediary stepped down wall 4638, joins a heel-side stepped down wall 4689, seen in FIG. 132, to the toe-side stepped down wall 4688. In one embodiment the dimensions associated with the stepped down walls 4688, 4689, 4638 are identical.

Similarly, at the heel side of the club head, a heel portion 4626 of the crown can extend all the way to a heelward-most extent of the club head, or further, and be bonded to the body ledge 4680 of the body. As shown in FIG. 130, the rear ring portion 4630 of the body can have a complementary ring ledge 4636 that is continuous with the body ledge 4680, and the heel portion 4626 of the crown 4620 can be bonded to one, or both. A heel end of the crown 4620 can contact and/or be bonded to heel-side stepped down wall 4689 and/or the intermediary stepped down wall 4638 where the body steps down to the recessed ledge 4680, 4636. The ring ledge 4636 and the intermediary stepped down wall 4638 can extend around the rear of the club head such that a rear portion of the crown 4620 can extend broadly to a maximum rearward extent of the club head as well, as shown in FIGS. 115 and 121.

As seen in FIG. 121 atop plan view coordinate system is defined with the top plan origin inline with the center face 205 and at a midpoint of a center face depth dimension 4999, measured along a vertical center face plane VCFP, which contains the y-axis 207 seen in FIGS. 70A-70D, from the forwardmost point of the club head in the vertical center face plane to a rearward most point of the club head in the vertical center face plane, with the club head at the address position. A zero degree line extends between the top plan origin and the rear of the club head along the vertical center face plane, a 90 degree line extends perpendicular to the zero degree line from the top plan origin toward the heel, a 180 degree line extends perpendicular to the 90 degree line from the top plan origin and passes through center face 205, and a 270 degree line extends perpendicular to the 180 degree line from the top plan origin toward the toe. In one embodiment the crown 4620 curves downward to create the topline throughout the region between 170-190 degrees, while in further embodiments it creates the topline throughout the regions between 160-200 degrees, 155-205 degrees, 150-210 degrees, 145-215 degrees, 140-215 degrees, and 135-215 degrees. However, in a further embodiment the crown 4620 curves downward to create the topline through any continuous 10 degree range, and in further embodiments any 20 degree range, any 30 degree range, any 40 degree range, any 50 degree range, any 60 degree range, any 70 degree range, and any 80 degree range. In one embodiment the crown 4620 curves downward to create the entire topline. In another embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 throughout the region between 170-190 degrees, while in further embodiments this is true throughout the regions between 160-200 degrees, 155-205 degrees, 150-210 degrees, 145-215 degrees, 140-215 degrees, and 135-215 degrees. However, in a further embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 through any continuous 10 degree range, and in further embodiments any 20 degree range, any 30 degree range, any 40 degree range, any 50 degree range, any 60 degree range, any 70 degree range, and any 80 degree range.

Another way to describe these relationships is with a front elevation view coordinate system illustrated in FIG. 126 and centered at center face 205 with the club head in the address position, with zero degrees vertically upward, 90 degrees horizontally to the heel, 180 degrees vertically downward, and 270 degrees horizontally to the toe. In another embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 throughout the region between 350-10 degrees, while in further embodiments this is true throughout the regions between 340-20 degrees, 335-25 degrees, 330-30 degrees, 325-35 degrees, 320-40 degrees, 315-45 degrees, 310-50 degrees, 305-55 degrees, or 300-60 degrees. However, in a further embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 through any continuous 10 degree range, and in further embodiments any 20 degree range, any 30 degree range, any 40 degree range, any 50 degree range, any 60 degree range, any 70 degree range, any 80 degree range, any 90 degree range, any 100 degree range, or any 110 degree range. In one embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 through any continuous 10 degree range located between the 45 degree line and the 90 degree line, while in further embodiments this 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees. Similarly, in another embodiment the crown 4620 curves downward to be adjacent the perimeter of the face plate 4610 through any continuous 5 degree range located between a 285 degree line and a 315 degree line, while in further embodiments this 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, or 25 degrees. [stopped here]

Referring again to the top plan view of FIG. 121, in another embodiment the crown 4620 curves downward along a perimeter of the club head so that the crown 4620 creates the outermost perimeter, when viewed in a straight down top plan view with the club head in the design address position as seen in FIG. 121, through any continuous 10 degree range located at the rear of the club head from the 90 degree line to the 270 degree line. While in further embodiments the 10 degree range is expanded to 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, 100 degrees, 110 degrees, 120 degrees, 120 degrees, 130 degrees, 140 degrees, 150 degrees, 160 degrees, 170 degrees, or the full 180 degrees. Additionally, in a further embodiment the crown 4620 creates the outermost perimeter through any continuous 10 degree range located between the 90 degree line and a 135 degree line; while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees. Similarly, in a further embodiment the crown 4620 creates the outer most perimeter through any continuous 10 degree range located between the 270 degree line and a 225 degree line; while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees. Further, in another embodiment the crown 4620 creates the outermost perimeter through any continuous 10 degree range located between the 300 degree line and a 60 degree line; while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees. However, in a further embodiment the crown 4620 does not curve downward along a perimeter of the club head through any continuous exposed 10 degree range located at the rear of the club head from the 90 degree line to the 270 degree line, and thereby leaving a portion of the rear ring portion 4630 exposed when viewed in a straight down top plan view with the club head in the design address position as seen in FIG. 121. In further embodiments the continuous exposed 10 degree range is broadened to at least 15 degrees, 20 degrees, 25 degrees, or 30 degrees. Another series of embodiments caps the continuous exposed 10 degree range to no more than 135 degrees, and in further embodiments no more than 125 degrees, 115 degrees, 105 degrees, 95 degrees, 85 degrees, 75 degrees, 65 degrees, 55 degrees, 45 degrees, or 35 degrees.

The extent that the crown 4620 curves downward to create the outermost perimeter may vary. However in one embodiment no portion of the crown 4620 extends downward to an elevation below that of club head center of gravity 350, referred to as Zup, seen in FIG. 82, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located in the rear of the club head between the 90 degree line and the 270 degree line; while in further embodiments the 5 degree range is expanded to 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, 100 degrees, 110 degrees, 120 degrees, 130 degrees, 140 degrees, 150 degrees, 160 degrees, 170 degrees, or the full 180 degrees. In another embodiment the predetermined range is at least a 5 degree range located in the rear of the club head between the 0 degree line and the 270 degree line; while in further embodiments the 5 degree range is expanded to 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, or the full 90 degrees. In still a further embodiment the predetermined range is at least a 5 degree range located in the rear of the club head between the 0 degree line and the 90 degree line; while in further embodiments the 5 degree range is expanded to 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, or the full 90 degrees.

In another embodiment no portion of the crown 4620 extends downward to an elevation below 125% of Zup, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located in the rear of the club head between the 90 degree line and the 270 degree line; while in further embodiments the 5 degree range is expanded to 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, 100 degrees, 110 degrees, 120 degrees, 130 degrees, 140 degrees, 150 degrees, 160 degrees, 170 degrees, or the full 180 degrees.

In still a further embodiment no portion of the crown 4620 extends downward to an elevation below 150% of Zup, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located in the rear of the club head between the 90 degree line and the 270 degree line; while in further embodiments the 5 degree range is expanded to 10 degrees, 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, 100 degrees, 110 degrees, 120 degrees, 130 degrees, 140 degrees, 150 degrees, 160 degrees, 170 degrees, or the full 180 degrees.

Now looking at the forward portion of the club head between the 90 degree line and the 270 degree line of FIG. 121, in one embodiment at least a portion of the crown 4620 extends to an elevation below 200% of Zup, while in another embodiment at least a portion of the crown 4620 extends to an elevation below 175% of Zup, and in still a further embodiment at least a portion of the crown 4620 extends to an elevation below 150% of Zup. Now looking at the forward portion of the club head between the 110 degree line and the 145 degree line of FIG. 121, in one embodiment at least a portion of the crown 4620 extends to an elevation below 200% of Zup, while in another embodiment at least a portion of the crown 4620 extends to an elevation below 175% of Zup, and in still a further embodiment at least a portion of the crown 4620 extends to an elevation below 150% of Zup.

Now looking at the forward portion of the club head between the 270 degree line and the 225 degree line of FIG. 121, in an embodiment no portion of the crown 4620 extends downward to an elevation below Zup, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located between the 270 degree line and the 225 degree line of FIG. 121; while in further embodiments the 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, or the full 45 degrees.

In another embodiment, again looking at the forward portion of the club head between the 270 degree line and the 225 degree line of FIG. 121, no portion of the crown 4620 extends downward to an elevation below 175% of Zup, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located between the 270 degree line and the 225 degree line of FIG. 121; while in further embodiments the 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, or the full 45 degrees.

In still a further, again looking at the forward portion of the club head between the 270 degree line and the 225 degree line of FIG. 121, no portion of the crown 4620 extends downward to an elevation below 150% of Zup, throughout a predetermined range. In one such embodiment, again with reference to FIG. 121, the predetermined range is at least a 5 degree range located between the 270 degree line and the 225 degree line of FIG. 121; while in further embodiments the 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, or the full 45 degrees.

In still a further, again looking at the forward portion of the club head between the 270 degree line and the 90 degree line of FIG. 121, the crown 4620 has particular aerodynamic curvatures including any of the relationships disclosed in U.S. patent application Ser. No. 17/360,179, which is incorporated by reference herein in its entirety. Often such relationships involve the location of a crown apex 4621, or the point of highest elevation on the crown 4620 above the ground plane 317, thereby establishing an apex plane 4623, seen in FIG. 126, including the crown apex 4621 and parallel to the ground plane 317, referred as the apex height and illustrated as the crown height in FIG. 81. The crown 4620 has a crown leading edge 4625, seen in FIGS. 127 and 158, and each point along the crown leading edge 4625 has a crown leading edge apex-offset distance 4627, seen in FIG. 126, which is the vertical distance of any point on the crown leading edge 4625 below the apex plane 4623, and will vary from a maximum crown leading edge apex-offset distance 4627 to a minimum crown leading edge apex-offset distance 4627, with the minimum crown leading edge apex-offset distance 4627 located on the crown leading edge 4625 adjacent a highest face point 4611, which is located at a top face elevation 4613 above the ground plane 317. The crown 4620 also has a crown perimeter edge 4631, seen in FIGS. 54, 56, and 89, which are the perimeter portions of the crown 4620 that do not encompass the crown leading edge 4625. The crown perimeter edge 4631 may include a crown-hosel perimeter edge portion 4632, seen in FIG. 89. As seen in FIGS. 53 and 89, in one embodiment a portion of the crown 4620 adjacent the crown-hosel perimeter edge portion 4632 is concave upward.

In one embodiment, with reference again to FIGS. 128 and 135B, the insert recess wall 4692 has a recess wall leading edge 6100. Similarly the face topline perimeter edge 4215, of FIG. 107, has a face topline leading edge 4221, seen in FIGS. 135B and 139, and the face lower portion perimeter edge 4216 has a face lower portion leading edge 4222, seen in FIG. 141. In one embodiment the crown leading edge 4625 is within 3 mm of the recess wall leading edge 6100, the recess wall leading edge 6100 is within 3 mm of the face topline leading edge 4221, and the crown leading edge 4625 is within 3 mm of the face topline leading edge 4221, when analyzing these relationships within a single vertical section parallel to the vertical center face plane VCFP; while in further embodiments the 3 mm relationship is reduced to 2.5 mm, 2.0 mm, 1.5 mm, or 1.0 mm. In a further embodiment the crown leading edge 4625 is proud of the face topline leading edge 4221 by a proud distance 4223, seen in FIG. 135B, meaning, within a vertical section parallel to the vertical center face plane VCFP, the crown leading edge 4625 is further forward, in the direction of the y-axis 207, than the adjacent face topline leading edge 4221; and in a further embodiment the proud distance 4223 is no more than 0.15 mm, while in another embodiment the proud distance is at least 0.02 mm, 0.04 mm, 0.06 mm, or 0.08 mm. While the discussion has been focused on the relationship within a single vertical section, the front elevation view coordinate system of FIG. 126 may be used to define regions in which the disclosed relationships may be true. For instance in one embodiment any of the proud relationships may be true through any continuous 15 degree range, while in further embodiments the range is expanded to 25, 35, 45, 55, 65, 75, 85, 95, 105, or 115 degrees, and in still another embodiment it is true for all sections along the face topline perimeter edge 4215. These relationships apply in general to a portion of the face that is adjacent to the crown leading edge 4625 and vertically aligned within any vertical section.

Now looking at FIG. 120 and the bottom perimeter of the face insert 4610, namely the relationship of the face lower portion perimeter edge 4216 and the face lower portion leading edge, here the front body portion 4602 creates the leading edge of the club head. Whereas in the embodiment of FIG. 141 the sole plate 4640 wraps upward to be adjacent to the face plate 4610, and has a sole plate leading edge 4641. In either case the proud relationship just described with respect to the crown leading edge 4625 may also apply to recess wall leading edge 6100, in FIG. 119, and/or sole plate leading edge 4641, in FIG. 141.

However, in a further embodiment the opposite may be true. Thus, just as the crown leading edge 4625 is proud to obscure a golfer from seeing a face topline leading edge, a portion of the face lower portion leading edge 4222 may be proud of the adjacent recess wall leading edge 6100, in FIG. 120, and/or sole plate leading edge 4641, in FIG. 141, so that now the lower portion of the face lower portion leading edge 4222 prevents a golfer in the address position from noticing a distinct joint around the lower portion of the face plate 4610. Thus, in this embodiment the components are precisely located so the face topline leading edge 4221 is slightly recessed in relation to the crown leading edge 4625, and transitions so that at least a portion of the face lower portion leading edge 4222 may be proud of the adjacent recess wall leading edge 6100, in FIG. 121, and/or sole plate leading edge 4641, in FIG. 141. In another embodiment it is proud by no more than 0.15 mm, measured in the same manner as the proud distance 4223 of FIG. 135B, while in another embodiment it is proud by at least 0.02 mm, 0.04 mm, 0.06 mm, or 0.08 mm. While the discussion has been focused on the relationship within a single vertical section, the front elevation view coordinate system of FIG. 126 may be used to define regions in which the disclosed relationships may be true. For instance in one embodiment any of the proud relationships may be true through any continuous 15 degree range, while in further embodiments the range is expanded to 25, 35, 45, 55, 65, 75, 85, or 95 degrees. In such embodiments the transition of the face plate 4610 being recessed with respect to an adjacent component to being proud with respect to an adjacent component is delicate to that it is not apparent along the toe side and/or heel side perimeter of the face plate 4610. In such embodiments the perimeter of the face plate 4610 is flush with the adjacent component, i.e. neither recessed or proud, at a flush-transition point, which may include a toe-side flush-transition point and a heel-side flush-transition point. In one embodiment an elevation of the toe-side flush-transition point and/or the heel-side flush-transition point is above the elevation of center face 205, while in an alternative embodiment the elevation of the toe-side flush-transition point and/or the heel-side flush-transition point is below the elevation of center face 205. In still a further embodiment the elevation of the heel-side flush-transition point is less than the elevation of the toe-side flush-transition point.

As seen in FIG. 135B, one embodiment has a face gap 4224 between the crown leading edge 4625 and the face topline leading edge 4221. Further, the face gap 4224 is present at any point along the face plate perimeter between it and an adjacent body component, whether located on the front body portion 4602 or the sole plate 4640. The face gap 4224 is measured parallel to the loft plane 5000. In one embodiment the face gap 4224 is no more than 75% of the maximum crown thickness 4629 of the portion of the crown 4620 located between the offset loft plane 5100 and the crown leading edge 4625, while in further embodiments is it no more than 65%, 55%, 45%, or 35%. In a further embodiment the face gap 4224 is at least 5% of the maximum crown thickness 4629 of the portion of the crown 4620 located between the offset loft plane 5100 and the crown leading edge 4625, while in further embodiments is it at least 10%, 15%, 20%, or 25%. In one embodiment, consistent with the illustrated embodiments, no portion of the front body portion 4602 extends into the face gap 4224; meaning no portion of the front body portion 4602 extends beyond the recess wall leading edge 6100 into the face gap 4224 to be adjacent the crown leading edge sidewall surface. In one embodiment the face gap 4224 is no more than 2 mm, and in further embodiments no more than 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, or 0.5 mm. As with all such relationships, the face gap 4224 is evaluated in any vertical section and the disclosed relationships may apply at any or all of the disclosed vertical sections. In another embodiment the face gap 4224 is greater than the proud distance 4223, and in further embodiments the face gap 4224 is at least 10%, 20%, or 30% greater than the proud distance 4223. In further embodiments the face gap 4224 is less than 250% of the proud distance 4223, and less than 225%, 200%, 175%, or 150% in further embodiments.

In one embodiment the maximum crown leading edge apex-offset distance 4627, seen in FIG. 126, is at least 40% of Zup, while in further embodiments it is at least 50%, 55%, 60%, 65%, or 70%. However, unlike past unitary composite club heads, in another embodiment the maximum crown leading edge apex-offset distance 4627 is no more than 120% of Zup, while in further embodiments it is no more than 110%, 100%, 90%, 85%, 80%, or 75%. In another embodiment the minimum crown leading edge apex-offset distance 4627 is at least 10% of Zup, while in further embodiments it is at least 12%, 14%, 16%, 18%, 20%, 22%, 24%, 26%, 28%, 30%, 32%, or 34%. However, in another embodiment the minimum crown leading edge apex-offset distance 4627 is no more than 35% of Zup, while in further embodiments it is no more than 32.5%, 30%, 29%, 28%, 27%, 26%, 25%, 24%, 23%, or 22%. In a further embodiment the maximum crown leading edge apex-offset distance 4627 is at least 100% greater than the minimum crown leading edge apex-offset distance 4627, and in further embodiments at least 125%, 150%, 175%, or 200%. In one embodiment the maximum crown leading edge apex-offset distance 4627 occurs at a point on the crown leading edge 4625 located between the vertical center face plane and hosel portion 4604, and the minimum crown leading edge apex-offset distance 4627 occurs at a point on the crown leading edge 4625 located between the vertical center face plane and the toe 1185. In still a further embodiment the minimum crown leading edge apex-offset distance 4627 occurs at a point on the crown leading edge 4625 located between the vertical center face plane and a parallel plane containing the crown apex 4621. In another embodiment dividing the head along the vertical center face plane passing through center face 205 to compare a heel-side maximum crown leading edge apex-offset distance with a toe-side maximum crown leading edge apex-offset distance, the heel-side maximum crown leading edge apex-offset distance is at least 10% greater than the toe-side maximum crown leading edge apex-offset distance, and in further embodiments at least 15%, 20%, or 25% greater. Additionally, the minimum crown leading edge apex-offset distance 4627 is greater than the effective face position height 1164, shown in FIG. 70A, in another embodiment.

With reference again to FIGS. 107 and 126, in the installed position the face toe transition region 4217 has a highest face toe transition region elevation, measured vertically from the ground plane 317, and a lowest face toe transition region elevation, also measured vertically from the ground plane 317. In one embodiment the toe-side crown-to-face junction point 4800 is adjacent to a face perimeter point in the face toe transition region 4217 having the highest face toe transition region elevation, such as the embodiment of FIG. 126. However, in another embodiment the toe-side crown-to-face junction point 4800 is adjacent to a face perimeter point in the face toe transition region 4217 having a face toe transition region elevation that is less than the highest face toe transition region elevation, such as the embodiment of FIG. 149. In still a further embodiment the toe-side crown-to-face junction point 4800 is adjacent to a face perimeter point in the face toe transition region 4217 having the lowest face toe transition region elevation.

Similarly, with reference again to FIGS. 107 and 126, in the installed position the face heel transition region 4218 has a highest face heel transition region elevation, measured vertically from the ground plane 317, and a lowest face heel transition region elevation, also measured vertically from the ground plane 317. In one embodiment the heel-side crown-to-face junction point 4700 is adjacent to a face perimeter point in the face heel transition region 4218 having the highest face heel transition region elevation, such as the embodiment of FIG. 126. However, in another embodiment the heel-side crown-to-face junction point 4700 has a heel-side junction point elevation and the toe-side crown-to-face junction point 4800 has a toe-side junction point elevation, measured vertically from the ground plane 317. In one embodiment the toe-side junction point elevation is at least 10% greater than the heel-side junction point elevation, and at least 15%, 20%, 25%, or 30% in further embodiments. However, in another embodiment the toe-side junction point elevation is less than 120% greater than the heel-side junction point elevation, and less than 110%, 100%, 90%, 80%, or 70% in further embodiments.

In one embodiment the heel-side crown-to-face junction point 4700 has a heel-side junction point elevation is greater than the highest face heel transition region elevation, as seen in FIGS. 149 and 150; and in a further embodiment the elevation differential between the two elevations is no more than 12 mm, and no more than 10 mm, 8 mm, 6 mm, or 4 mm in additional embodiments. However, in another embodiment the heel-side crown-to-face junction point 4700 is adjacent to a face perimeter point in the face heel transition region 4218 having a face heel transition region elevation that is less than the highest face heel transition region elevation. In still a further embodiment the heel-side crown-to-face junction point 4700 is adjacent to a face perimeter point in the face heel transition region 4218 having the lowest face heel transition region elevation. As seen in FIG. 149, the location of the heel-side crown-to-face junction point 4700 can be defined by a heel-side crown-to-face junction horizontal offset distance measured from the vertical center face plane VCFP, which in one embodiment is at least 40 mm, and is at least 42 mm, 44 mm, or 46 mm in further embodiments. In another embodiment the heel-side crown-to-face junction horizontal offset distance is no more than 70 mm, and no more than 66 mm, 62 mm, 60 mm, 58 mm, 56 mm, or 54 mm in additional embodiments. Similarly, as seen in FIG. 149, the vertical location of the heel-side crown-to-face junction point 4700 can be defined by a heel-side crown-to-face junction vertical offset distance measured from vertically from the elevation of center face 205. In one embodiment the heel-side crown-to-face junction vertical offset distance is less than 16 mm above center face 205, and less than 14 mm, 12 mm, 10 mm, 8 mm, or 6 mm in further embodiments. In one embodiment, as is apparent from FIG. 149, an edge of the crown 4620, namely a portion of the crown-hosel perimeter edge portion 4632, extends vertically, plus or minus 5 degrees, from the heel-side crown-to-face junction point 4700 to an intersection with the vertical forward hosel plane 3252 seen in FIG. 121. However in another embodiment, as is apparent from FIG. 137, an edge of the crown 4620, namely a portion of the crown-hosel perimeter edge portion 4632, extends upward from the heel-side crown-to-face junction point 4700 to the vertical forward hosel plane 3252 with a curved edge, which in the illustrated embodiment is concave toward center face 205; and in one embodiment the curved edge has a radius of curvature less than 25 mm, and in further embodiments less than 20 mm, 17.5 mm, 15 mm, or 12.5 mm.

Now again referring to the front elevation coordinate system illustrated in FIG. 126, and the prior disclosure that the face support ledge wall 4690 may be formed of multiple materials around the perimeter of the face plate 4610. One such embodiment has a first ledge wall region formed of a first ledge wall material having a first ledge wall material density, and a second ledge wall region formed of a second ledge wall material having a second ledge wall material density greater than the first ledge wall material density. FIG. 159 illustrates one such embodiment having a first ledge wall region 4710 and a second ledge wall region 4720. In a further embodiment the second ledge wall material density is at least 25% greater than the first ledge wall material density, and in further embodiments is at least 50%, 75%, 100%, 125%, 150%, 175%, 200%, 225%, 250%, or 275% greater. In a further embodiment the first ledge wall material density is less than 5 g/cc, while in another embodiment it is less than 3 g/cc, and in an even further embodiment it is less than 2 g/cc. The second ledge wall material density is at least 4 g/cc in one embodiment, at least 7 g/cc in another embodiment, and at least 10 g/cc in still a further embodiment.

As seen in FIG. 128 the following disclosure is applicable to all face support ledge wall 4690 embodiments, whether a single continuous face support ledge wall 4690, a face support ledge wall 4690 composed of multiple distinct sections separated from one another but formed of the same material, or a face support ledge wall 4690 with multiple distinct sections, whether separated or not, and formed of different materials. A ledge wall 4690 has a ledge wall average thickness 4699 from the ledge wall interior perimeter edge 4695 to the beginning of the fillet transitioning to the insert recess wall 4692. One embodiment has a first ledge wall having a first ledge wall average thickness 4699 from the ledge wall interior perimeter edge 4695 to the beginning of the fillet transitioning to the insert recess wall 4692, and similarly a second ledge wall having a second ledge wall average thickness 4699 from the ledge wall interior perimeter edge 4695 to the beginning of the fillet transitioning to the insert recess wall 4692. In one embodiment the second ledge wall average thickness is less than the first ledge wall average thickness; while in another embodiment the second ledge wall average thickness is at least 10% less than the first ledge wall average thickness; and in further embodiments it is at least 15% less, 20% less, 25% less, 30% less, or 35% less. In another series of embodiments the second ledge wall average thickness is 40-80% of the first ledge wall average thickness, and is 45-75%, 50-70%, or 55-65% in further embodiments. In one specific embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 1.1 mm and the second ledge wall average thickness is no more than 1.0 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 1.15 mm and the second ledge wall average thickness is no more than 0.95 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 1.20 mm and the second ledge wall average thickness is no more than 0.90 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 1.25 mm and the second ledge wall average thickness is no more than 0.85 mm. In one specific embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 0.875 mm and the second ledge wall average thickness is no more than 0.86 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 0.90 mm and the second ledge wall average thickness is no more than 0.85 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 0.925 mm and the second ledge wall average thickness is no more than 0.84 mm; in another embodiment the ledge wall average thickness and/or the first ledge wall average thickness is at least 0.95 mm and the second ledge wall average thickness is no more than 0.83 mm.

With reference again to the front elevation view coordinate system illustrated in FIG. 126, in one embodiment the first ledge wall region 4710 of FIG. 159 encompasses at least 90 degrees around the perimeter of the face plate 4610; while in further embodiments it encompasses at least 145 degrees, 180 degrees, 190 degrees, 200 degrees, 210 degrees, 220 degrees, 230 degrees, 240 degrees, 250 degrees, 260 degrees, 270 degrees, or 280 degrees. In one embodiment the first ledge wall region 4710 encompasses the entire top perimeter located from the 90 degree line to the 270 degree line. In a further embodiment the first ledge wall region 4710 encompasses at least 10 degrees around the perimeter of the face plate 4610 in the region between the 225 degree line and the 270 degree line, while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, 30 degrees, or 35 degrees. In yet another embodiment the first ledge wall region 4710 encompasses at least 10 degrees around the perimeter of the face plate 4610 in the region between the 135 degree line and the 90 degree line, while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, 30 degrees, or 35 degrees. In still another embodiment the first ledge wall region 4710 encompasses no more than 350 degrees around the perimeter of the face plate 4610; while in further embodiments it encompasses no more than 340 degrees, 330 degrees, 320 degrees, 310 degrees, 300 degrees, 290 degrees, 280 degrees, 270 degrees, or 260 degrees. While in the illustrated embodiment the first ledge wall region 4710 is continuous, in some embodiments it is discontinuous and formed of distinct sections with together total the ranges mentioned above. In fact one such embodiment includes at least 2 distinct sections of the first ledge wall region 4710, while further embodiments include at least 3 distinct sections, at least 4 distinct sections, or at least 5 distinct sections.

Similarly, with continued reference to the front elevation view coordinate system illustrated in FIG. 126, in one embodiment the second ledge wall region 4720 of FIG. 159 encompasses at least 10 degrees around the perimeter of the face plate 4610; while in further embodiments it encompasses at least 20 degrees, 30 degrees, 40 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees, or 100 degrees. In one embodiment the second ledge wall region 4720 encompasses at least 10 degrees around the perimeter of the face plate 4610 in the region between the 180 degree line and the 90 degree line, while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, or 50 degrees. In yet another embodiment the second ledge wall region 4720 encompasses at least 10 degrees around the perimeter of the face plate 4610 in the region between the 180 degree line and the 270 degree line, while in further embodiments the 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, 30 degrees, or 35 degrees. In still another embodiment at least a portion of the second ledge wall region 4720 is located above Zup, while in a further embodiment at least a portion of the second ledge wall region 4720 is located above center face 205. In one embodiment the second ledge wall region 4720 encompasses at least 5 degrees around the perimeter of the face plate 4610 in the region between the 270 degree line and the 0 degree line, while in further embodiments the 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, or 45 degrees. In another embodiment the second ledge wall region 4720 encompasses at least 5 degrees around the perimeter of the face plate 4610 in the region between the 0 degree line and the 90 degree line, while in further embodiments the 5 degree range is expanded to 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, or 45 degrees. In still another embodiment the second ledge wall region 4720 encompasses no more than 180 degrees around the perimeter of the face plate 4610; while in further embodiments it encompasses no more than 170 degrees, 160 degrees, 150 degrees, 140 degrees, 130 degrees, 120 degrees, 110 degrees, 100 degrees, 90 degrees, or 80 degrees. While in the illustrated embodiment of FIG. 159 the second ledge wall region 4720 is continuous, in some embodiments it is discontinuous and formed of distinct sections with together total the ranges mentioned above. In fact one such embodiment includes at least 2 distinct sections of the second ledge wall region 4720, while further embodiments include at least 3 distinct sections, at least 4 distinct sections, or at least 5 distinct sections. The second ledge wall region 4720 may be formed as a portion of a forward insert that also forms a portion of the sole, as described in detail in U.S. patent application Ser. No. 17/560,054, which is incorporated by reference herein in its entirety.

The crown can also extend close to and/or into the hosel portion of the body 4602 as well. As shown in FIGS. 115 and 118, a front-heel portion of the crown 4628 can extend into and around the hosel portion of the body 4602, with a forward edge wrapping over the front side of the hosel adjacent to a heel end of the face plate 4610. As shown in FIG. 132, the body can include a recessed surface 4682 that cuts into the hosel portion to receive the front-heel portion of the crown 4628.

With reference now to FIG. 132, the recessed surface 4682 can include a heel-side stepped down wall 4689 that extends around a portion of the hosel portion 4604 and down around the heel side of the face receiving portions of the forward body portion 4602, where the heel-side stepped down wall 4689 transitions into the insert recess wall 4692, that may be bonded to the side surfaces of the face plate 4610. The heel-side stepped down wall 4689 has a heel-side stepped down wall length 4697, as seen in FIG. 132. As seen in FIG. 131, the front-toe side of the body, the ledge 4688, also referred to as the toe-side stepped down wall 4688, can similarly wrap around all the way to the insert wall recess 4692 such that the front-toe part of the crown wraps down to the toe end of the face plate. The toe-side stepped down wall 4688 has a toe-side stepped down wall length 4698, as seen in FIG. 131. Referring again to FIG. 132, the point at which the heel-side stepped down wall 4689 intersects the insert recess wall 4692 is the heel-side crown-to-face junction point 4700. Referring again to FIG. 131, the point at which the toe-side stepped down wall 4688 intersects the insert recess wall 4692 is the toe-side crown-to-face junction point 4800. The location of the heel-side crown-to-face junction point 4700 and the toe-side crown-to-face junction point 4800, as well as all the associated relationships with the stepped down walls, their lengths, and those of the insert recess wall 4692, significantly influence the performance and durability of the club head.

The topline can therefore extend along the entire top edge of the face plate 4610 from adjacent the heel-side stepped down wall 4689 at the heel end to adjacent the toe-side stepped down wall 4688 at the toe end. As seen in FIG. 131, wall 4638, also referred to as intermediary stepped down wall 4638, joins the heel-side stepped down wall 4689 to the toe-side stepped down wall 4688. The illustrated embodiment demonstrates the importance of the bond gap promoting features, or BGPFs, to ensure the crown leading edge 4625 is not only proud of the adjacent portion of the face plate 4610 at the toe-side crown-to-face junction point 4800 of FIG. 131, but also to ensure the crown perimeter edge 4631, seen in FIGS. 119, 121, and 158, is also proud of the adjacent portion of the forward body portion 4602 at the toe-side crown-to-face junction point 4800 of FIG. 131. Thus, all the proud relationships associated with the crown leading edge 4625 also apply to the crown perimeter edge 4631 with respect to the adjacent portions of the forward body portion 4602 and/or rear ring portion 4630, including the intermediary stepped down wall 4638, which includes the curvature of the crown 4620 adjacent to the crown perimeter edge 4631. However, analysis of the curvature of the crown 4620 adjacent to the crown perimeter edge 4631 is performed with respect to a vertical head perimeter edge plane 4998 and an offset vertical head perimeter edge plane 4997, seen in FIGS. 114 and 157, wherein the offset vertical head perimeter edge plane 4997 is parallel to the vertical head perimeter edge plane 4998 but offset a vertical head perimeter offset plane distance toward the center of gravity of the club head. With reference not to FIG. 121, the vertical head perimeter edge plane 4998 is tangent to any analysis point located on the perimeter of the club head. For example, if the analysis point is located where the 270 degree line intersects the club head perimeter, then the vertical head perimeter edge plane 4998 would be approximately parallel to the y-axis, and thus the 0 degree line; whereas if the analysis point is located at the intersection of a 315 degree line and the club head perimeter, then the vertical head perimeter edge plane 4998 would be approximately parallel to 225 degree line. Then, for any analysis point the evaluation section is cut along a vertical evaluation plane that is perpendicular to the vertical head perimeter edge plane 4998, and the crown curvature is evaluated in the vertical evaluation plane between the analysis point and the offset vertical head perimeter edge plane 4997. Now, with this defined, one skilled in the art will appreciate that all embodiments regarding the crown curvature adjacent the face plate 4610 are applicable to the crown curvature between the vertical head perimeter edge plane 4998 and the offset vertical head perimeter edge plane 4997, including the disclosed 3-point method, the 5-point method, and the associated radius of curvatures.

This is particularly delicate at the heel-side crown-to-face junction point 4700, seen in FIG. 132, whereby in one embodiment the crown-hosel perimeter edge portion 4632, seen in FIGS. 137, 155, and 158, is flush with the adjacent forward body portion 4602 at the heel-side stepped down wall 4689, yet the crown leading edge 4625 is still proud of the face plate 4610, thereby ensuring the top edge of the face plate 4610 is obscured from a golfer's view at address while also ensuring the crown-hosel perimeter edge portion 4632 is not clearly projecting from the adjacent forward body portion 4602 as it extends upward from the heel-side crown-to-face junction point 4700, illustrating the importance of the heel-side stepped down wall length 4697 and its relationship with the bond gap promoting features, the insert recess wall length 4693, and the thickness of the crown 4620 and face plate 4610, as well as the curvature of the front body portion 4602. In fact this is further complicated in embodiments in which the crown perimeter edge 4631 is also proud of the toe-side stepped down wall 4688 and/or the intermediary stepped down wall 4638. In one embodiment the heel-side stepped down wall length 4697 is greater than the toe-side stepped down wall length 4698.

In one embodiment seen in FIGS. 133 and 134, the insert recess wall length 4693 is not constant throughout the entire perimeter of the face insert 110. As seen in the embodiment of FIGS. 126, 131, and 133, at the toe-side crown-to-face junction point 4800 the insert recess wall length 4693 changes by an amount equal to the toe-side stepped down wall length 4698. Thus, utilizing the front elevation coordinate system illustrated in FIG. 126 and centered at center face 205, with zero degrees vertically upward, 90 degrees horizontally to the heel, 180 degrees vertically downward, and 270 degrees horizontally to the toe, in one embodiment a change in the insert recess wall length 4693 occurs in the quadrant between 270 degrees and zero degrees, while in a further embodiment the change occurs a location in the region of 280-315 degrees, and in additional embodiments the change occurs a location in the region of 285-305 degrees, or 290-300 degrees. In a further embodiment, seen in FIGS. 132 and 134, and ignoring the internal hosel surface 3253 for the moment, at the heel-side crown-to-face junction point 4700 the insert recess wall length 4693 changes by an amount equal to the heel-side stepped down wall length 4697, and thus, with reference again to the front elevation coordinate system illustrated in FIG. 126, a change in the insert recess wall length 4693 occurs in the quadrant between zero degrees and 90 degrees, and in a further embodiment between 45 degrees and 90 degrees, while in another embodiment between 60 degrees and 85 degrees, and between 70 degrees and 85 degrees in still another embodiment.

While in a further embodiment, seen in FIGS. 132 and 134, a portion of the internal hosel surface 3253 extends beyond a portion of the face support ledge wall 4690, but does not extend beyond the recess wall leading edge 6100 and/or the forwardmost point of the insert recess wall 4692 adjacent the internal hosel surface 3253 extending beyond a portion of the face support ledge wall 4690. In one embodiment the curved nature of this portion of the internal hosel surface 3253 creates a varying insert recess wall length 4693, as seen best in FIGS. 132 and 134. Thus, in one embodiment, and again referring to the front elevation coordinate system illustrated in FIG. 126, the insert recess wall length 4693 is not constant at a location in the region of 45-135 degrees, while in a further embodiment it is not constant at a location in the region of 60-120 degrees, and in a still further embodiment it is not constant at a location in the region of 70-110 degrees. In another embodiment the insert recess wall length 4693 within any of the disclosed regions varies from a maximum insert recess wall length to a minimum insert recess wall length, and the maximum insert recess wall length is at least 10% greater than the minimum insert recess wall length; while in further embodiments the maximum insert recess wall length is at least 20%, 30%, 40%, or 50% greater than the minimum insert recess wall length. In still further embodiments the maximum insert recess wall length is no more than 150% greater than the minimum insert recess wall length; and in additional embodiments is no more than 140%, 130%, 120%, 110%, 100%, and 90% greater than the minimum insert recess wall length.

While the above paragraph discloses a portion of the internal hosel surface 3253 extending beyond a portion of the face support ledge wall 4690, but not extending beyond the recess wall leading edge 6100, one skilled in the art will appreciate how this applies equally to embodiments in which the face plate 4610 is joined to the front body portion 4602 without the use of a face support ledge wall 4690, for example via a butt weld, or other butt joining methodology, along the insert recess wall 4692. In such embodiments the front body portion 4602 adjacent the face opening has an internal surface adjacent to the insert recess wall 4692, and the internal hosel surface 3253 extends beyond the adjacent internal surface (i.e. between an internal edge of the insert recess wall 4692 and an external edge of the insert recess wall 4692), but obviously does not extend beyond the forwardmost edge of the insert recess wall 4692. Thus all the notch disclosure is equally applicable to metallic face plates 4610 and their perimeter to accommodate the internal hosel surface 3253 extending into the region between the internal edge of the insert recess wall 4692 and the external edge of the insert recess wall 4692, and achieve all the disclosed benefits.

Now looking specifically at the change in the insert recess wall length 4693 occurring at the toe-side crown-to-face junction point 4800 of FIGS. 126, 131, and 133, in one embodiment the minimum insert recess wall length is at least 5% less than the maximum insert recess wall length, and in further embodiments the minimum insert recess wall length is at least 10%, 15%, 20%, or 25% less than the maximum insert recess wall length. While in a further series of embodiments the minimum insert recess wall length is 5-75% less than the maximum insert recess wall length, and in further embodiments the minimum insert recess wall length is 10-65%, 15-60%, or 20-55% less than the maximum insert recess wall length. In one embodiment the insert recess wall length 4693 is at least 2 mm, while in further embodiments it is at least 2.5 mm or 3.0 mm; and in a further embodiment the insert recess wall length 4693 is no more than 5.0 mm, and no more than 4.75 mm, 4.5 mm, 4.25 mm, or 4.0 mm in further embodiments.

At the bottom of the club head 4600, in some embodiments a sole insert 4640 is bonded to a sole support ledge 4690, seen in FIG. 125, of the body, with forward aspects of the sole support ledge 4690 being part of the front body portion 4602 and rear and lateral aspects of the sole support ledge 4690 being part of the rear ring portion 4630. The sole insert 4640 can comprise any of the nonmetallic low density composite materials disclosed herein, like the crown, to reduce mass.

While many of the disclosed embodiments relate to interfaces associated with a crown 4620 bonded to the frame and wrapping toward the face plate 4610, all of the disclosed relationships apply equally to one, or more, sole panels 4640 wrapping toward the face plate 4610, skirt panels wrapping toward the face plate 4610 at the heel and/or toe, and/or the rear ring portion 4630 wrapping toward the face plate 4610. For instance, FIG. 146 illustrates a sole insert 4640 that wraps around the front body portion 4602 to terminate adjacent the face plate 4610 at the toe side of the club head. In this embodiment the previously discussed the toe-side crown-to-face junction point 4800 is illustrated, but now there is also a first sole-to-face junction point 4910 and a second sole-to-face junction point 4920. In this embodiment the first sole-to-face junction point 4910 occurs where the sole insert 4640 is adjacent to the face plate 4610 and the front body portion 4602. Similarly, in this embodiment the second sole-to-face junction point 4920 occurs where the sole insert 4640 is adjacent to the face plate 4610 and the front body portion 4602. While in FIGS. 146 and 147 the sole insert 4640 only wraps around to be adjacent the face plate 4610 in the region between about 285 degrees and 260 degrees, referencing the front elevation coordinate system illustrated in FIG. 126, the region may be much greater, as seen in FIG. 145 where the second sole-to-face junction point 4920 is located between 180 degrees and 90 degrees. Further, in one embodiment the second sole-to-face junction point 4920 may be adjacent the heel-side crown-to-face junction point 4700. Likewise, while the embodiment of FIGS. 146 and 147 has a portion of the front body portion 4602 exposed between the crown 4620 and the sole insert 4640, and more specifically between the toe-side crown-to-face junction point 4800 and the first sole-to-face junction point 4910, this is not required and in one embodiment the first sole-to-face junction point 4910 is adjacent to the toe-side crown-to-face junction point 4800 without any exposed portion of the front body portion 4602, as seen in FIG. 142. Additionally, the sole insert 4640 may wrap around to be adjacent the face plate 4610 in multiple distinct regions, as seen in the shaded regions of FIGS. 142, 143, and 144. Thus, as seen in FIG. 142, the sole insert 4640 may additionally have a third sole-to-face junction point 4930 and a fourth sole-to-face junction point 4940.

A portion of sole insert 4640 is adjacent to the face plate 4610 at an elevation above center face 205, in one embodiment, while in another embodiment a portion of sole insert 4640 is adjacent to the face plate 4610 at an elevation both above center face 205 and below center face 205. Further, in another embodiment a portion of sole insert 4640 is adjacent to the face plate 4610 at an elevation above Zup, while in another embodiment a portion of sole insert 4640 is adjacent to the face plate 4610 at an elevation both above Zup and below Zup.

Further, using the front elevation view coordinate system illustrated in FIG. 126, in one embodiment the sole insert 4640 curves around the front body portion 4602 to be adjacent the perimeter of the face plate 4610 throughout any continuous 10 degree range, and in further embodiments any 20 degree range, 30 degree range, 40 degree range, 50 degree range, 60 degree range, 70 degree range, 80 degree range, 90 degree range, 100 degree range, or 110 degree range. In one embodiment the sole insert 4640 curves around the front body portion 4602 to be adjacent the perimeter of the face plate 4610 through any continuous 10 degree range located between the 285 degree line and the 180 degree line, while in further embodiments this 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees, while in further embodiments the range is located between the 285 degree line and the 225 degree line. In another embodiment the sole insert 4640 curves around the front body portion 4602 to be adjacent the perimeter of the face plate 4610 through any continuous 10 degree range located between the 90 degree line and the 180 degree line, while in further embodiments this 10 degree range is expanded to 15 degrees, 20 degrees, 25 degrees, or 30 degrees, while in further embodiments the range is located between the 90 degree line and the 135 degree line. In a further embodiment the sole insert 4640 curves around the front body portion 4602 to be adjacent the perimeter of the face plate 4610 throughout a continuous range of no more than 145 degrees, and in further embodiments no more than 135 degrees, 125 degrees, 115 degrees, 105 degrees, 95 degrees, 85 degrees, 75 degrees, 65 degrees, 55 degrees, 45 degrees, 35 degrees, or 25 degrees.

One skilled in the art will recognize that all the disclosed relationships associated with the crown 4620 apply equally to the sole insert 4640, as well as individual toe skirt inserts and/or heel skirt inserts, including, but not limited to, the interface with the toe-side stepped down wall 4688, the heel-side stepped down wall 4689, the intermediary stepped down wall 4638, the rear ring portion 4630, the face plate 4610, the insert recess wall length 4693, the heel-side stepped down wall length 4697, and the toe-side stepped down wall length 4698.

The phrase “adjacent to” or “adjacent the” is used throughout with reference to the proximity of certain components in relation to the perimeter of the face plate 4610, namely an edge of the crown 4620, an edge of the sole insert 4640, and/or the edge of skirt panels. Further, unless stated otherwise, the use of the term face plate is not to be inferred as being limited to a separate face component, or insert, joined to the club head; rather the perimeter of a face plate is applicable to (a) a separate face component joined to the club head and having a distinct perimeter edge after joining as seen in most of the illustrated embodiments, as well as (b) a separate face component bonded flush to the club head and not having a distinct perimeter edge after joining, as well as (c) a separate face component joined to the club head and not having a distinct perimeter edge after joining (such as by welding and brazing) as seen in FIGS. 152-154, as well as (d) unitarily cast or molded forward portions of the club head that include the striking surface. Regardless of these situations, a perimeter edge of the face plate 4610 may be easily identified. For situation (a) the perimeter of the face plate is the distinct perimeter edge left upon joining the face plate to the club head. However, for situation (b) careful sectioning of the club head, or analysis of the design drawings of the individual components, will allow one skilled in the art to identify the perimeter edge of the face plate 4610. For situation (c) when fusion of the face plate 4610 and club head has occurred such as by welding, one skilled in the art will be able to identify a center of the fusion zone 9000, seen in FIG. 154, by sectioning the club head and then the perimeter of the face plate 9020 is established by offsetting the center of fusion perimeter 9010, seen in FIGS. 152 and 154, outward by an offset distance 9099 of 3 mm, or via analysis of the design drawings of the individual components to establish a design component perimeter and offsetting the design component perimeter by an offset distance 9099 of 3 mm; when fusion of the face component and club head does not occur such as by brazing the face inserts are often still of a size similar to those used in fusion joining, and likewise one skilled in the art will be able to identify the center of the joint by sectioning the club head and then the perimeter of the face plate established by offsetting the center of joint perimeter outward by an offset distance 9099 of 3 mm, or via analysis of the design drawings of the individual components to establish a design component perimeter and offsetting the design component perimeter by an offset distance 9099 of 3 mm. For situation (d) involving unitarily cast or molded forward portions of the club head that include the striking surface, the perimeter of the face plate is defined as a series of points at which the striking surface radius becomes less than 127 mm; if the radius is not easily computed within a computer modeling program, three points that are 0.1 mm apart along a line passing through center face 205 can be used as the three points used for determining the striking surface radius, or a 127 mm curvature gauge aligned with face center 205 and rotated through the 360 degress of FIG. 126 can be used to detect the locations of the edge of the face where the curvature drops to 127 mm and the joining of these locations establishes the perimeter of the face plate.

Now with the perimeter of the face plate established, regardless of the construction, multiple different methods may be used to determine whether another component is “adjacent to” or “adjacent the” perimeter of the face plate 4610. A first method is referred to as the simple proximity method whereby a predefined proximity distance is used, which may be thought of as a string having a length, separating a first end and a second end, equal to the predefined proximity distance whereby the first end of the string is placed at a point on the perimeter of the face plate and the string is in contact with the external surface of the club head. Then if the other component or feature (i.e. an edge of the crown 4620, the sole insert 4640, face secondary alignment feature 1404, and/or a skirt insert) is contacted by the second end of the string, the other component is “adjacent to” or “adjacent the” perimeter of the face plate 4610. In one embodiment the predefined proximity distance is 4 mm, while in further embodiments it is 3 mm, 2 mm, 1 mm, or 0.75 mm.

A second method is referred to as the offset plane method. In the offset plane method a loft plane 5000 is established first at a vertical plane passing through face center 205 and perpendicular to the shaft axis plane, referred to as the vertical center face plane, sometimes abbreviated VCFP, and the loft plane 5000 is defined as a plane that is tangent to the face center 205 of the club head, as seen in FIG. 135A. The point at which the loft plane 5000 contacts the face center 205 is referred to as the loft plane origin.

Now, with the loft plane 5000 established and explanation with respect to the vertical center face plane completed, analysis of other vertical sections passing through the face plate 4610 will be explained. Again, this procedure is applicable for any vertical section passing through the face plate 4610 that is perpendicular to a shaft axis plane, which is a vertical plane perpendicular to the ground plane 317 and including the shaft axis SA. For instance, with reference to FIG. 126, the 0-180 degree line is within the center face plane, and corresponds to the z-axis 1206. However, to analyze relationships associated with an offset vertical section located −5 mm toeward from the vertical center face plane, the curvature of the face plate 4610 must be accounted for. Thus the loft plane 5000 is shifted −5 mm toeward along the 90-270 degree line of FIG. 126, which is also the x-axis 1208, and then it is translated toward the rear of the club head, along the y-axis 207 seen in FIGS. 70A-70D, until the loft plane origin contacts the face plate 4610 thereby establishing a −5 mm toeward localized loft plane 5000. This is the location of a −5 mm toeward vertical plane, whereby attributes of a −5 mm toeward vertical section through the club head are determined with respect to the −5 mm toeward localized loft plane 5000, which is then offset by the predetermined offset plane distance to established a −5 mm toeward localized offset loft plane 5100, which is used to evaluate the characteristics of the club head in the −5 mm toeward vertical section. Here the negative sign is used to represent that the location is 5 mm along the x-axis 1208 in the toeward direction, which is the negative direction, while the heelward direction is the positive x-axis 1208 direction. This process of translating the loft plane origin first along the x-axis 1208 to an analysis location, and then rearward along the y-axis 207 until the loft plane origin contacts the face plate 4610, may be repeated to establish a localized loft plane 5000 and a localized offset loft plane 5100 for any analysis location.

For instance, one embodiment evaluates club head characteristics at the following analysis locations: (a) a vertical center face plane including the y-axis and the z-axis and creating a vertical center face section through the club head and having a center face offset loft plane that is parallel to the loft plane and offset an offset plane distance from the loft plane; (b) at least a first heelward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 5 millimeters toward the hosel portion, and creating a 5 mm offset vertical section having a 5 millimeter heelward localized loft plane and a 5 millimeter heelward localized offset loft plane offset the offset plane distance from the 5 millimeter heelward localized loft plane; and (c) at least a first toeward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 5 millimeters away from the hosel portion, and creating a −5 millimeter offset vertical section having a −5 millimeter toeward localized loft plane and a −5 millimeter toeward localized offset loft plane offset the offset plane distance from the −5 millimeter toeward localized loft plane; wherein within the vertical center face section a portion of the crown leading edge is forward of the center face offset loft plane, within the 5 millimeter offset vertical section a portion of the crown leading edge is forward of the 5 millimeter heelward localized offset loft plane, and within the −5 millimeter offset vertical section a portion of the crown leading edge is forward of the −5 millimeter toeward localized offset loft plane. While in a further embodiment the vertical center face section a portion of the crown in front of the center face offset loft plane has a center face crown radius of curvature of less than 15 mm, within the 5 millimeter offset vertical section a portion of the crown in front of the 5 millimeter heelward localized offset loft plane has a 5 millimeter heelward crown radius of curvature of less than 15 mm, and within the −5 millimeter offset vertical section a portion of the crown in front of the −5 millimeter toeward localized offset loft plane has a −5 millimeter toeward crown radius of curvature of less than 15 mm. Another embodiment also evaluates club head characteristics at (a) a second heelward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 10 millimeters toward the hosel portion, and creating a 10 mm offset vertical section having a 10 millimeter heelward localized loft plane and a 10 millimeter heelward localized offset loft plane offset the offset plane distance from the 10 millimeter heelward localized loft plane; and (b) a second toeward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 10 millimeters away from the hosel portion, and creating a −10 millimeter offset vertical section having a −10 millimeter toeward localized loft plane and a −10 millimeter toeward localized offset loft plane offset the offset plane distance from the −10 millimeter toeward localized loft plane; wherein within the 10 millimeter offset vertical section a portion of the crown leading edge is forward of the 10 millimeter heelward localized offset loft plane, and within the −10 millimeter offset vertical section a portion of the crown leading edge is forward of the −10 millimeter toeward localized offset loft plane. In a further embodiment within the 10 millimeter offset vertical section a portion of the crown in front of the 10 millimeter heelward localized offset loft plane has a 10 millimeter heelward crown radius of curvature of less than 15 mm, and within the −10 millimeter offset vertical section a portion of the crown in front of the −10 millimeter toeward localized offset loft plane has a −10 millimeter toeward crown radius of curvature of less than 15 mm. Another embodiment also evaluates club head characteristics at (a) a third heelward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 20 millimeters toward the hosel portion, and creating a 20 mm offset vertical section having a 20 millimeter heelward localized loft plane and a 20 millimeter heelward localized offset loft plane offset the offset plane distance from the 20 millimeter heelward localized loft plane; and (b) a third toeward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 20 millimeters away from the hosel portion, and creating a −20 millimeter offset vertical section having a −20 millimeter toeward localized loft plane and a −20 millimeter toeward localized offset loft plane offset the offset plane distance from the −20 millimeter toeward localized loft plane; within the 20 millimeter offset vertical section a portion of the crown leading edge is forward of the 20 millimeter heelward localized offset loft plane, and within the −20 millimeter offset vertical section a portion of the crown leading edge is forward of the −20 millimeter toeward localized offset loft plane. In a further embodiment within the 20 millimeter offset vertical section a portion of the crown in front of the 20 millimeter heelward localized offset loft plane has a 20 millimeter heelward crown radius of curvature of less than 15 mm, and within the −20 millimeter offset vertical section a portion of the crown in front of the −20 millimeter toeward localized offset loft plane has a −20 millimeter toeward crown radius of curvature of less than 15 mm. Another embodiment also evaluates club head characteristics at (a) a fourth heelward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 30 millimeters toward the hosel portion, and creating a 30 mm offset vertical section having a 30 millimeter heelward localized loft plane and a 30 millimeter heelward localized offset loft plane offset the offset plane distance from the 30 millimeter heelward localized loft plane; and (b) a fourth toeward offset vertical plane parallel to the vertical center face plane and offset along the x-axis a distance of 30 millimeters away from the hosel portion, and creating a −30 millimeter offset vertical section having a −30 millimeter toeward localized loft plane and a −30 millimeter toeward localized offset loft plane offset the offset plane distance from the −30 millimeter toeward localized loft plane; within the 30 millimeter offset vertical section a portion of the crown leading edge is forward of the 30 millimeter heelward localized offset loft plane, and within the −30 millimeter offset vertical section a portion of the crown leading edge is forward of the −30 millimeter toeward localized offset loft plane. While in a further embodiment within the 30 millimeter offset vertical section a portion of the crown in front of the 30 millimeter heelward localized offset loft plane has a 30 millimeter heelward crown radius of curvature of less than 15 mm, and within the −30 millimeter offset vertical section a portion of the crown in front of the −30 millimeter toeward localized offset loft plane has a −30 millimeter toeward crown radius of curvature of less than 15 mm. One skilled in the art will appreciate that this methodology may be applied at any analysis location, and the disclosed relationships are applicable at any one or more of the analysis locations. Therefore, to be explicit the above procedure includes analysis of a −X mm toeward vertical plane, whereby attributes of a −X mm toeward vertical section through the club head are determined with respect to a −X mm toeward localized loft plane 5000, which is then offset by the predetermined offset plane distance to established a −X mm toeward localized offset loft plane 5100, which is used to evaluate the characteristics of the club head in the −X mm toeward vertical section, whereby −X represents any integer number from −1 to −70. Further, the above procedure includes analysis of a +X mm heelward vertical plane, whereby attributes of a +X mm heelward vertical section through the club head are determined with respect to a +X mm heelward localized loft plane 5000, which is then offset by the predetermined offset plane distance to established a +X mm heelward localized offset loft plane 5100, which is used to evaluate the characteristics of the club head in the +X mm heelward vertical section, whereby +X represents any integer number from 1 to 70.

This same procedure may be repeated anywhere along the along the 90-270 degree line of FIG. 126, which is also the x-axis 1208, to analyze specific vertical sections to determine if a component (i.e. an edge of the crown, sole, and/or skit) is “adjacent to” or “adjacent the” perimeter of the face plate 4610 through the use of an offset loft plane 5100, seen in FIG. 135 with respect to the vertical center face plane but applicable for any vertical section. Using the vertical center face section as an example, the offset loft plane 5100 is parallel to the loft plane 5000 but offset by a predetermined offset plane distance. For any other vertical sections the offset loft plane 5100 is parallel to the localized loft plane 5000 but offset by the predetermined offset plane distance. Then, when analyzing any vertical section, if a portion of a component (i.e. an edge of the crown 4620, the sole insert 4640, and/or a skirt insert) is located between the offset loft plane 5100 and either the loft plane 5000 or the localized loft plane 5000, then the component, at this particular analysis location, is “adjacent to” or “adjacent the” perimeter of the face plate 4610; further one skilled in the art will recognize that this applies to edges that are vertically above or below the point being analyzed and may include edges that are horizontally adjacent the perimeter of the face plate 4610, as is the case along the toe and/or heel portion of the perimeter. In one embodiment the predetermined offset plane distance is 6 mm, while in further embodiments it is 5 mm, 4 mm, 3 mm, or 2 mm. In another embodiment the predetermined offset plane distance is less than 150% of the peak thickness 4343, and less than 140%, 130%, 120%, 110%, 100%, 90%, 80%, 70%, 60%, or 50% in further embodiments. Unless specifically identified otherwise in the claims, the offset plane method with a predetermined offset plane distance of 6 mm is to be inferred.

As seen in FIGS. 146 and 147, the front body portion 4602 may include a forward ring portion 4950 extending rearward of the forward ledge 4680 and connecting to the rear ring portion 4630. In one embodiment the forward ring portion 4950 extends at least 15 mm behind the loft plane 5000 located at center face 205, while in further embodiment at least 20 mm, 25 mm, or 30 mm. Further, a portion of the forward ring portion 4950 may be exposed and visible after attachment of the crown 4620 and/or sole insert 4640. In the embodiment of FIG. 146, the exposed forward ring portion 4950 has an exposed ring width 4951 that is less than 50% of Zup, and in further embodiments less than 40%, 30%, or 20%. In one embodiment the exposed ring width 4951 is constant and the front body portion 4602 also has an exposed portion having an exposed front body width that matches the exposed ring width 4951 and extends all the way to the perimeter of the face plate 4610. In a further embodiment, also seen in FIG. 146, the rear ring portion 4630 is exposed at the connection to the forward ring portion 4950 and has an exposed rear ring width that is the same as the exposed ring width 4951.

As previously disclosed, in some embodiments the rear ring portion 4630 may be integrally formed with a portion of the front body portion 4602. For example FIG. 159 illustrates an embodiment in which the front body portion 4602 includes a distinct first ledge wall region 4710 and a second ledge wall region 4720. In one embodiment the first ledge wall region 4710 is integrally formed with a portion of the front body portion 4602, including the forward ledge 4680, and may be integrally formed with the rear ring portion 4630, while the second ledge wall region 4720 is part of a separate denser component. However, in another embodiment the rear ring portion 4630 is a separate component but extends all the way to the face plate 4610, on the toe side and/or heel side, and creates a third ledge wall region located between a distinct first ledge wall region 4710 and a second ledge wall region 4720. Thus, in this embodiment the ledge wall region includes at least three components, one forming a ledge wall region to support a portion of the face topline perimeter edge 4215, a second to support a portion of the face lower portion perimeter edge 4216, and a third to support a portion of the face plate 4610 at the toe side and/or heel side of the face plate 4610. As shown in FIG. 116, the sole of the body 4602 can also include a forward channel 4670 that extends into an interior of the body and a recess for inserting a head-shaft fastener 4606. The club head 4600 can also include a front sole weight 4660 that is secured to a receptacle 4662 located on a heelward side of the sole of the body 4602 via a fastener 4664. At the rear of the club head, a rear weight 4650 can be secured to the rear ring portion 4630 via a fastener 4652. The weights 4660 and 4650 can be used to allocated discretionary mass to lower aspects of the club head to adjust the center of gravity, moments of inertia, and other mass properties of the club head.

In the club head 4600, the amount of discretionary mass that can be allocated to the weights 4660, 4650 can be substantially greater than in convention wood-type club heads mainly due to the reduced volume of dense metallic material in the body 4602 and the correspondingly increased size of the crown, and the presence of lower-density components such as the sole portion 4640 and crown 4620, face plate 4610, and/or the rear ring portion 4630. In particular, the mass of the top-front portion of the club head 4600 can be reduced by replacing some of the denser metallic material of the body (e.g., titanium or steel) with lower-density material of the crown (e.g., carbon fiber reinforced polymer composite) in the areas around the topline, the hosel, and the toe and heel skirt areas. The construction of the club head 4600 can provide for a maximized volume of lower density material (e.g., composite material) and/or a minimized volume of higher density material (e.g., metallic material). The club head 4600 can also feature a maximized surface area of lower density material and/or a minimum surface area of higher density material, with the entire visible topline region being composite material and the forward body portion 4602 hidden from view in that area. For example, in a top down view, almost none of the forward body portion 4602 is visible except for a small area around the hosel.

The club head 4600 can be assembled with the face plate 4610 being coupled to the front face opening of the body 4602 prior to the crown 4620, sole panel 4640, and/or skirt panel(s) being coupled to the frame. After the face plate 4610 is seated and bonded to the frame as desired, the crown 4620, sole panel 4640, and/or skirt panel(s) can then be manipulated to create the desired positioning and gapping between a crown leading edge 4625 and the perimeter of the face plate 4610, a front edge of the sole panel 4640 and the perimeter of the face plate 4610, and/or a front edge of a skirt panel(s) and the perimeter of the face plate 4610. The sole panel 4640 and/or skirt panel(s) can be coupled to the body either before or after the face plate 4610 and the crown 4620.

Among the several novel features of the club head 4600, a large nonmetallic crown 4620 that extends to be adjacent to the face plate 4610, and creates at least a portion of the overall club head perimeter, in a top plan view, is one of the most interesting, as well as one of the most challenging to make and incorporate into a real world club head that is durable and performs to the highest standards. Just manufacturing the crown 4620 can be challenging due to its three-dimensional shape that wraps down around the front and side aspects of the club head, and in some embodiments hugs tightly around the hosel portion. This makes tooling for fabricating the crown 4620 difficult. Some even said it cannot be done due to draft issues which are needed to release the crown insert from the tool. For an initial embodiment, careful attention was paid during the design to avoid any undercuts in the crown 4620 design and have zero to positive draft angle to allow for release from the mold (e.g., draft range 0 degrees to 4 degrees). Undercuts were not an issue for the older crown designs that did not wrap at all and certainly did not wrap onto multiple surfaces.

Once the crown 4620, sole panel 4640, and/or skirt panel(s) are fabricated with care, they can be bonded to the rest of the club head. Bonding agents can include epoxy or other adhesives (e.g., DP420 or DP460), as adhesives performs best in shear. During a collision with a ball, the crown 4620 experiences both lateral and vertical forces that overtime can cause the crown 4620 to pop off or become detached from the club head. With a typical crown insert and club head design, the bonding surfaces are situated such that the adhesive is put in shear for lateral forces, but not in shear for any of the vertical forces. Initially, it was feared that extending the crown 4620 and its bonding region closer to the face would negatively impact durability due to crown 4620 pop-off or cracking of the nonmetallic material. Unexpectedly, however, it was found that by extending the bond region and the crown 4620 past a forward portion of the external hosel surface 3251, as seen in FIGS. 114, 117, and 121, and wrapping the bond region and the crown 4620 onto the front of the body adjacent the face plate 4610 produced better-to-similar durability compared to a more typical construction. The additional bond surfaces forward of the external hosel surface 3251 in the crown-to-face transition region provide bond surfaces that are more normal to the impact, which puts the adhesive in shear in a direction that is more normal to the impact, and which better supports or counteracts the extreme vertical forces experienced during impact. The disclosed club head 4600 was found to be more robust in durability than prior designs where the crown does not extend onto the front of the body adjacent the face plate 4610, or even past the external hosel surface 3251.

In the embodiment seen in FIGS. 114, 117, and 121 the forwardmost point on the constant diameter portion of the external hosel surface 3251 defines a vertical forward hosel plane 3252, which is parallel to the shaft axis plane. If a constant diameter portion cannot be identified, then the location at which the shaft, or a shaft sleeve, enters the club head is used, which will have a bore for receiving the shaft, or shaft sleeve, and a bearing surface that abuts an edge of the shaft sleeve, and the forwardmost point on the bearing surface is the external hosel surface 3251, seen in FIG. 117, and establishes the vertical forward hosel plane 3252.

As seen in FIG. 121, in one embodiment a portion of the crown leading edge 4625, adjacent the face plate 4610 and/or face topline perimeter edge 4215 of FIG. 107, is in front of the vertical forward hosel plane 3252, while in a further embodiment a portion of the crown leading edge 4625, adjacent the face plate 4610 and/or face topline perimeter edge 4215, is also behind the vertical forward hosel plane 3252. Now with reference to the front elevation view coordinate system of FIG. 126, in one embodiment the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, between the 45 degree line and the 90 degree line is in front of the vertical forward hosel plane 3252, while a portion of the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, between the 315 degree line and the 270 degree line is behind the vertical forward hosel plane 3252. In another embodiment the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, between the 0 degree line and the 90 degree line is in front of the vertical forward hosel plane 3252, while a portion of the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, between the 315 degree line and the 270 degree line is behind the vertical forward hosel plane 3252. Referring again to FIG. 121, in a further embodiment at least 4 mm of the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, is behind the vertical forward hosel plane 3252, and at least 5 mm, 6 mm, or 7 mm in additional embodiments. In yet another embodiment no more than 20 mm of the crown leading edge 4625 adjacent the face plate 4610, and/or face topline perimeter edge 4215, is behind the vertical forward hosel plane 3252, and no more than 15 mm, 12.5 mm, 10 mm, or 7.5 mm in additional embodiments. In another embodiment a portion of the crown leading edge 4625, and/or face topline perimeter edge 4215, between the 0 degree line and the 90 degree line is at least 1 mm in front of the vertical forward hosel plane 3252, and at least 1.5 mm, 2.0 mm, 2.5 mm, or 3 mm in further embodiments. Further, in another embodiment no portion of the crown leading edge 4625, and/or face topline perimeter edge 4215, between the 0 degree line and the 90 degree line is more than 20 mm in front of the vertical forward hosel plane 3252, and no more than 18 mm, 16 mm, 14 mm, or 13 mm in additional embodiments.

Referring again to FIG. 135, the offset plane method is also useful in analyzing the curvature of a portion of an adjacent component (i.e. the crown 4620, the sole insert 4640, and/or a skirt insert) located in front of any of the offset loft planes 5100, meaning between an offset loft plane 5100 and a loft plane 5000. For simplicity of explanation the curvature of the crown 4620 in front of the center face offset loft plane 5100 of FIG. 135 will be examined first. The curvature of the crown 4620 in front of the offset loft plane 5100 is determined in vertical sections, such as the vertical center face plane, or any vertical plane offset heelward or toeward therefrom. In the region in front of the offset loft plane 5100 the curvature is determined based upon 3 points located on the exterior surface of the crown 4620, spaced 0.5 mm apart, and joined by a constant curvature arc, whereby the radius of curvature of the arc is the radius of curvature of the crown 4620; with this being referred to as the 3-point method. In one embodiment the first of the 3 points is located at the crown leading edge 4625, while in a further embodiment the first of the 3 points is located at an intersection of the offset loft plane 5100 and the exterior surface of the crown 4620. In yet another embodiment the 3-point method is expanded to encompass additional points with one point at the crown leading edge 4625, one point at the intersection of the offset loft plane 5100 and the exterior surface of the crown 4620, and at least 3 additional points evenly spaced on the exterior surface of the crown 4620 between the point at the crown leading edge 4625 and the point at the intersection of the offset loft plane 5100 and the exterior surface of the crown 4620; with this being the 5-point method whereby the 5 points are joined by a best-fit arc, and the radius of curvature of the arc is the radius of curvature of the crown 4620.

In one embodiment the radius of curvature of the crown 4620 in front of the offset loft plane 5100 determined by the 3-point method beginning at the crown leading edge 4625, and has a crown radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, 15 mm, 13 mm, 11 mm, 9 mm, or 7 mm in further embodiments. In another embodiment the radius of curvature of the crown 4620 in front of the offset loft plane 5100 determined by the 3-point method beginning at the intersection of the offset loft plane 5100 and the exterior surface of the crown 4620, and has a crown radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, 15 mm,13 mm, 11 mm, 9 mm, or 7 mm in further embodiments. In yet a further embodiment the radius of curvature of the crown 4620 in front of the offset loft plane 5100 determined by the 5-point method, and has a crown radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, 15 mm, 13 mm, 11 mm, 9 mm, or 7 mm in further embodiments. Again, all of the embodiments disclosed in the prior three sentences reflect the curvature of the crown 4620 in a single vertical section either at the vertical center face plane or an offset plane parallel to the vertical center face plane. Nonetheless, any of these embodiments may further apply to any vertical section passing through the face plate 4610, which is why it is convenient to refer to the front elevation view coordinate system of FIG. 126 to define regions in which any of these embodiments occur. For example in one embodiment any of these relationships is present throughout all vertical sections in a predetermined angle range. In an embodiment the predetermined angle range is at least 5 degrees, while in further embodiments it is at least 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100 degrees. In a further embodiment any of these relationships is present throughout all vertical sections passing through the face topline perimeter edge 4215 of FIG. 107. In the illustrated embodiments the curvature of the forward ledge 4680, seen best in FIG. 136, mimics the forward curvature of the crown 4620 and therefore all of the disclosed relationships also apply to the forward ledge 4680 adjacent to the face plate 4610.

As mentioned above, this curvature analysis is not limited to the crown 4620 and in fact applies equally, as do all of the disclosed relationships, to any component adjacent to the face plate 4610, which includes the sole plate 4640, as well as independent skirt panels and the forward ledge 4680, which will not be repeated entirely for the sake of brevity but is easily understood by one skilled in the art. For example, FIG. 141 illustrates an embodiment having the sole plate 4640 wrapping upward to be adjacent to the face plate 4610, whereby in the illustrated embodiment a sole plate leading edge 4641 becomes the leading edge of the club head. In one embodiment the radius of curvature of the sole plate 4640 in front of the offset loft plane 5100 is determined by the 3-point method beginning at the sole plate leading edge 4641, and has a sole plate radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, or 15 mm in further embodiments. In another embodiment the radius of curvature of the sole plate 4640 in front of the offset loft plane 5100 is determined by the 3-point method beginning at the intersection of the offset loft plane 5100 and the exterior surface of the sole plate 4640, and has a sole plate radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, or 15 mm in further embodiments. In yet a further embodiment the radius of curvature of the sole plate 4640 in front of the offset loft plane 5100 is determined by the 5-point method and has a sole plate radius of curvature of less than 25 mm, and less than 23 mm, 21 mm, 19 mm, 17 mm, or 15 mm in further embodiments. Again, all of the embodiments disclosed in the prior three sentences reflect the curvature of the sole plate 4640 in a single vertical section. Nonetheless, any of these embodiments may further apply to any vertical section passing through the face plate 4610 as disclosed herein with respect to the crown 4620 and various analysis points or locations, which is why it is convenient to refer to the front elevation view coordinate system of FIG. 126 to define regions in which any of these embodiments occur. For example in one embodiment any of these relationships is present throughout all vertical sections in a predetermined angle range. In an embodiment the predetermined angle range is at least 5 degrees, while in further embodiments it is at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, or 200 degrees. In a further embodiment any of these relationships is present throughout all vertical sections passing through the face lower portion perimeter edge 4216 of FIG. 107. As previously disclosed, the sole insert 4640 may wrap around to be adjacent the face plate 4610 in multiple distinct regions, as seen in the shaded regions of FIGS. 142, 143, and 144. One such embodiment includes at least two separate and distinct regions.

Performance of the bonding agents is critical to ensure the face plate 4610, the crown 4620, the sole insert 4640, and/or skirt inserts remain in place and do not pop off during the club head's repeated impacts with a golf ball, which is more difficult than one would think and requires unique relationships to account for different stiffnesses and deflections of the these components, as well as the other components of the club head including the associated support structures and frame, as well as tight curvatures of the components adjacent the face plate 4610. This difficulty is further compounded by the use of multiple materials both in the exposed outer shell components of the crown 4620, the sole insert 4640, and/or the skirt inserts, as well as the underlying support components of the frame. Even further complicating this is the fact that in some embodiments the outer shell components such as the crown 4620, the sole insert 4640, and/or skirt inserts are extremely thin, while the face plate 4610 can be relatively thick; as well as having very different material properties. Additionally, controlling the placement of outer shell components to achieve desirable relationships with respect to the face plate 4610 is not only essential to performance but also to the finished look of the club head. For example, with reference to FIG. 135A, the placement of the crown leading edge 4625 is essential to ensuring the perimeter edge of the face plate 4610 is not visible when a golfer is addressing the ball. Thus, the location of the crown leading edge 4625, along the y-axis 207 seen in FIGS. 70A-70D, relative to the adjacent edge of the face plate 4610 is important, as is the joint spacing along the x-axis 1208 and z-axis 1206. In an embodiment the face plate 4610 is adhered with a face bonding agent, the crown 4620 is adhered with a crown bonding agent, and the sole insert 4640 is adhered with a sole bonding agent. In one embodiment the face bonding agent is different than the crown bonding agent and/or sole bonding agent. In a further embodiment the face bonding agent has an ASTM D3167 floating roller peel test average peeling load and/or maximum peeling load greater than that of the crown bonding agent and/or sole bonding agent, at 24 degrees Celsius. In a further embodiment the face bonding agent average peeling load and/or maximum peeling load is at least 3 N/cm greater than the average peeling load and/or maximum peeling load of the crown bonding agent and/or sole bonding agent; while in a further embodiment it is 4 N/cm greater or 5 N/cm greater, at 24 degrees Celsius.

Bond gap promoting features, abbreviated BGPF for simplicity, as well as their locations, sizes, and relationships to one another are essential to precise positioning of components with respect to one another, ensuring proper distribution and thickness of the bonding agents, and durability. For example, as seen in FIG. 153, one embodiment has a plurality of face-ledge BGPFs 7000 extending from the face support ledge wall 4690. As seen in FIGS. 139, 140, 148, and 150, the forward ledge 4680 may include a plurality of forward ledge BGPFs 7100 extending from the forward ledge 4680, which may include a plurality of face-crown transition BGPFs 7200, seen best in FIG. 148. While the plurality of forward ledge BGPFs 7100 project from the forward ledge 4680, the subset of face-crown transition BGPFs 7200 are distinguished as those having a portion of them adjacent to the face plate 4610, as defined by any of the previously disclosed methods. The rear ring portion 4630 may also have a plurality of rear ring BGPFs 7300 extending from the crown-supporting ledge 4636. Any disclosed relationship with respect to any one of the face-ledge BGPFs 7000, forward ledge BGPFs 7100, face-crown transition BGPFs 7200, and/or rear ring BGPFs 7300, may apply to any of the BGPFs.

Referring now to FIG. 149, one embodiment includes at least 2 face-ledge BGPFs 7000 located at an elevation above center face 205, and at least 2 face-ledge BGPFs 7000 located at an elevation below center face 205. The center of each face-ledge BGPFs 7000, in a x-axis 1208 direction, is located a face-ledge BGPF x-axis offset distance 7010, measured horizontally along x-axis 1208 direction to the vertical center face plane VCFP, which contains the y-axis 207. In one embodiment at least one of the face-ledge BGPFs 7000 located at an elevation above center face 205 and toeward of center face 205 has a first face-ledge BGPF x-axis offset distance 7010 that is greater than a second face-ledge BGPF x-axis offset distance 7010 of at least one of the face-ledge BGPFs 7000 located at an elevation above center face 205 and heelward of center face 205. Similarly, in another embodiment at least one of the face-ledge BGPFs 7000 located at an elevation below center face 205 and toeward of center face 205 has a third face-ledge BGPF x-axis offset distance 7010 that is greater than a fourth face-ledge BGPF x-axis offset distance 7010 of at least one of the face-ledge BGPFs 7000 located at an elevation below center face 205 and heelward of center face 205. In a further embodiment the first face-ledge BGPF x-axis offset distance 7010 is not equal to the third face-ledge BGPF x-axis offset distance 7010, and/or the second face-ledge BGPF x-axis offset distance 7010 is not equal to the fourth face-ledge BGPF x-axis offset distance 7010. In still another embodiment the third face-ledge BGPF x-axis offset distance 7010 is at least 1 mm greater than the first face-ledge BGPF x-axis offset distance 7010, and/or the fourth face-ledge BGPF x-axis offset distance 7010 is at least 1 mm greater than the second face-ledge BGPF x-axis offset distance 7010, while in further embodiments the at least 1 mm distance is at least 2 mm, 3 mm, 4 mm, 5 mm, or 6 mm. Yet another embodiment has only two face-ledge BGPFs 7000 located at an elevation above center face 205, and only two face-ledge BGPFs 7000 located at an elevation below center face 205. In one embodiment having 2 face-ledge BGPFs 7000 located at an elevation above center face 205, the face-ledge BGPFs 7000 are located at least 30 mm apart, measured along the x-axis 1208, and in further embodiments at least 35 mm, 40 mm, 45 mm, or 50 mm. In another embodiment having 2 face-ledge BGPFs 7000 located at an elevation above center face 205, the face-ledge BGPFs 7000 are located no more than 90 mm apart, measured along the x-axis 1208, and in further embodiments no more than 80 mm, 75 mm, 70 mm, or 65 mm.

Similarly, as seen best in FIG. 149, the plurality of face-crown transition BGPFs 7200 includes at least a first face-crown transition BGPF 7200 located toeward of face center 205, and at least a second face-crown transition BGPF 7200 located heelward of face center 205. The center of each face-crown transition BGPF 7200, in a x-axis 1208 direction, is located a face-crown transition BGPF x-axis offset distance 7210, measured horizontally along x-axis 1208 direction to the vertical center face plane VCFP. Thus the first face-crown transition BGPF 7200 has a first face-crown transition BGPF x-axis offset distance 7210, and the second face-crown transition BGPF 7200 has a second face-crown transition BGPF x-axis offset distance 7210. In one embodiment the first face-crown transition BGPF x-axis offset distance 7210 is not equal to the second face-crown transition BGPF x-axis offset distance 7210. In a further embodiment the first face-crown transition BGPF x-axis offset distance 7210 is not equal to the first face-ledge BGPF x-axis offset distance 7010, and/or the second face-crown transition BGPF x-axis offset distance 7210 is not equal to the second face-ledge BGPF x-axis offset distance 7010. In yet another embodiment the absolute value of the difference between the first face-crown transition BGPF x-axis offset distance 7210 and first face-ledge BGPF x-axis offset distance 7010 is at least 1 mm, while in further embodiments at least 2 mm, 3 mm, 4 mm, or 5 mm. Similarly, in another embodiment the absolute value of the difference between the second face-crown transition BGPF x-axis offset distance 7210 and second face-ledge BGPF x-axis offset distance 7010 is at least 1 mm, while in further embodiments at least 2 mm, 3 mm, 4 mm, or 5 mm. In a further embodiment no face-crown transition BGPF 7200 have a face-crown transition BGPF x-axis offset distance 7210 equal to a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located above center face 705, and/or no face-crown transition BGPF 7200 have a face-crown transition BGPF x-axis offset distance 7210 equal to a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located below center face 705. In a further embodiment no face-crown transition BGPF 7200 have a face-crown transition BGPF x-axis offset distance 7210 within plus or minus 2 mm of a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located above center face 705, and/or no face-crown transition BGPF 7200 have a face-crown transition BGPF x-axis offset distance 7210 within plus or minus 2 mm of a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located below center face 705, while in further embodiments the disclosed plus/minus 2 mm range is broadened to 3 mm, 4 mm, 5 mm, or 6 mm. In a further embodiment at least a portion of one of the face-crown transition BGPFs 7200 is located in front of the center face offset loft plane 5100, while in further embodiments at least a portion of 2, 3, or 4 face-crown transition BGPFs 7200 are located in front of the center face offset loft plane 5100. In one embodiment each face-crown transition BGPFs 7200 is located at least 5 mm away from the nearest adjacent face-crown transition BGPFs 7200, measure along the x-axis 1208, and in further embodiments at least 10 mm, 12.5 mm, or 15 mm.

Similarly, as seen best in FIG. 148, the plurality of forward ledge BGPFs 7100 includes at least a first forward ledge BGPF 7100 located toeward of face center 205, and at least a second forward ledge BGPF 7100 located heelward of face center 205. The center of each forward ledge BGPFs 7100, in a x-axis 1208 direction, is located a forward ledge BGPFs x-axis offset distance 7110, measured horizontally along x-axis 1208 direction to the vertical center face plane VCFP. Thus the first forward ledge BGPF 7100 has a first forward ledge BGPF x-axis offset distance 7110, and the second forward ledge BGPF 7100 has a second forward ledge BGPF x-axis offset distance 7110. In one embodiment the first forward ledge BGPF x-axis offset distance 7110 is not equal to the second forward ledge BGPF x-axis offset distance 7110. In a further embodiment the first forward ledge BGPF x-axis offset distance 7210 is not equal to the first face-ledge BGPF x-axis offset distance 7010, and/or the second forward ledge BGPF x-axis offset distance 7210 is not equal to the second face-ledge BGPF x-axis offset distance 7010. In yet another embodiment the absolute value of the difference between the first forward ledge BGPF x-axis offset distance 7110 and first face-ledge BGPF x-axis offset distance 7010 is at least 1 mm, while in further embodiments at least 2 mm, 3 mm, 4 mm, or 5 mm. Similarly, in another embodiment the absolute value of the difference between the second forward ledge BGPF x-axis offset distance 7110 and second face-ledge BGPF x-axis offset distance 7010 is at least 1 mm, while in further embodiments at least 2 mm, 3 mm, 4 mm, or 5 mm. In a further embodiment no forward ledge BGPFs 7100 have a forward ledge BGPF x-axis offset distance 7110 equal to a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located above center face 705, and/or no forward ledge BGPFs 7100 have a forward ledge BGPF x-axis offset distance 7110 equal to a face-ledge BGPF x-axis offset distance 7010 for any face-ledge BGPF 7000 located below center face 705. Another embodiment has at least two forward ledge BGPFs 7100 in close proximity to the shaft axis. An imaginary cylinder having a diameter of 50 mm is positioned on the shaft axis so the center of the cylinder is on the shaft axis, with the cylinder extending parallel to the shaft axis from the ground plane to the highest point on the hosel portion. Then, the location of at least two forward ledge BGPFs 7100 are located within the imaginary cylinder. While in a further embodiment the diameter of the imaginary cylinder is 45 mm, and in further embodiments is 40 mm, 35 mm, 30 mm, or 25 mm.

As seen in FIGS. 128, the forward ledge BGPFs 7100 extend from the adjacent forward ledge 4680 a forward ledge BGPF distance 7120. Likewise, as seen in FIG. 131, the face-ledge BGPFs 7000 extend from the adjacent face support ledge wall 4690 a face-ledge BGPF distance 7020. Similarly, as seen in FIG. 140, the face-crown transition BGPFs 7200 extend from the adjacent forward ledge 4680 a face-crown transition BGPF distance 7220. In one embodiment the forward ledge BGPF distance 7120, and/or the face-crown transition BGPF distance 7220 are at least 0.1 mm, and in further embodiments at least 0.15 mm, 0.20 mm, 0.25 mm, or 0.30 mm. In another embodiment the forward ledge BGPF distance 7120, the face-ledge BGPF distance 7020, and/or the face-crown transition BGPF distance 7220 are no more than 0.6 mm, and in further embodiments no more than 0.5 mm, 0.45 mm, 0.4 mm, or 0.35 mm. In one embodiment the face-ledge BGPF distance 7020 is less than the forward ledge BGPF distance 7120 and/or the face-crown transition BGPF distance 7220. In a further embodiment the forward ledge BGPF distance 7120 is equal to the face-crown transition BGPF distance 7220. In another embodiment the face-ledge BGPF distance 7020 is at least 3% of the insert recess wall length 4693, and in further embodiments at least 4%, 5%, or 6%. In another embodiment the face-ledge BGPF distance 7020 is no more than 10% of the insert recess wall length 4693, and in further embodiments no more than 9%, 8%, or 7%.

The crown 4620 has a crown thickness 4629, seen in FIG. 135A. In one embodiment the portion of the crown 4620 between the offset loft plane 5100 and the crown leading edge 4625 has a crown thickness 4629 is less than 0.95 mm, while in further embodiments it is less than 0.90 mm, 0.85 mm, 0.80 mm, 0.75 mm, 0.70 mm, or 0.65 mm. In another embodiment the portion of the crown 4620 between the offset loft plane 5100 and the crown leading edge 4625 has a crown thickness 4629 is at least 0.35 mm, while in further embodiments it is at least 0.40 mm, 0.45 mm, 0.50 mm, 0.55 mm, 0.60 mm, or 0.65 mm. In another embodiment the crown thickness 4629 is constant between the offset loft plane 5100 and the crown leading edge 4625; while in a further embodiment the crown thickness 4629 is constant between a forward ledge rear edge 4683, seen in FIGS. 135A, and the crown leading edge 4625. As seen in FIG. 135B, the crown leading edge 4625 occurs at the intersection of a crown leading edge sidewall surface and a crown exterior surface, and the crown leading edge sidewall surface extends to a crown interior surface, which is bonded to the forward ledge 4680. In one embodiment the crown leading edge sidewall surface is substantially parallel, meaning plus/minus 5 degrees, to the insert recess wall 4692; while in a further embodiment the length of the crown leading edge sidewall surface is no less than 75% of the crown thickness 4629 over the forward ledge 4680, and no less than 85% or 95% in further embodiments.

In yet another embodiment a portion of the crown 4620 covering the opening 340, seen in FIGS. 83A and 152, extending from the forward ledge rear edge 4683 to an inner edge of the crown-supporting ledge 4636, has a crown thickness 4629 that varies from a minimum opening crown thickness to a maximum opening crown thickness. In one embodiment the minimum opening crown thickness is less than the crown thickness 4629 between the forward ledge rear edge 4683 and the crown leading edge 4625; and/or the maximum opening crown thickness is greater than the crown thickness 4629 between the forward ledge rear edge 4683 and the crown leading edge 4625. In one embodiment the minimum opening crown thickness is at least 5% less than the crown thickness 4629 between the forward ledge rear edge 4683 and the crown leading edge 4625, while in further embodiments it is at least 10%, 15%, or 20% less. In another embodiment the maximum opening crown thickness is at least 5% greater than the crown thickness 4629 between the forward ledge rear edge 4683 and the crown leading edge 4625, while in further embodiments it is at least 10%, 15%, 20%, 25%, 35%, 45%, 55%, 65%, or 75% greater.

One embodiment includes at least one reinforcement rib 8000, seen in FIG. 121, integrally formed with the crown 4620 and/or sole insert 4640, having a rib length 8010, a rib thickness measured in the same direction as the adjacent crown thickness 4629, and a rib width 8020. In one embodiment the rib length 8010 is at least 35% of the face profile length 4212, and in additional embodiments at least 50%, 60%, or 70%. In another embodiment the rib length 8010 is no more than the face profile length 4212, and in additional embodiments no more than 90%, 80%, or 75%. In another embodiment the rib width 8020 is no more than a predetermined % of the maximum forward ledge thickness 4681, the minimum forward ledge thickness 4681, the crown thickness 4629, the maximum crown thickness 4629, the minimum crown thickness 4629, or the ledge wall thickness 4699; wherein in one embodiment the predetermined % is 100%, and in further embodiments it is 90%, 80%, 70%, or 60%. In another embodiment the rib width 8020 is at least a predetermined % of the maximum forward ledge thickness 4681, the minimum forward ledge thickness 4681, the crown thickness 4629, the maximum crown thickness 4629, the minimum crown thickness 4629, or the ledge wall thickness 4699; wherein in one embodiment the predetermined % is 25%, and in further embodiments it is 30%, 35%, 40%, or 45%.

In one embodiment the forward ledge BGPF distance 7120, the face-crown transition BGPF distance 7220, and/or the face-ledge BGPF distance 7020 is no more than a predetermined % of the maximum forward ledge thickness 4681, the minimum forward ledge thickness 4681, the crown thickness 4629, the maximum crown thickness 4629, the minimum crown thickness 4629, or the ledge wall thickness 4699; wherein in one embodiment the predetermined % is 45%, and in further embodiments it is 40%, 35%, 30%, or 25%. In another embodiment the forward ledge BGPF distance 7120, the face-crown transition BGPF distance 7220, and/or the face-ledge BGPF distance 7020 is at least a predetermined % of the maximum forward ledge thickness 4681, the minimum forward ledge thickness 4681, the crown thickness 4629, the maximum crown thickness 4629, the minimum crown thickness 4629, or the ledge wall thickness 4699; wherein in one embodiment the predetermined % is 5%, and in further embodiments it is 10%, 15%, or 20%.

While the face-ledge BGPFs 7000, the forward ledge BGPFs 7100, and the face-crown transition BGPFs 7200 are illustrated as having a round perimeter shape in FIGS. 148-152, and rectangular in the embodiments of FIGS. 139 and 140, they may have any perimeter shape, including, but not limited to, rectangles, stars, triangles, polygons, including, but not limited to, concave polygons, constructible polygons, convex polygons, cyclic polygons, decagons, digons, dodecagons, enneagons, equiangular polygons, equilateral polygons, henagons, hendecagons, heptagons, hexagons, Lemoine hexagons, Tucker hexagons, icosagons, octagons, pentagons, regular polygons, stars, and star polygons; triangles, including, but not limited to, acute triangles, anticomplementary triangles, equilateral triangles, excentral triangles, tritangent triangles, isosceles triangles, medial triangles, auxiliary triangles, obtuse triangles, rational triangles, right triangles, scalene triangles, Reuleaux triangles; parallelograms, including, but not limited to, equilateral parallelograms: rhombuses, rhomboids, and Wittenbaue's parallelograms; Penrose tiles; rectangles; rhombus; squares; trapezium; quadrilaterals, including, but not limited to, cyclic quadrilaterals, tetrachords, chordal tetragons, and Brahmagupt's trapezium; equilic quadrilateral kites; rational quadrilaterals; strombus; tangential quadrilaterals; tangential tetragons; trapezoids; polydrafters; annulus; arbelos; circles; circular sectors; circular segments; crescents; lunes; ovals; Reuleaux polygons; rotors; spheres; semicircles; triquetras; Archimedean spirals; astroids; paracycles; cubocycloids; deltoids; ellipses; smoothed octagons; super ellipses; and tomahawks; polyhedra; prisms; pyramids; and sections thereof, just to name a few.

The size and location of the face-ledge BGPFs 7000, the forward ledge BGPFs 7100, and the face-crown transition BGPFs 7200 are essential for performance and durability. Each BGPF has a BGPF contact area which is the surface area of the BGPF intended to be in contact with the adjoining component, whether it be the crown 4620, the face plate 4610, the sole insert 4640, and/or the skirt panel(s). In one embodiment the BGPF contact area is no more than 10 mm², while in further embodiments it is no more than 7.5 mm², 6.5 mm², 5.5 mm², or 4.5 mm². In a further embodiment the BGPF contact area is at least 1 mm², while in further embodiments it is at least 1.5 mm², 2.0 mm², 2.5 mm², or 3.0 mm².

A total face-ledge BGPF contact area is the sum of the BGPF contact area of each face-ledge BGPFs 7000; likewise, the total face-crown transition BGPF contact area is the sum of the BGPF contact area of each face-crown transition BGPFs 7200. In one embodiment the total face-crown transition BGPF contact area is at least 5% greater than the total face-ledge BGPF contact area, while in further embodiments it is at least 10%, 15%, 20%, or 25% greater. In another embodiment the total face-crown transition BGPF contact area is no more than 250% of the total face-ledge BGPF contact area, while in further embodiments it is no more than 225%, 200%, 175%, or 150%.

The forward ledge 4680 has a forward ledge thickness 4681, seen in FIG. 136, which is located at least 2 mm behind the rearwardmost point on the face support ledge wall 4690. The forward ledge thickness 4681 may vary from a minimum forward ledge thickness to a maximum forward ledge thickness. In one embodiment the maximum forward ledge thickness is at least 1.0 mm, and at least 1.1 mm, 1.2 mm, or 1.3 mm in further embodiments. Further, in one embodiment the minimum forward ledge thickness is no more than 0.9 mm, and no more than 0.85 mm, 0.80 mm, or 0.75 mm in further embodiments. In another embodiment the maximum forward ledge thickness occurs for at least 5 mm toeward and heelward from the center face 205 location, measured in the x-axis 1208 direction; while in further embodiments the 5 mm range is expanded to 7.5 mm, 10 mm, or 12.5 mm. In a further embodiment the minimum forward ledge thickness occurs for at least 5 mm measured in the x-axis 1208 direction, while in a further embodiment the minimum forward ledge thickness occurs both on the heel side and toe side of face center 205, while in still a further embodiment the minimum forward ledge thickness occurs in the region of the forward ledge 4680 aligned above the face plate 4610. Extending at least portions of the crown 4620 in front of the various offset loft planes unexpectedly allowed for a reduction in forward ledge thickness, while maintaining durability, in part due to the strength of the crown and the associated bonding agent; thereby freeing up mass that could be reallocated elsewhere in the head to achieve more desirably mass properties.

As previously discussed, relationships between the various components of the club head are essential to achieve the desired performance and durability. The disclosed relationships account for different stiffnesses and deflections of the components including the associated support structures, as well as tight curvatures of the components adjacent the face plate 4610. This difficulty is further compounded by the use of multiple materials both in the exposed outer shell components, as well as the underlying support components. Now some additional specific embodiments will be discussed to illustrate the complexities associated with components made of varied materials having widely variable material properties, while achieving the needed stiffness to support discretionary mass requited to achieve the desired placement of the center of gravity and moments of inertia, while also accommodating the desired deflection characteristics of the face plate 4610, and distribution of the impact forces, as well as the associated deformation, while ensuring components secured via bonding agents do not pop off of the clubhead; all the foregoing complicated by the proximity of bonded components to the face plate 4610 and their curvatures.

With reference now to FIG. 119, while the front body portion 4602 and the rear ring portion 4630 may be separate and distinct components mechanically joined, adhesively bonded, welded, and/or brazed together, they may also be formed as a single unitary component, as seen in the fairway wood embodiment of FIG. 153. Additionally, the front body portion 4602 may be formed as a unitary body, or may be composed of multiple components joined together such as disclosed in detail in U.S. patent application Ser. No. 17/560,054, which is incorporated by reference herein in its entirety. Regardless, in the illustrated embodiment of FIG. 119 the front body portion 4602 includes the forward ledge 4680 to support and engage a portion of the crown 4620, and forms the face opening for receipt of the face plate 4610. The front body portion 4602 has an internal surface which is exposed to the hollow void created in the finished club head, and an external surface opposite the internal surface; thus, the outer surface of the forward ledge 4680 is part of the outer surface of the front body portion 4602. In one embodiment the crown 4620 completely covers the forward ledge 4680 between the heel-side crown-to-face junction point 4700 and the toe-side crown-to-face junction point 4800.

In one embodiment at least a portion of the front body portion 4602 is formed of a metal alloy having a density of less than 5 g/cc, and in a further embodiment less than 3 g/cc, and in yet a further embodiment less than 2 g/cc. In another embodiment at least a portion of the front body portion 4602 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, and in a further embodiment at least 7 g/cc. Thus, in one embodiment at least a portion of the front body portion 4602 located above the elevation of center face 205 is formed of a metal alloy having a density of less than 5 g/cc, 3 g/cc, or 2 g/cc; while at least a portion of the front body portion 4602 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, 7 g/cc, 9 g/cc, or 11 g/cc. In one embodiment the forward ledge 4680 is formed of a metal alloy having a density that is no more than two times the density of the crown 4620 and/or sole insert 4640.

In one embodiment at least a portion of the front body portion 4602 is formed of nonmetallic material having a density of less than 2 g/cc, and in a further embodiment less than 1.75 g/cc, and in yet a further embodiment less than 1.5 g/cc. In another embodiment at least a portion of the front body portion 4602 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, and in a further embodiment at least 7 g/cc. Thus, in one embodiment at least a portion of the front body portion 4602 located above the elevation of center face 205 is formed of a non-metal material having a density of less than 2 g/cc, 1.75 g/cc, or 1.5 g/cc; while at least a portion of the front body portion 4602 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, 7 g/cc, 9 g/cc, or 11 g/cc.

In one embodiment the rear ring portion 4630 is formed of a metal alloy having a density of less than 5 g/cc, and in a further embodiment less than 3 g/cc, and in yet a further embodiment less than 2 g/cc. In another embodiment at least a portion of the rear ring portion 4630 is formed to also incorporate a metal alloy having a density of at least 5 g/cc, and in a further embodiment at least 7 g/cc, 9 g/cc, 11 g/cc, 13 g/cc, 15 g/cc, or 17 g/cc. Thus, in one embodiment all of the rear ring portion 4630 located above the elevation of center face 205 is formed of a metal alloy having a density of less than 5 g/cc, 3 g/cc, or 2 g/cc; while at least a portion of the rear ring portion 4630 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, 7 g/cc, 9 g/cc, or 11 g/cc.

In one embodiment rear ring portion 4630 is formed of non-metallic material having a density of less than 2 g/cc, and in a further embodiment less than 1.75 g/cc, and in yet a further embodiment less than 1.5 g/cc. In another embodiment at least a portion of the rear ring portion 4630 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, and in a further embodiment at least 7 g/cc, 9 g/cc, 11 g/cc, 13 g/cc, 15 g/cc, or 17 g/cc. Thus, in one embodiment all of the rear ring portion 4630 located above the elevation of center face 205 is formed of a nonmetal material having a density of less than 2 g/cc, 1.75 g/cc, or 1.5 g/cc; while at least a portion of the rear ring portion 4630 located below the elevation of center face 205 is formed of a metal alloy having a density of at least 5 g/cc, 7 g/cc, 9 g/cc, 11 g/cc, 13 g/cc, 15 g/cc, or 17 g/cc.

In one embodiment the crown 4620 is formed of at least 3, 5, or 7 unidirectional prepreg plies with each having a crown unidirectional fiber areal weight and a crown unidirectional prepreg resin content, and in another embodiment the crown unidirectional fiber areal weight of the at least 3 unidirectional prepreg plies is equal. In a further embodiment the face plate 4610 includes at least 3 unidirectional prepreg plies with each having a face unidirectional fiber areal weight equal to the crown unidirectional fiber areal weight of at least one of the crown unidirectional prepreg plies and a face unidirectional prepreg resin content, while in a further embodiment the face unidirectional fiber areal weight of at least 3 unidirectional face plies is equal to the crown unidirectional fiber areal weight of at least three of the crown unidirectional prepreg plies. In another embodiment the crown 4620 includes at least one prepreg layer that is a weave and has a weave layer fiber areal weight that is at least 200% of the crown unidirectional fiber areal weight. In another embodiment the weave layer fiber areal weight is at least 200 gsm, 220 gsm, or 240 gsm; while in another embodiment the crown unidirectional fiber areal weight is no more than 100 gsm, and no more than 70 gsm in a further embodiment. In yet another embodiment the weave layer is a twill weave layer.

In one embodiment the sole insert 4640 is formed of at least 3, 4, 5, 6, or 7 unidirectional prepreg plies with each having a sole unidirectional fiber areal weight and a sole unidirectional prepreg resin content, and in another embodiment the sole unidirectional fiber areal weight of the at least 3 unidirectional prepreg plies is equal. In a further embodiment the sole unidirectional fiber areal weight is greater than the crown unidirectional fiber areal weight and/or the face unidirectional fiber areal weight. In another embodiment the sole unidirectional fiber areal weight is at least 20, 30, or 40 gsm greater than the crown unidirectional fiber areal weight and/or the face unidirectional fiber areal weight. While in another series of embodiments the sole unidirectional fiber areal weight is no more than 70, 60, 50, 40, or 30 gsm greater than the crown unidirectional fiber areal weight and/or the face unidirectional fiber areal weight.

The sole insert 4640 may have X sole unidirectional plies, the crown 4620 may have Y crown unidirectional plies, and the face plate 4610 may have Z face unidirectional plies. In one embodiment X is greater than Y, while in a further embodiment X is at least 2 greater than Y, and in an even further embodiment X is at least 3 greater than Y. In a further embodiment X is no more than 6 greater than Y, and no more than 5 or 4 in further embodiments. Z is at least four times X and/or Y in one embodiment, while in another embodiment Z is at least five, six, or seven times X and/or Y in further embodiments. In another series of embodiments Z is no more than fifteen times X and/or Y, and no more than twelve times, ten times, or eight times in further embodiments.

Further, the resin of the unidirectional prepreg plies is essential to performance and balancing the stiffness and deflection capabilities and durability of the various components of the club head. Thus the resin of the crown unidirectional prepreg plies has a crown resin elongation to break, likewise the sole insert unidirectional prepreg plies has a sole insert resin elongation to break, and the face insert unidirectional prepreg plies has a face insert resin elongation to break. In one embodiment the face insert resin elongation to break is greater than the crown resin elongation to break and/or the sole insert resin elongation to break, while in another embodiment the face insert resin elongation to break is at least 2%, and at least 2.1%, 2.2%, or 2.3% in further embodiments. In another embodiment the crown resin elongation to break and/or the sole insert resin elongation to break is less than 2%, and in further embodiments less than 1.9%, 1.8%, 1.7%, 1.6%, or 1.5%. Further, the resin content of the unidirectional plies is also essential and in one embodiment any of these relationships are achieve while having the face unidirectional prepreg resin content differ from the crown unidirectional prepreg resin content and/or sole unidirectional prepreg resin content by less than a predetermined resin content variation. In one embodiment the predetermined resin content variation is 4%, and in further embodiments it is 3%, 2.5%, 2%, 1.5%, or 1%. Similarly, in another embodiment the crown unidirectional prepreg resin content and sole unidirectional prepreg resin content vary from each other by less than the predetermined resin content variation. The disclosed resin content is the pre-cured resin content of the indicated unidirectional prepreg play. The overall components also have a final cured resin content, specifically a cured face resin content, a cured crown resin content, and/or a cured sole resin content. In one embodiment the cured face resin content is less than the cured crown resin content, and/or the cured sole resin content, while in a further embodiment either, or both, the cured crown resin content and/or the cured sole resin content is 40% or greater, while in a further embodiment the cured face resin content is 39.5% or less. In another embodiment the cured face resin content is at least 36%, and at least 37% or 38% in further embodiments.

Returning now to the embodiments, such as those seen in FIGS. 151-156, having a face plate 4610 that is welded, or brazed in place, with or without a face support ledge wall 4690, seen in FIG. 128, in such embodiments the forward ledge 4680 has a forward sidewall 4685, seen in FIG. 153, with a sidewall height 4686, seen in FIG. 154. Further, in these embodiments the face plate 4610 has a perimeter thickness 9030 at the perimeter of the face plate 9020. The forward sidewall 4685 may be cast with the forward ledge 4680, milled into the forward ledge 4680, or molded with the forward ledge 4680. In one embodiment the sidewall height 4686 is at least 25% of the perimeter thickness 9030, and in further embodiments is at least 30%, 35%, 40%, or 45%. In another series of embodiments the sidewall height 4686 is no more than 85%, 80%, 75%, 70%, or 65% of the perimeter thickness 9030. In a further embodiment the sidewall height 4686 is equal to, or greater than, the forward ledge thickness 4681 of a portion of the forward ledge 4680 located in front of the shaft axis plane and/or the offset loft plane 5100. In further embodiments the sidewall height 4686 is at least 5%, 10%, or 15% greater than the forward ledge thickness 4681 of a portion of the forward ledge 4680 located in front of the shaft axis plane and/or the offset loft plane 5100.

In one embodiment, with reference again to FIGS. 128, 135, and 136, the insert recess wall 4692 has a recess wall leading edge 6100, abbreviated RWLE. Any of the relationships disclosed with respect to the simple proximity method and the offset plane method regarding whether another component is “adjacent to” or “adjacent the” perimeter of the face plate 4610, and/or in defining attributes of those components and their relationships, apply equally to a third method, referred to as the RWLE zone method, based upon the recess wall leading edge 6100. In this method, when analyzing any vertical section parallel to the vertical center face plan VCFP, an offset loft plane 5100 is positioned to contact the recess wall leading edge 6100, as seen in FIG. 136, and referred to as the RWLE contact loft plane. The RWLE contact loft plane is then rotated about the recess wall leading edge 6100 through a RWLE angle 6010 to establish a RWLE plane 6200, as seen in FIG. 136, with the intersection of a surface of any component with the RWLE plane 6200 establishing a RWLE plane intersection 6300, illustrated one the forward ledge 4680 in FIG. 136, but easily understood with respect to the crown 4620 in FIG. 135. This process is repeated in vertical sections offset at 1 mm increments from the vertical center face plane VFCP across the entire face topline perimeter edge 4215, with the portion of the club head located in front of the RWLE planes 6200, which is the same as the portion in front of the RWLE plane intersections 6300, defining the analysis region 6000 seen in FIGS. 126, 139, and 140, which has a analysis region leading edge 6100 and an analysis region trailing edge 6110, which corresponds to the RWLE plane intersections 6300. In one embodiment any component is “adjacent to” or “adjacent the” perimeter of the face plate 4610 if it is within the analysis region 6000; and again all the disclosed relationships mentioned with respect to the simple proximity method and/or the offset plane method apply equally to the RWLE zone method. In one embodiment the RWLE angle 6010 is 40 degrees, while in further embodiments it is 35, 30, 25, or 20 degrees.

Referring again to FIG. 135A, the offset plane method is also useful in analyzing the roughness of an adjacent component (i.e. the crown 4620, the sole insert 4640, and/or the skirt insert) located in front of the offset loft plane 5100, meaning between the offset loft plane 5100 and the loft plane 5000. For simplicity of explanation the crown 4620 in front of the offset loft plane 5100 will be discussed, but the relationships apply to any of the other components. The crown 4620 in front of the offset loft plane 5100 is determined in vertical sections, such as the vertical center face plane, or any vertical plane offset therefrom, and has a forward crown surface roughness. Similarly the face plate 4610 has a face surface roughness.

Surface textures or roughness can be conveniently characterized based a surface profile, i.e., a surface height as a function of position on the surface. A surface profile is typically obtained by interrogating a sample surface with a stylus that is translated across the surface. Deviations of the stylus as a function of position are recorded to produce the surface profile. In other examples, a surface profile can be obtained based on other contact or non-contact measurements such as with optical measurements. Surface profiles obtained in this way are often referred to as “raw” profiles. Alternatively, surface profiles for a golf club striking surface can be functionally assessed based on shot characteristics produced when struck with surfaces under wet conditions.

For convenience, a control layer is defined as a striking face configured so that shots are consistent under wet and dry playing conditions. Generally, satisfactory roughened or textured striking surfaces (or other control surfaces) provide ball spins of at least about 2000 rpm, 2500 rpm, 3000 rpm, or 3500 rpm under wet conditions when struck with club head speeds of between about 75 mph and 120 mph. Such control surfaces thus provide shot characteristics that are substantially the same as those obtained with conventional metal woods. Stylus or other measurement based surface roughness characterizations for such control surfaces are described in detail below.

A surface profile is generally processed to remove gradual deviations of the surface from flatness. For example, a wood-type golf club striking face generally has slight curvatures from toe-to-heel and crown-to-sole to improve ball trajectory, and a “raw” surface profile of a striking surface or a cover layer on the striking surface can be processed to remove contributions associated with these curvatures. Other slow (i.e., low spatial frequency) contributions can also be removed by such processing. Typically features of size of about 1 mm or greater (or spatial frequencies less than about 1/mm) can be removed by processing as the contributions of these features to ball spin about a horizontal or other axis tend to be relatively small. A raw (unprocessed) profile can be spatially filtered to enhance or suppress high or low spatial frequencies. Such filtering can be required in some measurements to conform to various standards such as DIN or other standards. This filtering can be performed using processors configured to execute a Fast Fourier Transform (FFT).

Generally, a patterned roughness or texture is applied to a substantial portion of a striking surface or at least to an impact area. For wood-type golf clubs, an impact area is based on areas associated with inserts used in traditional wood golf clubs. For irons, an impact area is a portion of the striking surface within 20 mm on either side of a vertical centerline, but does not include 6.35 mm wide strips at the top and bottom of the striking surface. Generally, such patterned roughness need not extend across the entire striking surface and can be provided only in a central region that does not extend to a striking surface perimeter.

Striking surface roughness can be characterized based on a variety of parameters. A surface profile is obtained over a sampling length of the striking surface and surface curvatures removed as noted above. An arithmetic mean R_ais defined a mean value of absolute values of profile deviations from a mean line over a sampling length of the surface. For a surface profile over the sampling length that includes N surface samples each of which is associated with a mean value of deviations Y_i, from the mean line, the arithmetic mean R_ais:

$R_{a} = \frac{1}{N} \sum_{i = 1}^{N} ❘ Y_{i} ❘,$

wherein i is an integer i=1, . . . , N. The sampling length generally extends along a line on the striking surface over a substantial portion or all of the striking area, but smaller samples can be used, especially for a patterned roughness that has substantially constant properties over various sample lengths. Two-dimensional surface profiles can be similarly used, but one dimensional profiles are generally satisfactory and convenient. For convenience, this arithmetic mean is referred to herein as a mean surface roughness.

A surface profile can also be further characterized based on a reciprocal of a mean width S_mof the profile elements. This parameter is used and described in one or more standards set forth by, for example, the German Institute for Standardization (DIN) or the International Standards Organization (ISO). In order to establish a value for S_m, an upper count level (an upward surface deviation associated with a peak) and a lower count level (a downward surface deviation associated with a valley) are defined. Typically, the upper count level and the lower count level are defined as values that are 5% greater than the mean line and 5% less than the mean line, but other count levels can be used. A portion of a surface profile projecting upward over the upper count level is called a profile peak, and a portion projecting downward below the given lower count level is called a profile valley. A width of a profile element is a length of the segment intersecting with a profile peak and the adjacent profile valley. S_mis a mean of profile element widths S, within a sampling length:

$S_{m} = \frac{1}{K} \sum_{i = 1}^{K} S_{mi}$

For convenience, this mean is referred to herein as a mean surface feature width.

In determining S_m, the following conditions are generally satisfied: 1) Peaks and valleys appear alternately; 2) An intersection of the profile with the mean line immediately before a profile element is the start point of a current profile element and is the end point of a previous profile element; and 3) At the start point of the sampling length, if either of the profile peak or profile valley is missing, the profile element width is not taken into account. Rpc is defined as a reciprocal of the mean width S_mand is referred to herein as mean surface feature frequency.

Another surface profile characteristic is a surface profile kurtosis Ku that is associated with an extent to which profile samples are concentrated near the mean line. As used herein, a the profile kurtosis Ku is defined as:

$Ku = \frac{1}{R_{q}^{4}} ▯ \frac{1}{N} \sum_{i = 1}^{N} {(Y_{i})}^{4},$

wherein R_qa square root of the arithmetic mean of the squares of the profile deviations from the mean line,

$i . e ., R_{q} = {(\frac{1}{N} \sum_{i = 1}^{N} Y_{i}^{2})}^{1 / 2} .$

Profile kurtosis is associated with an extent to which surface features are pointed or sharp. For example, a triangular wave shaped surface profile has a kurtosis of about 0.79, a sinusoidal surface profile has a kurtosis of about 1.5, and a square wave surface profile has a kurtosis of about 1.

Other parameters that can be used to characterize surface roughness include R_zwhich is based on a sum of a mean of a selected number of heights of the highest peaks and a mean of a corresponding number of depths of the lowest valleys. One or more values or ranges of values can be specified for surface kurtosis Ku, mean surface feature width S_m, and arithmetic mean deviation R_a(mean surface roughness) for a particular golf club striking surface and/or other component of the club head.

In one embodiment the forward crown surface roughness is the forward crown mean surface roughness c-R_a, and the face surface roughness is the face mean surface roughness f-R_a. In one such embodiment the forward crown mean surface roughness c-R_ais at least 1 μm less than the face mean surface roughness f-R_a, and in further embodiments at least 1.5 μm less, 2.0 μm less, 2.5 μm less, or 3 μm less. In a further embodiment at least a portion of the face plate 4610 has a face mean surface roughness f-R_ais at least 2.0 μm, and in further embodiments at least 2.5 μm, 3.0 μm, 3.5 μm, or 4.0 μm. In a further embodiment at least 50% of the external surface of the face plate 4610 has a face mean surface roughness f-R_ais at least 2.0 μm, and in further embodiments at least 2.5 μm, 3.0 μm, 3.5 μm, or 4.0 μm. In still another embodiment at least 70% of the external surface of the face plate 4610 has a face mean surface roughness f-R_ais at least 2.0 μm, and in further embodiments at least 2.5 μm, 3.0 μm, 3.5 μm, or 4.0 μm. Similarly, in one embodiment at least 50% of the crown 4620 located in front of the offset loft plane 5100 has a face mean surface roughness f-R_aof less than 3.0 μm, and in further embodiments less than 2.5 μm, 2.0 μm, or 1.5 μm. In another embodiment at least 75% of the crown 4620 located in front of the offset loft plane 5100 has a face mean surface roughness f-R_aof less than 3.0 μm, and in further embodiments less than 2.5 μm, 2.0 μm, or 1.5 μm. In still another embodiment at least 90% of the crown 4620 located in front of the offset loft plane 5100 has a face mean surface roughness f-R_aof less than 3.0 μm, and in further embodiments less than 2.5 μm, 2.0 μm, or 1.5 μm. Such relationships balance diminishing returns and trade-offs regarding performance of the face plate 4610 and aerodynamic performance of the club head.

Any of the metal alloy components disclosed herein may be formed by casting, forging, stamping, metal injection molding (MIM), metal additive manufacturing (metal AM), and/or freeform injection molding that combines MIM and metal AM. Metal additive manufacturing (metal AM) includes, but is not limited to, powder bed additive manufacturing, metal binderjetting manufacturing, sheet lamination manufacturing, direct energy deposition manufacturing, and bound powder extrusion. One such embodiment utilizes powder bed fusion (PBF) methods employing the use of either a laser or electron beam to melt and fuse the metal powder into a solid. This technique includes the following metal additive manufacturing methods: electron beam melting (EBM), direct metal laser sintering (DMLS), selective heat sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS). One such metal binder jetting manufacturing embodiment utilizes metal powders that are jetted onto a build platform to print objects using either a continuous or drop on demand (DOD) approach, followed by application of a liquid binder combine the powder layer by layer, building the desired object, followed by post-processing steps of sintering and/or infiltration to be strengthened. One such sheet lamination process includes the joining of sheets, or strips, of material together layer by layer through bonding, ultrasonic welding or ultrasonic additive manufacturing, or brazing to build an object. Sheet lamination methods are low-temperature processes and can bond different materials together. In a direct energy deposition manufacturing embodiment a focused energy source, such as a laser or electron beam, is directed at the building material to melt it while it is simultaneously being deposited layer by layer, and/or may incorporate use of a heated nozzle to deposit melted material onto the specified surface where it solidifies, which may include powder DED such as laser metal deposition (LMD) and/or laser engineering net shaping (LENS), as well as wire DED techniques such as electron beam additive manufacturing (EBAM).

The front body portion 4602 and/or the rear ring portion 4630 may be formed of titanium alloy, a steel alloy, a boron-infused steel alloy, a copper alloy, a beryllium alloy, aluminum alloy, magnesium alloy, nonmetallic material, composite material, hard plastic, resilient elastomeric material, and/or carbon-fiber reinforced thermoplastic with short or long fibers, and/or any other materials and coatings disclosed herein, and any method of formation and attachment disclosed herein. In one embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 can comprise a thermoplastic material, such as fiber-reinforced thermoplastic. In certain embodiments, the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 comprise a polyamide material such as nylon. Particular examples include polyphthalamide (PPA) resin, polycarbonate resin, etc., reinforced with carbon fibers (e.g., chopped fibers). The composite material can include 20% to 60% fiber by mass, or by volume. Particular examples include 20% to 50% fiber, 30% to 40% fiber, 60% fiber or less, 50% fiber or less, 40% fiber or less, 30% fiber or less, etc., by mass or by volume. In certain embodiments, the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 can be injection molded. Any of these components may includes a metal film deposited on its surface. The front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 can comprise PPA or similar resins compatible with primer materials for metal film deposition. The front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 may comprise a composite material, such as a fiber-reinforced plastic or a chopped-fiber compound (e.g., bulk molded compound or sheet molded compound), or an injection-molded polymer either alone or in combination with prepreg plies. In one embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 achieve desirable strain relationships by being formed of a polyamide resin, while in a further embodiment the polyamide resin includes fiber reinforcement, and in yet another embodiment the polyamide resin includes at least 35% fiber reinforcement. In one such embodiment the fiber reinforcement includes long-glass fibers having a length of at least 10 millimeters pre-molding and produce a finished component having fiber lengths of at least 3 millimeters, while another embodiment includes fiber reinforcement having short-glass fibers with a length of at least 0.5-2.0 millimeters pre-molding. Incorporation of the fiber reinforcement increases the tensile strength of the component, however it may also reduce the elongation to break therefore a careful balance must be struck to maintain sufficient elongation. Therefore, one embodiment includes 35-55% long fiber reinforcement, while in an even further embodiment has 40-50% long fiber reinforcement. One specific example is a long-glass fiber reinforced polyamide 66 compound with 40% carbon fiber reinforcement, such as the XuanWu XW5801 resin having a tensile strength of 245 megapascal and 7% elongation at break. Long fiber reinforced polyamides, and the resulting melt properties, produce a more isotropic material than that of short fiber reinforced polyamides, primarily due to the three-dimensional network formed by the long fibers developed during injection molding. Another advantage of long-fiber material is the almost linear behavior through to fracture resulting in less deformation at higher stresses. In one particular embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 is formed of a polycaprolactam, a polyhexamethylene adipinamide, or a copolymer of hexamethylene diamine adipic acid and caprolactam, however other embodiments may include polypropylene (PP), nylon 6 (polyamide 6), polybutylene terephthalates (PBT), thermoplastic polyurethane (TPU), PC/ABS alloy, PPS, PEEK, and semi-crystalline engineering resin systems that meet the claimed mechanical properties. In one embodiment at least two of the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 are separately formed of thermoplastic material having compatible resins and are subsequently joined via heat and/or pressure, and without the use of a bonding agent; wherein in a further embodiment this is true for the front body portion 4602, the rear ring portion 4630, and in another embodiment this is true for the front body portion 4602 and the face plate 4610, and in still another embodiment this is true for the front body portion 4602, the rear ring portion 4630, and the crown 4620, while in still a further embodiment this is true for the front body portion 4602, the rear ring portion 4630, the crown 4620, and the face plate 4610, and in a final embodiment this is true for all five of the listed components. In another embodiment a first component selected from the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 is formed using a thermoset resin, and second component is selected from the same the five components is injection molded and over-molded the first component to joint the first component and the second component. In another embodiment at least two of the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 are joined via through the use of a thermoset adhesive tape or a thermoset gasket located between a portion of the two components, and application of heat and/or pressure bonds the two components together.

In another embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 is injection molded and is formed of a material having a high melt flow rate, namely a melt flow rate (2750/2.16 Kg), per ASTM D1238, of at least 10 g/10 min. A further embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 is formed of a primary non-metallic material having a density of less than 1.75 grams per cubic centimeter and a primary tensile strength of at least 200 megapascal; while another embodiment has a density of less than 1.50 grams per cubic centimeter and a tensile strength of at least 250 megapascal. In a further embodiment the front body portion 4602, the rear ring portion 4630, the face plate 4610, the crown 4620, and/or sole plate 4640 is formed of a secondary metallic material having a secondary density of 1.8-3.0 grams per cubic centimeter and a secondary tensile strength that is greater than the primary tensile strength and at least 200 megapascal, while still maintaining a secondary percent elongation to break that is 75-200% of a primary percent elongation to break. While in yet a further embodiment the secondary metallic material has a secondary portion density of 1.8-3.0 grams per cubic centimeter and a secondary tensile strength that is greater than the primary tensile strength and at least 250 megapascal, while still maintaining a secondary percent elongation to break that is 100-185% of the primary percent elongation to break; and in an even further embodiment the secondary metallic material has a secondary density of 2.5-4.5 grams per cubic centimeter and a secondary tensile strength is at least 475 megapascal, while maintaining a secondary percent elongation to break that is 115-165% of the primary percent elongation to break.

In addition to those noted above, some examples of metals and metal alloys that can be used to form the components include, without limitation, carbon steels (e.g., 1020 or 8620 carbon steel), stainless steels (e.g., 304 or 410 stainless steel), PH (precipitation-hardenable) alloys (e.g., 17-4, C450, or C455 alloys), titanium alloys (e.g., 3-2.5, 6-4, SP700, 15-3-3-3, 10-2-3, or other alpha/near alpha, alpha-beta, and beta/near beta titanium alloys), aluminum/aluminum alloys (e.g., 3000 series alloys, 5000 series alloys, 6000 series alloys, such as 6061-T6, and 7000 series alloys, such as 7075), magnesium alloys, copper alloys, and nickel alloys. In some examples, any of the components may include one or more of the following materials: carbon steel, stainless steel (e.g. 17-4 PH stainless steel), alloy steel, Fe—Mn—Al alloy, nickel-based ferroalloy, cast iron, super alloy steel, aluminum alloy (including but not limited to 3000 series alloys, 5000 series alloys, 6000 series alloys, such as 6061-T6, and 7000 series alloys, such as 7075), magnesium alloy, copper alloy, titanium alloy (including but not limited to 6-4 titanium, 3-2.5, 6-4, SP700, 15-3-3-3, 10-2-3, Ti 9-1-1, ZA 1300, or other alpha/near alpha, alpha-beta, and beta/near beta titanium alloys) or mixtures thereof. In one example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is a 9-1-1 titanium alloy. Titanium alloys comprising aluminum (e.g., 8.5-9.5% Al), vanadium (e.g., 0.9-1.3% V), and molybdenum (e.g., 0.8-1.1% Mo), optionally with other minor alloying elements and impurities, herein collectively referred to a “9-1-1 Ti”, can have less significant alpha case, which renders HF acid etching unnecessary or at least less necessary compared to faces made from conventional 6-4 Ti and other titanium alloys. Further, 9-1-1 Ti can have minimum mechanical properties of at least 820 MPa yield strength, 958 MPa tensile strength, and 10.2% elongation. These minimum properties can be significantly superior to typical cast titanium alloys, such as 6-4 Ti, which can have minimum mechanical properties of 812 MPa yield strength, 936 MPa tensile strength, and ˜6% elongation. In certain examples, the titanium alloy is 8-1-1 Ti. In another example, when forming part of the golf club heads disclosed herein, such as when forming part of the strike plate, the titanium alloy is an alpha-beta titanium alloy comprising 6.5% to 10% Al by weight, 0.5% to 3.25% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti (one example is sometimes referred to as “1300” or “ZA1300” titanium alloy). The alpha-beta titanium alloy or ZA1300 titanium alloy has a first ultimate tensile strength of at least 1,000 MPa in some examples and at least 1,100 MPa in other examples. An ultimate tensile strength of the material forming the body 102, other than the strike face 145, can be less than the first ultimate tensile strength by at least 10%. In another representative example, the alloy may comprise 6.75% to 9.75% Al by weight, 0.75% to 3.25% or 2.75% Mo by weight, 1.0% to 3.0% Cr by weight, 0.25% to 1.75% V by weight, and/or 0.25% to 1% Fe by weight, with the balance comprising Ti. In yet another representative example, the alloy may comprise 7% to 9% Al by weight, 1.75% to 3.25% Mo by weight, 1.25% to 2.75% Cr by weight, 0.5% to 1.5% V by weight, and/or 0.25% to 0.75% Fe by weight, with the balance comprising Ti. In a further representative example, the alloy may comprise 7.5% to 8.5% Al by weight, 2.0% to 3.0% Mo by weight, 1.5% to 2.5% Cr by weight, 0.75% to 1.25% V by weight, and/or 0.375% to 0.625% Fe by weight, with the balance comprising Ti. In another representative example, the alloy may comprise 8% Al by weight, 2.5% Mo by weight, 2% Cr by weight, 1% V by weight, and/or 0.5% Fe by weight, with the balance comprising Ti (such titanium alloys can have the formula Ti-8Al-2.5Mo-2Cr-1V-0.5Fe). As used herein, reference to “Ti-8Al-2.5Mo-2Cr-1V-0.5Fe” refers to a titanium alloy including the referenced elements in any of the proportions given above. Certain examples may also comprise trace quantities of K, Mn, and/or Zr, and/or various impurities. Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have minimum mechanical properties of at least 1150 MPa yield strength, 1180 MPa ultimate tensile strength, and 8% elongation. These minimum properties can be significantly superior to other cast titanium alloys, including 6-4 Ti and 9-1-1 Ti, which can have the minimum mechanical properties noted above. In some examples, Ti-8Al-2.5Mo-2Cr-1V-0.5Fe can have a tensile strength of from about 1180 MPa to about 1460 MPa, a yield strength of from about 1150 MPa to about 1415 MPa, an elongation of from about 8% to about 12%, a modulus of elasticity of about 110 GPa, a density of about 4.45 g/cc, and a hardness of about 43 on the Rockwell C scale (43 HRC). In particular examples, the Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy can have a tensile strength of about 1320 MPa, a yield strength of about 1284 MPa, and an elongation of about 10%. The Ti-8Al-2.5Mo-2Cr-1V-0.5Fe alloy, particularly when used to cast golf club head bodies, promotes less deflection for the same thickness due to a higher ultimate tensile strength compared to other materials. In some implementations, providing less deflection with the same thickness benefits golfers with higher swing speeds because over time the face of the golf club head will maintain its original shape over time.

In addition to those noted above, some examples of nonmetallic composites that can be used to form the components include, without limitation, glass fiber reinforced polymers (GFRP), carbon fiber reinforced polymers (CFRP), metal matrix composites (MMC), ceramic matrix composites (CMC), and natural composites (e.g., wood composites). Further, some examples of polymers that can be used to form the components include, without limitation, thermoplastic materials (e.g., polyethylene, polypropylene, polystyrene, acrylic, PVC, ABS, polycarbonate, polyurethane, polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyether block amides, nylon, and engineered thermoplastics), thermosetting materials (e.g., polyurethane, epoxy, and polyester), copolymers, and elastomers (e.g., natural or synthetic rubber, EPDM, and Teflon.RTM.).Additionally, as discussed above, typically the face-to-crown transition region is painted in a conventional wood-type club head, and this paint chips over time due to repeated impacts. The inventors expected the front portion of the nonmetal crown 4620 and/or sole insert 4640 to chip or crack due to repeated high face impacts. Surprisingly, however, it was found that the nonmetallic crown 4620 and/or sole insert 4640 held up just as well as a painted club head and in some instances was even more robust. The inventors did not see any cracking or chipping of the nonmetallic crown 4620 and/or sole insert 4640 under extreme durability testing.

Another advantage of the club head 4600 is that the large size of the crown 4620 removes seams between the crown and body that are visible to the golfer from an address view in conventional wood-type club heads, providing a cleaner look and a more precise and accurate topline for visual alignment. The boundaries of the crown 4620 in the club head 4600 are instead located more on the lateral aspects of the club head where they are less visible and less distracting to a golfer, while allowing the golfer to focus more on the topline as desired. Furthermore, the topline produce by the juncture of the crown and face plate is predesigned by the shapes of the components themselves and does not rely on manual painting, which can lead to a lot of variability in the topline from club head to club head. The present disclosure is not limited to drivers, but is also intended to be applied to fairway woods, hybrids, irons, or putters.

As previously noted, the unique club head construction has resulted in more discretionary mass to achieve desirable mass properties. For example, Tables 3-5 below provides several mass properties of exemplary embodiments of the golf club head 4600, with the club head oriented with a face angle of 0 degrees.

TABLE 3

Examples 1,
Examples 2,
Examples 3,
Examples 4,
Examples 5,

35A, & 37A
35B, & 37B
35C, & 37C

35D, & 37D

35E, & 37E

CGX
−5 to 5
mm
−4 to 4
mm
−4 to 3
mm
−4 to 2.5
mm
−4 to 1.5
mm

CGY
33-50
mm
35-47
mm
37-47
mm
39-47
mm
41-47
mm

CGZ
−10 to 0
mm
−7 to −1
mm
−6 to −1.5
mm
−6 to −2.5
mm
−6 to −3
mm

ZUP
18-30
mm
20-28
mm
21-27
mm
22-27
mm
23-27
mm

DELTA1
20-40
mm
23-36
mm
24-35
mm
25-34
mm
26-33
mm

DELTA2
34-42
mm
35-41
mm
35.5-40
mm
35.5-40
mm
35.5-40
mm

MASS
180-210
g
195-208
g
197-206
g
198-205
g
198-205
g

IXX
300-450
kg · mm²
320-445
kg · mm²
340-440
kg · mm²
360-435
kg · mm²
380-430
kg · mm²

IYY
265-350
kg · mm²
270-340
kg · mm²
275-330
kg · mm²
280-320
kg · mm²
285-315
kg · mm²

IZZ
480-700
kg · mm²
500-675
kg · mm²
520-625
kg · mm²
540-600
kg · mm²
560-600
kg · mm²

CFX
45-70
mm
45-65
mm
45-60
mm
45-55
mm
43-54
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
37-43
mm
38-42
mm
38-42
mm
38-42
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 4
mm
−2 to 4
mm
−1 to 4
mm

BODY LIE
53-60
degrees
54-59
degrees
55-58
degrees
55-58
degrees
55-58
degrees

(CASTING)

ASM LIE (FCT IN
51.25-58.25
degrees
52-57
degrees
53-56.5
degrees
53-56.5
degrees
53-56.5
degrees

STD)

LOFT
6-12
degrees
7-12
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-500
cm³
400-490
cm³
410-480
cm³
420-470
cm³
420-465
cm³

TABLE 4

Examples 6,
Examples 7,
Examples 8,
Examples 9,
Examples 10,

35F, & 37F
35G, & 37G
35H, & 37H
351, & 371
35J, & 37J

MASS
180-200
g
182.5-197.5

185-197.5
g
187.5-197.5
g
190-197
g

CGX
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2.5 to 2.5
mm
−1.5 to 1.5
mm

CGY
33-50
mm
36-49
mm
39-48
mm
42-48
mm
44-48
mm

CGZ
−10 to 0
mm
−7 to −1
mm
−6 to −1.5
mm
−5 to −1.5
mm
−4 to −1.5
mm

ZUP
18-30
mm
20-28
mm
21-27
mm
22-27
mm
23-27
mm

DELTA1
20-40
mm
23-36
mm
24-35
mm
25-34
mm
26-34
mm

DELTA2
34-42
mm
35-40
mm
35.5-39
mm
35.5-38
mm
35.5-38
mm

IXX
300-440
kg · mm²
310-435
kg · mm²
320-430
kg · mm²
340-430
kg · mm²
360-430
kg · mm²

IYY
265-350
kg · mm²
270-340
kg · mm²
275-330
kg · mm²
280-320
kg · mm²
280-315
kg · mm²

IZZ
480-700
kg · mm²
500-675
kg · mm²
520-625
kg · mm²
540-600
kg · mm²
560-600
kg · mm²

CFX
45-70
mm
45-70
mm
45-70
mm
45-70
mm
45-70
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
37-43
mm
38-41
mm
38-41
mm
38-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 4
mm
−2 to 4
mm
−1 to 4
mm

BODY LIE
53-60
degrees
54-59
degrees
55-58
degrees
55-58
degrees
55-58
degrees

(CASTING)

ASM LIE
51.25-58.25
degrees
52-57
degrees
53-56.5
degrees
53-56.5
degrees
53-56.5
degrees

(FCT IN

STD)

LOFT
6-12
degrees
7-12
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-500
cm³
400-490
cm³
410-480
cm³
420-470
cm³
420-465
cm³

TABLE 5

Examples 11,
Examples 12,
Examples 13,
Examples 14,
Examples 15,

35K, & 37K
35L, & 37L
35M, & 37M
35N, & 37N
350, & 370

MASS
200-210
g
201-209
g
202-208
g
202-207
g
202-207
g

CGX
−5 to 5
mm
−4 to 4
mm
−4 to 3
mm
−4 to 2.5
mm
−4 to 1.5
mm

CGY
38-50
mm
39-47
mm
40-47
mm
41-47
mm
42-46
mm

CGZ
−10 to 0
mm
−7 to −1
mm
−6 to −1.5
mm
−6 to −2
mm
−6 to −2.5
mm

ZUP
18-30
mm
20-28
mm
21-27
mm
22-27
mm
23-27
mm

DELTA1
24-40
mm
26-36
mm
28-35
mm
29-34
mm
30-33
mm

DELTA2
34-42
mm
35-40
mm
35.5-40
mm
35.5-40
mm
35.5-40
mm

IXX
340-450
kg · mm²
350-445
kg · mm²
360-440
kg · mm²
370-435
kg · mm²
380-430
kg · mm²

IYY
265-350
kg · mm²
270-340
kg · mm²
280-330
kg · mm²
285-320
kg · mm²
285-315
kg · mm²

IZZ
530-700
kg · mm²
540-675
kg · mm²
550-625
kg · mm²
560-600
kg · mm²
570-600
kg · mm²

CFX
45-70
mm
45-70
mm
45-70
mm
45-70
mm
45-70
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
37-43
mm
38-41
mm
38-40
mm
38-40
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 4
mm
−2 to 4
mm
−1 to 3.5
mm

BODY LIE
53-60
degrees
54-59
degrees
55-58
degrees
55-58
degrees
55-58
degrees

(CASTING)

ASM LIE
51.25-58.25
degrees
52-57
degrees
53-56.5
degrees
53-56.5
degrees
53-56.5
degrees

(FCT IN

STD)

LOFT
6-12
degrees
7-12
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-500
cm³
400-490
cm³
410-480
cm³
420-470
cm³
420-465
cm³

In the tables above, if a value is not defined herein, the definitions used in U.S. patent Ser. No. 10/195,497 and/or U.S. patent application Ser. No. 17/722,748 are to be applied, both of which are herein incorporated by reference in their entirety. As used in the tables above, “BP PROF” means “BP projection,” “balance point projection,” .projected CG location,” also referred to as “balance pont” projection, or “CG projection,” explained later in great detail with respect to FIGS. 220-222. In fact, CFZ is measured in the same manner as DELTA2, as defined later with respect to FIGS. 220-222, but is measured to a projection of center face 205, in the y-axis direction, onto the imaginary vertical shaft axis plane thereby defining a point referred to as the CFZ point, and the shortest distance from the CFZ point to the shaft axis is the CFZ value.

In the club head 4600, the crown 4620 can have a larger external surface area, such as between 10,000 mm²and 15,000 mm², between 11,000 mm²and 15,000 mm², between 12,000 mm²and 15,000 mm², between 12,500 mm²and 15,000 mm², between 12,600 mm²and 15,000 mm², between 12,650 mm²and 15,000 mm², between 12,700 mm²and 15,000 mm², between 12,750 mm²and 15,000 mm², and/or between 12,800 mm²and 15,000 mm². In a particular embodiment the crown 4620 has an external surface area of about 12,694 mm².

The surface area of the crown-supporting ledge (the entire ledge area around the upper opening of the body, including ledge portions 4680, 4682, and 4636) can be between 3,000 mm²and 4,000 mm², between 3,200 mm²and 3,900 mm², between 3,400 mm²and 3,800 mm², between 3,600 mm²and 3,700 mm², and/or between 3,611 mm²and 3,682 mm².

FIGS. 160-175 illustrate an embodiment incorporating the disclosed technologies to precisely tailor the mass distribution to obtain desirable performance. First the grid illustrated in many of figures will be disclosed in detail. A shaft axis vertical plane (SAVP), also simply referred to as a shaft axis plane, is a vertical plane extending perpendicular to the ground plane (GP) and containing the previously defined shaft axis (SA). A face center vertical plane (FCVP), is a vertical plane extending through center face 205 and perpendicular to both the ground plane (GP) and the shaft axis vertical plane (SAVP). A face center horizontal plane (FCHP) is a horizontal plane extending through center face 205 and perpendicular to the face center vertical plane (FCVP). It is important to note that any of the features and characteristics of the embodiments of FIGS. 70-159 may be incorporated in the embodiments of any subsequent figures and aren't being explicitly illustrated in these later figures for the sake of clarity. Additionally, for the purposes of this disclosure, and in light of the 10 mm grid shown in many of the figures, the embodiments shown with the grids are illustrated to scale and the disclosed grid may be used to identify the location of all aspects of the club head.

Now referring to the top plan views for simplicity, and specifically FIG. 160, a 1F plane is located 10 mm in front of the shaft axis vertical plane (SAVP) and is parallel to the shaft axis vertical plane (SAVP), and similarly a 1R plane is located 10 mm behind the shaft axis vertical plane (SAVP) and is parallel to the shaft axis vertical plane (SAVP). Extrapolating this grid provides a 2F plane located 10 mm in front of the 1F plane, and a 2R plane located 10 mm behind the 1R plane, and so on and so forth. Thus, the 2R plane is located 20 mm behind the shaft axis vertical plane (SAVP), the 3R plane is located 30 mm behind the shaft axis vertical plane (SAVP), the 4R plane is located 40 mm behind the shaft axis vertical plane (SAVP), the 5R plane is located 50 mm behind the shaft axis vertical plane (SAVP), the 6R plane is located 60 mm behind the shaft axis vertical plane (SAVP), the 7R plane is located 70 mm behind the shaft axis vertical plane (SAVP), the 8R plane is located 80 mm behind the shaft axis vertical plane (SAVP), the 9R plane is located 90 mm behind the shaft axis vertical plane (SAVP), the 10R plane is located 100 mm behind the shaft axis vertical plane (SAVP), and the 11R plane is located 110 mm behind the shaft axis vertical plane (SAVP); with additional planes continued in the same fashion if needed to encompass the entire club head. Likewise the 2F plane is located 20 mm in front of the shaft axis vertical plane (SAVP), and a 3F plane may be located 30 mm in front of the shaft axis vertical plane (SAVP); with additional planes continued in the same fashion if needed to encompass the entire club head.

Still referring to FIG. 160, but now with emphasis on planes parallel to the face center vertical plane (FCVP), a 1T plane is located 10 mm toeward from the face center vertical plane (FCVP), and a 1H plane is located 10 mm heelward from the face center vertical plane (FCVP). Extrapolating this grid provides a 2T plane is located 20 mm toeward from the face center vertical plane (FCVP), a 3T plane is located 30 mm toeward from the face center vertical plane (FCVP), a 4T plane is located 40 mm toeward from the face center vertical plane (FCVP), a 5T plane is located 50 mm toeward from the face center vertical plane (FCVP), a 6T plane is located 60 mm toeward from the face center vertical plane (FCVP), a 7T plane is located 70 mm toeward from the face center vertical plane (FCVP), and a 8T plane is located 80 mm toeward from the face center vertical plane (FCVP); with additional planes continued in the same fashion if needed to encompass the entire club head. Similarly, a 2H plane is located 20 mm heelward from the face center vertical plane (FCVP), a 3H plane is located 30 mm heelward from the face center vertical plane (FCVP), a 4H plane is located 40 mm heelward from the face center vertical plane (FCVP), a 5H plane is located 50 mm heelward from the face center vertical plane (FCVP), a 6H plane is located 60 mm heelward from the face center vertical plane (FCVP), a 7H plane is located 70 mm heelward from the face center vertical plane (FCVP), and a 8H plane is located 80 mm heelward from the face center vertical plane (FCVP); with additional planes continued in the same fashion if needed to encompass the entire club head.

Now referring to FIGS. 161 and 162, but now with emphasis on planes parallel to the face center horizontal plane (FCHP), a 1C plane is located 10 mm upward from the face center horizontal plane (FCHP), and a 1S plane is located 10 mm downward from the face center horizontal plane (FCHP). Extrapolating this grid provides a 2C plane is located 20 mm upward from the face center horizontal plane (FCHP), a 3C plane is located 30 mm upward from the face center horizontal plane (FCHP), and a 4C plane is located 40 mm upward from the face center horizontal plane (FCHP); with additional planes continued in the same fashion if needed to encompass the entire club head. Similarly, a 2S plane is located 20 mm downward from the face center horizontal plane (FCHP), a 3S plane is located 30 mm downward from the face center horizontal plane (FCHP), and a 4S plane is located 40 mm downward from the face center horizontal plane (FCHP); with additional planes continued in the same fashion if needed to encompass the entire club head.

With these planes defined the location and mass of any aspect of the club head can be easily described. For instance, the prefaces of “pre” and “post” will be used to describe the mass of the portion of the club head in front of an analysis plane in the case of “pre”, or the mass of the portion of the club head behind the analysis plane in the case of “post.” For instance, a pre-1F mass is the mass of the portion of the club head that is located in front of the 1F plane, a pre-SAVP mass is the mass of the portion of the club head that is located in front of the SAVP plane, a pre-1R mass is the mass of the portion of the club head that is located in front of the 1R plane, and likewise for the other planes. Similarly, a post-SAVP mass is the mass of the portion of the club head that is located behind the SAVP plane, a post-1R mass is the mass of the portion of the club head that is located behind the 1R plane, a post-2R mass is the mass of the portion of the club head that is located behind the 2R plane, and likewise for the other planes. Similarly a mass of the portion of the club head located between any two planes may be referred to by calling out the boundary planes. For example, a 8R-7R mass is the mass of the portion of the club head that is located between the 8R plane and the 7R plane, a 7R-6R mass is the mass of the portion of the club head that is located between the 7R plane and the 6R plane, a 6R-5R mass is the mass of the portion of the club head that is located between the 6R plane and the 5R plane, a 5R-4R mass is the mass of the portion of the club head that is located between the 5R plane and the 4R plane, and a 4R-3R mass is the mass of the portion of the club head that is located between the 4R plane and the 3R plane. Each of these references is between adjacent planes, however the nomenclature may be expanded to any non-adjacent planes such as a 8R-4R mass is the mass of the portion of the club head that is located between the 8R plane and the 4R plane, and likewise for any two of the disclosed planes.

Further, the mass of the club head may be further specified with reference to ranges, or combinations, of these 10 mm by 10 mm cells. For instance, a 4T-4H, 1S-4C, pre-2R mass, also referred to as a center-forward mass, is the mass of the portion of the club head that is located between the 4T plane and the 4H plane, and between the 1S plane and the 4C plane, and is in front of the 2R plane, as illustrated by the dotted line boundary shown in FIGS. 164, 165, and 166. Another commonly referred to region defines a 4H-8H, 1S-4C, pre-2R mass, which is the mass of the portion of the club head that is located between the 4H plane and the 8H plane, and between the 1S plane and the 4C plane, and is in front of the 2R plane. Likewise another commonly referred to region defines a 4T-8T, 1S-4C, pre-2R mass, which is the mass of the portion of the club head that is located between the 4T plane and the 8T plane, and between the 1S plane and the 4C plane, and is in front of the 2R plane. Yet another commonly referenced region defines a pre-SAVR central-4 array mass, which is the mass of the portion of the club head that is located between the 1T plane and the 1H plane, and between the 1S plane and the 1C plane, and is in front of the SAVR plane. One skilled in the art that the order of the nomenclature is irrelevant and be rearranged yet still cover the same region. For instance, the 4H-8H, 1S-4C, pre-2R region may likewise be referred to as the pre-2R, 4H-8H, 1S-4C region and/or mass, the 1S-4C, 4H-8H, pre-2R region and/or mass, the pre-2R, 1S-4C, 4H-8H region and/or mass, or any combination thereof; which also applies for all regions and/or masses disclosed herein.

A forward heel and toe mass is defined as the sum of the 4H-8H, 1S-4C, pre-2R mass and the 4T-8T, 1S-4C, pre-2R mass, and is useful in comparison to the mass in other areas of the club head. For instance, comparing the forward heel and toe mass with the 4T-4H, 1S-4C, pre-2R mass, provides a nice comparison of mass of the club head in the central region, namely between the 4T-4H planes, versus the mass of the club head in the heel and toe regions, for the same front-to-rear region, namely pre-2R, and the same sole-to-crown region, namely between the 1S and 4C planes. Similarly, a 2T-2H, post-9R mass, also referred to as a rear-center mass, is the mass of the portion of the club head that is located between the 2T plane and the 2H plane, and is behind of the 9R plane, and is useful in comparison to the mass in other areas of the club head.

One embodiment has a center-forward-to-HT mass ratio of 0.8-1.3, where the center-forward-to-HT mass ratio is a ratio of a 4T-4H, 1S-4C, pre-2R mass to the forward heel and toe mass, with the forward heel and toe mass being the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass. In a further embodiment the center-forward-to-HT mass ratio is at least 0.825, and at least 0.85, 0.875, 0.9, or 0.925 in additional embodiments. The center-forward-to-HT mass ratio is no more than 1.25 in another embodiment, and no more than 1.2, 1.15, 1.1, 1.05, 1.0, or 0.975 in still further embodiments. Having a center-forward-to-HT mass ratio close to unity provides stability at impact not found in club heads having conventional weight distribution, provides the ability to increase Izz and Ixx, and/or control Iyy, while reducing the elevation of the balance point projection and/or controlling the magnitude of the CGy value and/or delta1 value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 20 grams, 22 grams, 24 grams, or 26 grams. In one embodiment the forward heel and toe mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the forward heel and toe mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

Another embodiment has a center-forward-to-mid-section mass ratio of 0.8-1.3, where the center-forward-to-mid-section mass ratio is a ratio of a 4T-4H, 1S-4C, pre-2R mass to a mid-section mass. Here the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. In an embodiment the center-forward-to-mid-section mass ratio is at least 0.85, and at least 0.9, 0.95, 1.0, or 1.05 in further embodiments. The center-forward-to-mid-section mass ratio is no more than 1.25 in an embodiment, and is no more than 1.2, 1.15, or 1.10 in further embodiments. Having a center-forward-to-mid-section mass ratio close to unity enhances impact stability compared to clubs with standard weight distribution, allowing for increased Izz and Ixx, or controlled Iyy, while simultaneously reducing the elevation of the balance point projection and managing the CGy value and delta1 value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In a further embodiment the mid-section mass is no more than 50% of a pre-SAVR mass, and no more than 48%, 46%, 44%, or 42% in further embodiments. The mid-section mass is at least 34% of the pre-SAVR mass in one embodiment, and is at least 36% or 38% in additional embodiments. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 20 grams, 22 grams, 24 grams, or 26 grams. In one embodiment the forward heel and toe mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the forward heel and toe mass is at least 20 grams, 22 grams, 24 grams, or 26 grams. In one embodiment the mid-section mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the mid-section mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

Still a further embodiment has a forward-HT-to-mid-section mass ratio of 0.8-1.3, where the forward-HT-to-mid-section mass ratio is a ratio of a forward heel and toe mass to a mid-section mass. Here the forward heel and toe mass is the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass; and the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. In one embodiment the forward-HT-to-mid-section mass ratio is at least 0.85, and at least 0.9, 0.95, 1.0, or 1.05 in further embodiments. The forward-HT-to-mid-section mass ratio is no more than 1.25 in an embodiment, and no more than 1.2, 1.15, or 1.1 in further embodiments. Having a forward-HT-to-mid-section mass ratio close to unity delivers impact stability not typically found in clubs with traditional weight distribution providing the flexibility to boost Izz and/or Ixx, or regulate Iyy, while decreasing the elevation of the balance point projection and managing both the CGy and delta1 values, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In a further embodiment the mid-section mass is no more than 50% of a pre-SAVR mass, and no more than 48%, 46%, 44%, or 42% in further embodiments. The mid-section mass is at least 34% of the pre-SAVR mass in one embodiment, and is at least 36% or 38% in additional embodiments. In one embodiment the forward heel and toe mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the forward heel and toe mass is at least 20 grams, 22 grams, 24 grams, or 26 grams. In one embodiment the mid-section mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the mid-section mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

A rear-center-to-forward-center mass ratio is at least 1.05, where the rear-center-to-forward-center mass ratio is a ratio of a rear center mass to a center-forward mass. Here the rear center mass is the 2T-2H, post-9R mass, and the center-forward mass is the 4T-4H, 1S-4C, pre-2R mass. The rear-center-to-forward-center mass ratio is at least 1.1 in one embodiment, and at least 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, or 1.45 in further embodiments. The rear-center-to-forward-center mass ratio is no more than 1.85 in an embodiment, and no more than 1.8, 1.75, 1.7, 1.65, 1.6, or 1.55 in additional embodiments. Having a rear-center-to-forward-center mass ratio greater than unity provides unmatched stability upon impact, distinguishing it from clubs with conventional weight distribution, and affording the ability to enhance Izz and Ixx, or fine-tune Iyy, while concurrently minimizing the elevation of the balance point projection, and governing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. The rear center mass is at least 32.5 grams in one embodiment, and at least 35, 37.5, or 40 grams in further embodiments. The rear center mass is no more than 52.5 grams in an embodiment, and no more than 50, 47.5, 45, or 42.5 grams in additional embodiments. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

A rear-center-to-forward-HT mass ratio is at least 1.05, where the rear-center-to-forward-center mass ratio is a ratio of a rear center mass to a forward heel and toe mass. Here the rear center mass is the 2T-2H, post-9R mass, and the forward heel and toe mass is the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass. The rear-center-to-forward-HT mass ratio is at least 1.1 in one embodiment, and at least 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, or 1.45 in further embodiments. The rear-center-to-forward-HT mass ratio is no more than 1.85 in an embodiment, and no more than 1.8, 1.75, 1.7, 1.65, 1.6, or 1.55 in additional embodiments. Having a rear-center-to-forward-HT mass ratio greater than unity provides improved stability and face performance at impact, while facilitating increased Izz and/or Ixx, and precise control over Iyy, all the while reducing the elevation of the balance point projection and managing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. The rear center mass is at least 32.5 grams in one embodiment, and at least 35, 37.5, or 40 grams in further embodiments. The rear center mass is no more than 52.5 grams in an embodiment, and no more than 50, 47.5, 45, or 42.5 grams in additional embodiments. In one embodiment the forward heel and toe mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the forward heel and toe mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

A rear-center-to-mid-section mass ratio is at least 1.05, where the rear-center-to-mid-section mass ratio is a ratio of a rear center mass to a mid-section mass. Here the rear center mass is the 2T-2H, post-9R mass, and the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. The rear-center-to-mid-section mass ratio is at least 1.1 in one embodiment, and at least 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, or 1.45 in further embodiments. The rear-center-to-mid-section mass ratio is no more than 1.85 in an embodiment, and no more than 1.8, 1.75, 1.7, 1.65, 1.6, or 1.55 in additional embodiments. Having a rear-center-to-mid-section mass ratio greater than unity provides preferred weight distribution and precise control of the elevation of the balance point projection, CGy, and delta1 values, while the controlling Iyy and achieving desirable ranges for Izz and Ixx, while improving face performance, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In a further embodiment the mid-section mass is no more than 50% of a pre-SAVR mass, and no more than 48%, 46%, 44%, or 42% in further embodiments. The mid-section mass is at least 34% of the pre-SAVR mass in one embodiment, and is at least 36% or 38% in additional embodiments. The rear center mass is at least 32.5 grams in one embodiment, and at least 35, 37.5, or 40 grams in further embodiments. The rear center mass is no more than 52.5 grams in an embodiment, and no more than 50, 47.5, 45, or 42.5 grams in additional embodiments. In one embodiment the mid-section mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, or 28 grams. In another embodiment the mid-section mass is at least 20 grams, 22 grams, 24 grams, or 26 grams.

In one embodiment a rear-to-front mass ratio of a post-9R plane mass to a pre-SAVP mass is at least 0.61. The rear-to-front mass ratio is at least 0.7 in another embodiment, and at least 0.62, 0.63, or 0.64 in further embodiments. The rear-to-front mass ratio is no more than 0.825 in one embodiment, and no more than 0.8, 0.775, 0.75, or 0.725 in additional embodiments. A post-10R plane mass is at least 20% of the pre-1F plane mass in one embodiment, and is at least 25%, 30%, 32.5%, 35%, or 37.5% in further embodiments. A post-10R plane mass is no more than 50% of the pre-1F plane mass in one embodiment, and is no more than 47.5%, 45%, 42.5%, or 40% in additional embodiments. A post-10R plane mass is at least 150% of the pre-SAVR central-4 array mass in one embodiment, and is at least 160%, 170%, 180%, 190%, or 200% in further embodiments. The post-10R plane mass is no more than 300% of the pre-SAVR central-4 array mass in one embodiment, and is no more than 275%, 250%, or 225% in additional embodiments. The pre-SAVR central-4 array mass is less than 4 grams in one embodiment, and less than 3.75, 3.5, 3.25, 3.0, or 2.75 grams in further embodiments. Further, the pre-SAVR central-4 array mass is at least 1.5 grams in an embodiment, and at least 1.75, 2.0, or 2.25 grams in additional embodiments. In one embodiment the pre-SAVP mass is less than 69 grams, and is less than 68.5 or 68 grams in additional embodiments. In one embodiment the pre-SAVP mass is at least 58 grams, and at least 60, 62, 64, or 66 grams in further embodiments. The pre-1F plane mass is at least 4 grams and less than 22.5 grams in an embodiment, while in further embodiments the pre-1F plane mass is no more than 20, 17.5, 15, 14.5, 14, 13.5, or 13.25 grams. The pre-1F plane mass is at least 5 grams in another embodiment, and at least 6, 7, 8, 9, 10, 11, or 12 grams in additional embodiments. In one embodiment at least one of the disclosed 10 mm×10 mm×10 mm cells of the club head has a cell mass that is 2.5 times the pre-SAVR central-4 array mass, and at least 3 times, 3.25 times, or 3.5 times in additional embodiments. In another embodiment a greatest cell mass of the golf club head is no more than 5 times the pre-SAVR central-4 array mass, and no more than 4.75 times, 4.5 times, 4.25 times, 4 times, or 3.75 times in additional embodiments. In one embodiment a heaviest cell associated with the greatest cell mass is located between the FCVP and the 4T plane, and in another embodiment between the FCVP and the 3T plane, and between the FCVP and the 3T plane in yet a further embodiment. In one embodiment, at least one of the following are true: the pre-1F mass is 10.5-16 grams, the SAVP-1F mass is 43-65 grams, the 1R-SAVP mass is 26-39 grams, the 2R-1R mass is 13-20 grams, the 3R-2R mass is 6-10 grams, the 4R-3R mass is 4-7.5 grams, the 5R-4R mass is 4-7.5 grams, the 6R-5R mass is 4-7.5 grams, the 7R-6R mass is 4-7.5 grams, the 8R-7R mass is 4-7.5 grams, the 9R-8R mass is 6-11 grams, the 10R-9R mass is 30-45 grams, or the 11R-10R mass is 4-20 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. In another embodiment, at least one of the following are true: the pre-1F mass is 11.25-15.25 grams, the SAVP-1F mass is 46-62 grams, the 1R-SAVP mass is 28-37 grams, the 2R-1R mass is 14-19 grams, the 3R-2R mass is 7-9.5 grams, the 4R-3R mass is 4.25-7 grams, the 5R-4R mass is 4.25-7 grams, the 6R-5R mass is 4.25-7 grams, the 7R-6R mass is 4.25-7 grams, the 8R-7R mass is 4.25-7 grams, the 9R-8R mass is 7.5-10 grams, the 10R-9R mass is 32-43 grams, or the 11R-10R mass is 4.5-18 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. In still a further embodiment, at least one of the following are true: the pre-1F mass is 12-15 grams, the SAVP-1F mass is 49-59 grams, the 1R-SAVP mass is 29-36 grams, the 2R-1R mass is 15-18 grams, the 3R-2R mass is 7.5-9 grams, the 4R-3R mass is 4.5-6.7 grams, the 5R-4R mass is 4.5-6.7 grams, the 6R-5R mass is 4.5-6.7 grams, the 7R-6R mass is 4.5-6.7 grams, the 8R-7R mass is 4.5-6.7 grams, the 9R-8R mass is 8-10 grams, the 10R-9R mass is 33-41 grams, or the 11R-10R mass is 4.75-16 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. In yet another embodiment, at least one of the following are true: the pre-1F mass is 12.5-14 grams, the SAVP-1F mass is 51-57 grams, the 1R-SAVP mass is 31-34 grams, the 2R-1R mass is 16-17.5 grams, the 3R-2R mass is 7.7-8.5 grams, the 4R-3R mass is 4.75-6.4 grams, the 5R-4R mass is 4.75-6.4 grams, the 6R-5R mass is 4.75-6.4 grams, the 7R-6R mass is 4.75-6.4 grams, the 8R-7R mass is 4.75-6.4 grams, the 9R-8R mass is 8.5-9.5 grams, the 10R-9R mass is 35-40 grams, or the 11R-10R mass is 5-14 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. Having the disclosed rear-to-front mass ratio, the post-10R mass relationships, the pre-SAVP mass, the pre-1F plane mass, and/or the pre-SAVR central-4 array mass provides improved face performance and the ability to enhance Izz and/or Ixx, while meticulously controlling Iyy, all while lowering, and/or precisely positioning, the elevation of the balance point projection and managing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

The disclosed goals and mass distribution are further achieved via extremely lightweight regions in the middle of the club head. For example, in one embodiment the 7R-6R plane mass is less than a grams and within β% of the 8R-7R plane mass. In additional embodiments the 6R-5R plane mass is less than a grams and within β% of the 5R-4R plane mass, the 4R-3R plane mass is less than a grams and within β% of the 5R-4R plane mass, and/or the 8R-7R plane mass and the 5R-4R plane mass are less than a grams. In one embodiment a is 7 grams, and in further embodiments is 6.5, 6.0, or 5.5 grams. In one embodiment β is 20, and in further embodiments is within 15, 10, or 5. Additionally, any of these plane masses may have a minimum value of at least 3.0 grams in one embodiment, and at least 3.5, 4.0, or 4.5 grams in additional embodiments. As seen in FIGS. 160 and 161, each of the disclosed slices of the club head has a section width 11000, measured in the top plan view, including a maximum section width and a minimum section width, and a section height 12000, measured in a side elevation view, including a maximum section height and a minimum section height. For instance, the portion of the club head between the 4R plane and the 3R plane, i.e. the 4R-3R region, has a 4R-3R section width 11000, as seen in FIG. 160, and a 4R-3R section height 12000, as seen in FIG. 161; and likewise for each region of the club head, namely the 1F-2F region, the SAVP-1F region, the 1R-SAVP region, the 2R-1R region, the 3R-2R region, the 4R-3R region, the 5R-4R region, the 6R-5R region, the 7R-6R region, the 8R-7R region, the 9R-8R region, the 10R-9R region, and the 11R-10R region. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 4R-3R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 4R-3R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 4R-3R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 4R-3R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%. In another embodiment the consistency of the disclosed plane masses is true even when a maximum 5R-4R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 5R-4R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 5R-4R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 5R-4R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%. In still a further embodiment the consistency of the disclosed plane masses is true even when a maximum 6R-5R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 6R-5R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 6R-5R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 6R-5R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%.

Controlling the jump in mass in the planes, aka regions, adjacent the lightweight mid-section is also very important to achieving the desired performance. Unless noted otherwise, the lightweight mid-section comprises adjacent sections, aka regions, where each region has a mass less than previously disclosed a grams. In one embodiment the lightweight mid-section includes at least N regions selected from the group of the 4R-3R region, the 5R-4R region, the 6R-5R region, the 7R-6R region, and the 8R-7R region, wherein in one embodiment N is 3, and in additional embodiments N is 4 or 5. It is worth noting that within the disclosure reference to a plane mass such as a 4R-3R plane mass is the same as a reference to a region mass such as a 4R-3R region mass. Thus, controlling the mass of the first forward region located in front of the lightweight mid-section and/or the first rearward region located behind the lightweight mid-section plays a significant role in achieving the disclosed goals. Thus, a leading-mid-section mass ratio is a ratio of the first forward region mass to the mass of the adjacent region within the lightweight mid-section; and a trailing-mid-section mass ratio is a ratio of the first rearward region mass to the mass of the adjacent region within the lightweight mid-section.

The leading-mid-section mass ratio is no more than 1.55 in one embodiment, and no more than 1.5, 1.45, or 1.4 in additional embodiments. The leading-mid-section mass ratio is at least 1.1 in an embodiment, and is at least 1.15, 1.2, 1.25, or 1.3 in further embodiments. The trailing-mid-section mass ratio is no more than 1.95 in one embodiment, and no more than 1.9, 1.85, or 1.8 in additional embodiments. In one embodiment the first forward region is the 3R-2R region. The trailing-mid-section mass ratio is at least 1.2 in an embodiment, and is at least 1.3, 1.4, 1.5, 1.6, or 1.7 in further embodiments. In one embodiment the first rearward region is the 9R-8R region.

Controlling the mass of a second forward region located in front of the first forward region also plays a significant role in achieving the disclosed goals, and likewise for a third forward region located in front of the second forward region. Thus, a second-leading-mid-section mass ratio is a ratio of the second forward region mass to the first forward region mass; and a third-leading-mid-section mass ratio is a ratio of the third forward region mass to the second forward region mass. The second-leading-mid-section mass ratio is no more than 2.5 in one embodiment, and no more than 2.4, 2.3, 2.2, or 2.1 in additional embodiments. The second-leading-mid-section mass ratio is at least 1.35 in an embodiment, and is at least 1.45, 1.55, 1.65, 1.75, 1.85, 1.95, or 2.05 in further embodiments. The third-leading-mid-section mass ratio is no more than 2.5 in one embodiment, and no more than 2.4, 2.3, 2.2, or 2.1 in additional embodiments. The third-leading-mid-section mass ratio is at least 1.35 in an embodiment, and is at least 1.45, 1.55, 1.65, 1.75, 1.85, 1.95, or 2.05 in further embodiments. In one embodiment the second forward region is the 2R-1R region, and the third forward region is the 1R-SAVP region.

A LHR-forward-toe mass ratio is 0.9-1.3, where the LHR-forward-toe mass ratio is a ratio of a large forward toe region mass to a limited heel region mass. The large forward toe region mass is the 5T-8T, 3S-1C, 3R-1F mass, and the limited heel region mass is the 4H-6H, 2S-1C, 3R-SAVP mass. The LHR-forward-toe mass ratio is at least 0.95 in another embodiment, and at least 1.0, or 1.05 in further embodiments. The LHR-forward-toe mass ratio is no more than 1.25 in an embodiment, and no more than 1.2, 1.15, or 1.10 in additional embodiments. The large forward toe region mass is at least 14 grams in an embodiment, and at least 15, 16, 17, or 18 grams in additional embodiments. The large forward toe region mass is no more than 25 grams in an embodiment, and no more than 24, 23, 22, 21, or 20 grams in further embodiments. The limited heel region mass is no more than 24 grams in an embodiment, and no more than 23, 22, 21, 20, 19, or 18 grams in further embodiments. The limited heel region mass is at least 14 grams in an embodiment, and at least 15, 16, or 17 grams in additional embodiments. This specifically identified and crafted LHR-forward-toe mass ratio, and associated masses, provides preferred mass distribution and the performance benefits associated with a preferred center of gravity window providing a reduced elevation of the balance point projection while maintaining preferred Izz and Ixx values, and/or controlled Iyy value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

The disclosed relationships are significant in that they allow the achievement of the goals disclosed herein while presenting the user with a comfortable and confidence inspiring club head shape. In one embodiment the head shape is such that no portion of the club head is found in the 5H-7H, 3S-4C, post-7R region, and in further embodiments no portion of the club head is found in the 5H-7H, 3S-4C, post-6R region or the 5H-7H, 3S-4C, post-5R region. In another embodiment the head shape is such that no portion of the club head is found in the 6T-8T, 3S-4C, post-9R region, and in a further embodiment no portion of the club head is found in the 6T-8T, 3S-4C, post-8R region. In another embodiment the head shape is such that no portion of the club head is found in the 6T-8T, 3S-4C, pre-SAVP region, the 6T-8T, 3S-1S, 2F-11R region, the 4T-8T, 3S-2S, 2F-11R region, the 4H-8H, 3S-2S, 2F-11R region, the 6T-8T, 4C-3C, 2F-11R region, the 5T-8T, 4C-3C, 2F-11R region, the 4H-5H, 4C-2C, 2F-11R region, or the 5H-7H, 4C-3S, pre-1F region. Further, the shape of the club head may be as illustrated in FIGS. 160-175 with reference to the disclosed grid structure, but will not be repeated entirely in words herein. However, with reference to FIG. 160, in one embodiment at least a portion of the club head is located at least 100 mm behind the SAVP plane, meaning behind the 10R plane, and at least 102 mm, 104 mm, 106 mm, or 108 mm in additional embodiments. In another embodiment at least a portion of the club head is located at least 10 mm in front of the SAVP plane, meaning in front of the 1F plane, and at least 13 mm, 15 mm or 16 mm in further embodiments. No portion of the club head extends behind the 11R plane or in front of the 2F plane in still another embodiment.

Conventional golf club head design thinking often suggests that a heavier face can potentially generate more ball speed and distance when struck properly because a well-designed heavier face can provide increased energy transfer to the ball, resulting in higher initial ball velocity. Further, conventional thinking suggests that a heavier face may enhance forgiveness by reducing the chances of the clubhead twisting or rotating upon impact, and thereby maintain a more consistent ball flight. Conversely, some research suggests that a lighter face results in less moving mass as the face is deflected at impact, and therefore an increase in the coefficient of restitution (COR).

Improved club head performance can be associated with many variables, not all of which track one another. For instance, one measure of performance is the preservation of ball speed from a max speed impact location on the face that produces the greatest ball speed for a set club head speed, to a second impact that produces a second ball speed. More specifically, the area on the striking face that produces a second ball speed within 0.5 mph of the greatest ball speed. As one skilled in the art will appreciate, increasing the ball speed preservation area is a complex balance of many variables. Afterall, ball speed preservation is easy when the greatest ball speed is low. However, ball speed preservation becomes increasingly complex as the greatest ball speed increases, and other performance criteria such as ball spin and launch angle are factored in. Having the disclosed lightweight regions of the club head facilitate mass movement to other areas of the club head which aid in the preservation of ball speed.

In one embodiment the coefficient of restitution (COR) at the location of the greatest ball speed is at least γ, and/or the characteristic time (CT) at the location of the greatest ball speed is at least δ, and/or a ball speed preservation area on the striking face is at least a mm². The ball speed preservation area is the surface area on the exterior of the striking face where the second ball speed is within 0.5 mph of the greatest ball speed. In one embodiment γ is 0.810, and is 0.815, 0.820, or 0.825 in further embodiments. In another embodiment δ is 245, and is 247, 249, 251, or 253 in further embodiments. In still another embodiment ε is 180, and is 190, 200, 210, 220, 230, or 240 in further embodiments. The γ is less than 0.840 in one embodiment, and less than 0.835 or 0.830 in further embodiments; and the δ is less than 275 in one embodiment, and less than 270, 265, or 260 in further embodiments; and the ε is less than 350 in one embodiment, and less than 340, 330, 320, 310, 300, or 290 in further embodiments.

As previously noted, the unique club head construction has resulted in more discretionary mass to achieve desirable mass properties. For example, Table 6 below provides several mass properties of exemplary embodiments of the golf club head 4600, with the club head oriented with a face angle of 0 degrees.

TABLE 6

Examples 16,
Examples 17,
Examples 18,
Examples 19,
Examples 20,

35P, & 37P
35Q, & 37Q
35R, & 37R
35S, & 37S
35T, & 37T

CGX
−5 to 5
mm
−4 to 4
mm
−4 to 3
mm
−4 to 2.5
mm
−3.5 to 1.5
mm

CGY
40-50
mm
41-49
mm
42-48
mm
43-47
mm
43-46
mm

CGZ
−10 to 0
mm
−7 to −1
mm
−6 to −1.5
mm
−5.5 to −2.5
mm
−5 to −3
mm

ZUP
18-30
mm
20-28
mm
21-27
mm
22-27
mm
23-27
mm

DELTA1
24-40
mm
26-38
mm
27-36
mm
28-34
mm
29-33
mm

DELTA2
33-42
mm
34-41
mm
35-40
mm
36-40
mm
36-40
mm

MASS
180-210
g
195-209
g
197-208
g
199-207
g
200-206
g

IXX
360-480
kg · mm²
370-470
kg · mm²
380-460
kg · mm²
390-450
kg · mm²
400-440
kg · mm²

IYY
265-350
kg · mm²
270-340
kg · mm²
275-330
kg · mm²
280-320
kg · mm²
285-315
kg · mm²

IZZ
560-700
kg · mm²
570-675
kg · mm²
580-625
kg · mm²
585-610
kg · mm²
590-600
kg · mm²

CFX
42-67
mm
43-64
mm
44-61
mm
45-58
mm
46-55
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
39-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 4
mm
−2 to 3.5
mm
−1 to 3.25
mm

BODY LIE
52-63
degrees
53-62
degrees
54-62
degrees
55-61
degrees
56-60
degrees

(CASTING)

ASM LIE
51.25-59.25
degrees
52-59
degrees
53-58.5
degrees
54-58
degrees
55-57.5
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
420-465
cm³

Further, one skilled in the art will appreciate that the thickness, shape, material, and construction of the ring 406 of FIG. 21 may be used to achieve the relationships disclosed herein. However, any of the disclosed relationships may also be obtained by Joining the disclosed front body portion 4602 to a rear cap component, as disclosed in U.S. Ser. No. 15/504,887, filed Nov. 8, 2023, U.S. Ser. No. 18/124,325, filed Mar. 21, 2023, and U.S. Ser. No. 18/913,535, filed Oct. 11, 2024, each of which is incorporated by reference in the entirety. Further, U.S. Ser. No. 18/647,379, filed Apr. 26, 2024, is incorporated by reference in the entirety. Improved club head performance can be associated with many variables, not all of which track one another. For instance, one measure of performance is the preservation of ball speed from a max speed impact location on the face that produces the greatest ball speed for a set club head speed, to a second impact that produces a second ball speed. More specifically, the area on the striking face that produces a second ball speed within 0.5 mph of the greatest ball speed. As one skilled in the art will appreciate, increasing the ball speed preservation area is a complex balance of many variables. Afterall, ball speed preservation is easy when the greatest ball speed is low. However, ball speed preservation becomes increasingly complex as the greatest ball speed increases, and other performance criteria such as ball spin and launch angle are factored in. Having the disclosed lightweight regions of the club head facilitate mass movement to other areas of the club head which aid in the preservation of ball speed.

In one embodiment the coefficient of restitution (COR) at the location of the greatest ball speed is at least γ, and/or the characteristic time (CT) at the location of the greatest ball speed is at least δ, and/or a ball speed preservation area on the striking face is at least ε mm². The ball speed preservation area is the surface area on the exterior of the striking face where the second ball speed is within 0.5 mph of the greatest ball speed. In one embodiment γ is 0.810, and is 0.815, 0.820, or 0.825 in further embodiments. In another embodiment δ is 245, and is 247, 249, 251, or 253 in further embodiments. In still another embodiment E is 180, and is 190, 200, 210, 220, 230, or 240 in further embodiments. The γ is less than 0.840 in one embodiment, and less than 0.835 or 0.830 in further embodiments; and the δ is less than 275 in one embodiment, and less than 270, 265, or 260 in further embodiments; and the E is less than 350 in one embodiment, and less than 340, 330, 320, 310, 300, or 290 in further embodiments.

As previously noted, the unique club head construction has resulted in more discretionary mass to achieve desirable mass properties. For example, Table 7 below provides several mass properties of exemplary forward weighted portion 13000 embodiments of the golf club head 4600, with the club head oriented with a face angle of 0 degrees, as well as later disclosed significant aluminum mass percentage embodiments, with or without the exemplary forward weighted portion 13000.

TABLE 7

Examples 21,
Examples 22,
Examples 23,
Examples 24,
Examples 25,

35U, & 37U
35V, & 37V
35W, & 37W
35X, & 37X
35Y, & 37Y

CGX
−5 to 5
mm
−4 to 4
mm
−4 to 3
mm
−3.5 to 2
mm
−3.5 to 1
mm

CGY
33-49
mm
34-48
mm
35-47
mm
36-46
mm
37-46
mm

CGZ
−10 to 0
mm
−7 to −1
mm
−6 to −1.5
mm
−5.5 to −2
mm
−5 to −3
mm

ZUP
18-30
mm
20-28
mm
21-27
mm
22-27
mm
23-27
mm

DELTA1
20-36
mm
21-35
mm
22-34
mm
22-32
mm
22-32
mm

DELTA2
33-42
mm
34-41
mm
35-40
mm
35-40
mm
36-40
mm

MASS
180-210
g
195-209
g
197-208
g
199-207
g
200-206
g

IXX
370-480
kg · mm²
380-470
kg · mm²
390-460
kg · mm²
400-450
kg · mm²
410-440
kg · mm²

IYY
265-350
kg · mm²
270-340
kg · mm²
275-330
kg · mm²
280-320
kg · mm²
285-315
kg · mm²

IZZ
560-700
kg · mm²
570-675
kg · mm²
580-625
kg · mm²
585-610
kg · mm²
590-600
kg · mm²

CFX
42-60
mm
43-58
mm
44-56
mm
44-54
mm
45-53
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
39-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 4
mm
−2 to 4
mm
−1.5 to 3.5
mm

BODY LIE
52-63
degrees
53-62
degrees
54-62
degrees
55-61
degrees
56-60
degrees

(CASTING)

ASM LIE
51.25-59.25
degrees
52-59
degrees
53-58.5
degrees
54-58
degrees
55-57.5
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
420-465
cm³

A front channel 390 may be formed in the forward weighted portion 13000. Further, the forward weighted portion 13000 may form a multi-material ledge for the face insert. In one embodiment the forward weighted portion 13000 is formed of a steel alloy and the adjacent lightweight front body portion 4602 is formed of a different material having a significantly different density, as previously disclosed, and therefore imparts spin profile changes that are adjusted to obtain preferred performance via the disclosed mass distribution of the club head. Such spin variations can also affect the distance a ball travels off the golf club face. Finally, the placement of the weight in the golf club head can affect the launch angle—the angle at what the golf ball leaves the golf club head after impact—but launch angle may also be affected by the introduction of slot technology, and the placement of weight in the golf club head affects spin as well. Although distance gains were seen with the slot technology previously described, it was unclear exactly how those distance gains were achieved. Although COR was increased, the effect of the slot technology on launch angle and spin rates was not previously well understood.

Material Volume Distribution

Tables 8-17 below illustrates unique relationships among the club head components and the materials used in the construction of the driver-type golf club heads described herein. The disclosure contains a delicate interplay of relationships of the various components, variables within each component as well, as relationships across the components, which impact the performance, sound, feel, durability, and manufacturability of the golf club head. The disclosed relationships are more than mere optimization, maximization, or minimization of a single characteristic or variable, and are often contrary to conventional design thinking, yet have been found to achieve a unique balance of the trade-offs associated with competing criteria such as durability, acoustics, vibration, fatigue resistance, weight, and ease of manufacture. The relationships disclosed do more than maximize or minimize a single characteristic such as characteristic time (CT), coefficient of restitution (COR) at a single point such as face center or offset/distributed COR, moments of inertia, deflection of a single component, rigidity of a single component, ductility of a single component, stiffness of the overall club head, deflection of a single component, frequency of a single components, damping, and/or changes in mode frequencies of the individual components, rather, the relationships achieve a unique balance among these characteristics, which are often conflicting, to produce a club head that has improved feel, sound, durability, and/or performance. After all, the interaction of the numerous components of the present golf club head, particularly when they have such varied material properties, has the potential to adversely impact the sound and feel of the golf club head, as well as its durability, manufacturability, and overall performance. Afterall, joining multiple components having varied densities, material properties, and stiffnesses is difficult. The aforementioned balance requires trade-offs among the competing characteristics recognizing key points of diminishing returns. Further, it is important to recognize that all the associated disclosure and relationships apply equally to all embodiments and should not be interpreted as being limited to the particular embodiment being discussed when a relationship is mentioned. The aforementioned balances require trade-offs among the competing characteristics recognizing key points of diminishing returns, as often disclosed with respect to open and closed ranges for particular variables and relationships. Proper functioning of each component, and the overall club head, on each and every shot, over thousands of impacts during the life of a golf club, is critical, and must be capable of surviving extreme temperature cycles, often associated with players storing golf clubs in the trunk of an automobile. Therefore, this disclosure contains unique combinations of components and relationships that achieve these goals. While the relationships of the various features and dimensions of a single component play an essential role in achieving the goals, the relationships of features and/or characteristics across multiple components are just as critical, if not more critical, to achieving the goals. Further, the relative length, width, thickness, geometry, and material properties of various components, and their relationships to one another and the other design variables disclosed herein, influence the performance, durability, feel, sound, safety, and ease of manufacture. Additionally, many embodiments have identified upper and/or lower limits ranges of relationships when extension outside the range the performance may suffer and adversely impact the goals. Therefore, this disclosure contains unique combinations of components and relationships that achieve these goals. Additionally, the material and associated density, strength, and stiffness, for each component also influencing the spin characteristics at impact. Spin variations can affect the distance a ball travels off the golf club face. Finally, the placement of the weight in the golf club head can affect the launch angle—the angle at what the golf ball leaves the golf club head after impact—but launch angle may also be affected by the club head construction.

Embodiments A-P and Tables 8-17 are directed to club heads having a club head volume of 390-600 cubic centimeters, or cc, and a total head mass of 185-210 grams. Each component of the club head forming a portion of the structural shell, or attached to the structural shell, has a component volume, a component density, and a component mass. The component volumes may be determined by a water displacement test, by analyzing an electronic model or drawings of the component, and/or simply utilizing the measured mass and the component material density when the component material is a homogeneous material or a uniformly distributed heterogeneous material. Nonmetallic materials placed in the interior of a club head are excluded from the component volume calculations discussed herein but are included in determining the total club head mass; for example, foam inserts 3276, such as those shown in FIG. 100, and what is commonly referred to as hot-melt, or rat-glue, are excluded from the volume calculations. To be clear, the hosel bore 324 is not considered the interior of the club head, and thus the shaft connection assembly 355, and components thereof, are included in the volumetric calculations and relationships.

For the purposes of these examples the variety of materials used may be categorized into three different specific density criteria. A first material has a first material density of 0.1 g/cc to 3.5 g/cc, a second material has a second material density of 3.6 g/cc to 5.5 g/cc, and a third material has a third material density of 5.6 g/cc to 20.0 g/cc). Table 8 below provides masses, volumes, mass ratios, and volume ratios for four different embodiments of driver type golf club heads that employ varying construction techniques and satisfy some or all of the above material composition, material volume distribution, and volume allocation of materials.

TABLE 8

A
B
C
D

Total Volume of Material
≥70
≥72.5
≥75
≥77.5

(cm{circumflex over ( )}3): Vol_Total

First material Volume
≥40
≥50
≥60
≥70

(cm{circumflex over ( )}3): Vol_M1

Vol_M1/Vol_Total(%)
≥60%
≥70%
≥80%
≥90%

Second material Volume
≥0
≥0.4
≥0.7
≥10

(cm{circumflex over ( )}3): Vol_M2

Vol_M2/Vol_Total(%)
≥0%
≥0.5%
≥0.75%
≥15%

Third material Volume
≥2.5
≥5
≥7.5
≥10

(cm{circumflex over ( )}3): Vol_M3

Vol_M3/Vol_Total(%)
≥4%
≥8%
≥11%
≥15%

Total Head Mass
≥185
≥190
≥195
≥200

(grams): Mass_Total

First material Mass
≥80
≥90
≥110
≥120

(grams): Mass_M1

Mass_M1/Mass_Total(%)
≥40%
≥45%
≥50%
≥55%

Second material Mass
≥0
≥1
≥2
≥3

(grams): Mass_M2

Mass_M2/Mass_Total(%)
≥0%
≥0.5%
≥1%
≥1.5%

Third material Mass
≥40
≥60
≥80
≥100

(grams): Mass_M3

Mass_M3/Mass_Total(%)
≥20%
≥30%
≥40%
≥50%

Table 9 below provides masses, volumes, mass ratios, and volume ratios for four additional embodiments of driver type golf club heads that employ varying construction techniques and satisfy some or all of the above material composition, material volume distribution, and volume allocation of materials. Further, each of the values indicated in embodiments A-H stand on their own as an independent upper or lower boundary, and any of embodiments E-H of Table 9 may be combined with any of embodiments A-D of Table 8 to established closed end ranges, for example ranges Of Vol_Totalinclude not only the obvious ranges of 70-90, 72.5-85, 75-82.5, or 77.5-80, but also any other combination such as, for example, 70-80, 72.5-90, 75-80, or 77.5-82.5, and likewise for each variable of the tables. Further, a lower end limitation in one embodiment that is higher than an upper end limitation in another embodiment does not conflict, but rather merely indicates that those two boundaries may not be used together. For example, the lower end limitation of embodiment D for the Vol_M1-to-Vol_Totalratio is ≥90%, while the upper end limitation of embodiment H for the Vol_M1-to-Vol_Totalratio is ≤87.500 which does not present a conflict but merely indicates that those two boundaries may not be used together. Further, any discreet value within the disclosed ranges is fully enabled and may be claimed either as a value or as a boundary to a range, which applies to all the disclosure herein but will be illustrated only with respect to embodiments A-H for the sake of brevity. For instance, while embodiments A-D explicitly disclose values for Vol_Totalof ≥70, ≥72.5, ≥75, and ≥77.5, any integer value meeting these limitations is enabled and may be claimed, such as ≥71, ≥72, ≥73, ≥74, ≥76, ≥77, and likewise for the disclosed upper end boundary values, and likewise for any disclosed variable. As previously noted, the club head volume for these embodiments is 390-600 cubic centimeters, however in further embodiments it is at least 400 cc, 410 cc, 420 cc, 430 cc, 440 cc, 450 cc, or 460 cc. The use of the term embodiments in the tables does not imply distinct and/or different club head designs, the use of the references A-H is Just for convenience to identify columns in the tables and ease of disclosing embodiments in tabular form, which is true for all embodiment references not just A-H.

TABLE 9

E
F
G
H

Total Volume of Material
≤90
≤85
≤82.5
≤80

(cm{circumflex over ( )}3): Vol_Total

First material Volume
≤80
≤77.5
≤75
≤72.5

(cm{circumflex over ( )}3): Vol_M1

Vol_M1/Vol_Total(%)
≤95%
≤92.5%
≤90%
≤87.5%

Second material Volume
≤4
≤3
≤2
≤1

(cm{circumflex over ( )}3): Vol_M2

Vol_M2/Vol_Total(%)
≤6%
≤4%
≤2%
≤1%

Third material Volume
≤15
≤13
≤11
≤9

(cm{circumflex over ( )}3): Vol_M3

Vol_M3/Vol_Total(%)
≤20%
≤17%
≤14%
≤11%

Total Head Mass
≤210
≤207.5
≤205
≤202.5

(grams): Mass_Total

First material Mass
≤135
≤125
≤115
≤105

(grams): Mass_M1

Mass_M1/Mass_Total(%)
≤70%
≤67.5%
≤65%
≤62.5%

Second material Mass
≤80
≤10
≤7
≤4

(grams): Mass_M2

Mass_M2/Mass_Total(%)
≤40%
≤8
≤4%
≤2%

Third material Mass
≤120
≤110
≤100
≤90

(grams): Mass_M3

Mass_M3/Mass_Total(%)
≤65%
≤55%
≤45%
≤35%

As disclosed above, the first material has a first material density of 0.1 g/cc to 3.5 g/cc, and therefore may include metallic and nonmetallic material. For instance the first material may be an aluminum alloy, magnesium alloy, or other low density metal alloy, or it may be any of the disclosed nonmetallic materials within the density range. However, some embodiments further characterize the first material by the volume and mass of the first material that is a fiber containing first material. In other words, there are embodiments in which some of the components are composed of a first material that meets the density requirement but does not have fiber reinforcing, such as low density metal alloys, as well as some components that are formed of fiber containing first material. Thus, Tables 10 and 11 below include the first material volume and mass boundaries from Tables 8 and 9, and further specify a fiber reinforced first material volume (Vol_M1FR), a fiber reinforced first material mass (Mass_M1FR), and the associated volume and mass ratios. The total volume of material, sometimes referred to as the total material volume, specifically excludes any lightweight fillers that may be incorporated within the club head and have a density less than 0.05 g/cc.

TABLE 10

I
J
K
L

Total Volume of Material (cm{circumflex over ( )}3):
≥70
≥72.5
≥75
≥77.5

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
≥40
≥50
≥60
≥70

Vol_M1/Vol_Total(%)
≥60%
≥70%
≥80%
≥90%

First material Mass (grams): Mass_M1
≥80
≥90
≥110
≥120

Mass_M1/Mass_Total(%)
≥40%
≥45%
≥50%
≥55%

Fiber reinforced first material volume
≥40
≥45
≥50
≥60

(cm{circumflex over ( )}3): Vol_M1FR

Vol_M1FR/Vol_M1(%)
≥60%
≥70%
≥80%
≥90%

Fiber reinforced first material mass
≥60
≥70
≥75
≥85

(grams): Mass_M1FR

Mass_M1FR/Mass_M1(%)
≥45%
≥50%
≥60%
≥70%

TABLE 11

M
N
O
P

Total Volume of Material (cm{circumflex over ( )}3):
≤90
≤85
≤82.5
≤80

Vol_Total

First material Volume (cm{circumflex over ( )}3):
≤80
≤77.5
≤75
≤72.5

Vol_M1

Vol_M1/Vol_Total(%)
≤95%
≤92.5%
≤90%
≤87.5%

First material Mass (grams):
≤135
≤125
≤115
≤105

Mass_M1

Mass_M1/Mass_Total(%)
≤0%
≤67.5%
≤65%
≤62.5%

Fiber reinforced first material
≤75
≤65
≤55
≤45

volume (cm{circumflex over ( )}3): Vol_M1FR

Vol_M1FR/Vol_M1(%)
≤97.5%
≤95%
≤90%
≤85%

Fiber reinforced first material
≤110
≤100
≤90
≤80

mass (grams): Mass_M1FR

Mass_M1FR/Mass_M1(%)
≤95%
≤90%
≤85%
≤80%

In further embodiments the fiber reinforced first material volume (Vol_M1FR) includes the volume associated with components containing a long-fiber first material and components containing a short-fiber first material, and thus there is a long-fiber first material volume, a long-fiber first material mass, a short-fiber first material volume, and a short-fiber first material mass. The long-fiber first material is distinguished from the short-fiber first material by the average length of the fibers contained in the material, with the long-fiber first material having an average fiber length of 10 mm or greater, and the short-fiber first material having an average fiber length of less than 9 mm. In further embodiments the long-fiber first material has an average fiber length of at least 15 mm, 20 mm, or 25 mm; and in an embodiment the long-fiber first material includes a plurality of continuous fibers that extends continuously between two points on a perimeter of the crown 4620, the sole plate 4640, and/or the face plate 4610. If a component comprises multiple layers and at least one layer has long-fiber first material then the mass and volume of the entire component is included in the long-fiber first material volume and the long-fiber first material mass. In a further embodiment the short-fiber first material having an average fiber length of less than 8 mm, and less than 7 mm, 6 mm, or 5 mm in additional embodiments. In one such embodiment the long-fiber first material mass is at least 101% of the short-fiber first material mass, and in further embodiments at least 120%, 140%, 160%, 180%, or 200%. In another embodiment the long-fiber first material mass is no more than 500% of the short-fiber first material mass, and in further embodiments no more than 475%, 450%, 425%, 400%, 375%, or 350%.

Tables 12A-12C further provides examples implementing the disclosed embodiments. Example 26 corresponds to embodiments such as those illustrated in FIGS. 160-175 and 176-191, and variations thereof, which have a front body portion 4602, a lightweight rear ring portion 4630, a lightweight composite face plate 4610, which may be a separate component attached to the front body portion 4602 or integrally formed therewith, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640. Example 27 corresponds to the embodiments having a lightweight front body portion 4602 that is integrally formed with a lightweight rear ring portion 4630, together referred to as a lightweight core frame 14000, along with a forward weighted portion 13000, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640. Example 28 corresponds to the embodiments having a lightweight front body portion 4602, a separate lightweight rear ring portion 4630, a forward weighted portion 13000, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640; the lightweight composite crown 4620 is not illustrated but is easily understood in light of the disclosure. Example 29 corresponds to the embodiments having a lightweight core frame 14000 that integrally includes the lightweight composite crown 4620, the lightweight composite sole plate 4640, and the lightweight rear ring portion 4630, all formed together as a single component with a front opening to receive a lightweight composite face plate 4610. Examples 31-33 corresponds to embodiments such as those illustrated in FIGS. 160-175, 176-191, and variations thereof, which have a front body portion 4602, a lightweight rear ring portion 4630, a lightweight composite face plate 4610, which may be a separate component attached to the front body portion 4602 or integrally formed therewith, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640. In one embodiment of examples 31-33 the front body portion 4602 comprises titanium alloy, while in another embodiment the lightweight rear ring portion 4630 comprises aluminum alloy. Examples 34-35 corresponds to embodiments such as those illustrated in FIGS. 160-175, 176-191, and variations thereof, which have a front body portion 4602, a lightweight rear ring portion 4630, a lightweight composite face plate 4610, which may be a separate component attached to the front body portion 4602 or integrally formed therewith, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640. In one embodiment of examples 34-35 the front body portion 4602 comprises aluminum alloy, while in another embodiment the lightweight rear ring portion 4630 comprises aluminum alloy. Examples 36-37 corresponds to embodiments such as those illustrated in FIGS. 160-175, and 176-222, and variations thereof, which have a front body portion 4602, a lightweight rear ring portion 4630, a face plate 4610, which may be a separate component attached to the front body portion 4602 or integrally formed therewith, and a lightweight composite crown 4620 and/or a lightweight composite sole plate 4640. In one embodiment of examples 36-37 the front body portion 4602 comprises aluminum alloy, while in another embodiment the face plate 4610 comprises titanium alloy, while in another embodiment the lightweight rear ring portion 4630 comprises aluminum alloy. With respect to all embodiments and examples, the lightweight rear ring portion 4630 need not be a distinct separate component, unless claimed as such, and may be formed as an integral portion of the front body portion 4602, the lightweight composite crown 4620, or the lightweight composite sole plate 4640. In such embodiments the lightweight rear ring portion 4630 is identified by a region in which a thickness is at least double the average thickness of the lightweight composite crown 4620, or the lightweight composite sole plate 4640. Similarly, the lightweight composite crown 4620 and the lightweight composite sole plate 4640 need not be distinct and separate components, unless claimed as such, and may be formed as an integral aft-body having a lightweight composite crown portion and a lightweight composite sole portion.

TABLE 12A

Example 26
Example 27
Example 28
Example 29

Total Volume of Material (cm{circumflex over ( )}3):
78.2 ±
C1
75.1 ±
C1
75.9 ±
C1
79.3 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
57.6 ±
C2
61.9 ±
C2
66.8 ±
C2
71.8 ±
C2

Vol_M1/Vol_Total(%)
74% ±
C3
82% ±
C3
88% ±
C3
91% ±
C3

Second material Volume (cm{circumflex over ( )}3): Vol_M2
17 ±
C4
0.72 ±
C5
0.7 ±
C5
0.8 ±
C5

Vol_M2/Vol_Total(%)
22% ±
C6
1.0% ±
C7
0.9% ±
C7
1.0% ±
C7

Third material Volume (cm{circumflex over ( )}3): Vol_M3
3.6 ±
C8
12.48 ±
C9
8.4 ±
C10
6.7 ±
C10

Vol_M3/Vol_Total(%)
4.6% ±
C11
16.6% ±
C12
11.1% ±
C13
8.4% ±
C13

Total Head Mass (grams): Mass_Total
205 ±
C14
200 ±
C14
199 ±
C14
200 ±
C14

First material Mass (grams): Mass_M1
89 ±
C15
96 ±
C15
126 ±
C16
112 ±
C16

Mass_M1/Mass_Total(%)
43.4% ±
C17
48.0% ±
C17
63.3% ±
C18
56.0% ±
C18

Second material Mass (grams): Mass_M2
74 ±
C19
3 ±
C20
3 ±
C20
3 ±
C20

Mass_M2/Mass_Total(%)
36.1% ±
C21
1.5% ±
C22
1.5% ±
C22
1.5% ±
C22

Third material Mass (grams): Mass_M3
42 ±
C23
101 ±
C24
70 ±
C25
85 ±
C26

Mass_M3/Mass_Total(%)
20.5% ±
C27
50.5% ±
C28
35.2% ±
C29
42.5% ±
C29

TABLE 12B

Example
Example
Example
Example
Example

31
32
33
34
35

Total Volume of Material (cm{circumflex over ( )}3):
72 ±
C1
71 ±
C1
71 ±
C1
77 ±
C1
78 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
51 ±
C2
51 ±
C2
47 ±
C2
74 ±
C2
74 ±
C2

Vol_M1/Vol_Total(%)
71% ±
C3
72% ±
C3
66% ±
C3
96% ±
C3
95% ±
C3

Second material Volume (cm{circumflex over ( )}3): Vol_M2
19 ±
C4
16 ±
C4
21 ±
C4
1 ±
C4
1 ±
C4

Vol_M2/Vol_Total(%)
27% ±
C6
23% ±
C6
30% ±
C6
1% ±
C6
1% ±
C6

Third material Volume (cm{circumflex over ( )}3): Vol_M3
2 ±
C8
4 ±
C8
3 ±
C8
3 ±
C8
3 ±
C8

Vol_M3/Vol_Total(%)
3% ±
C11
5.6% ±
C11
4% ±
C11
4% ±
C11
4% ±
C11

Total Head Mass (grams): Mass_Total
200 ±
C14
203 ±
C14
200 ±
C14
203 ±
C14
203 ±
C14

First material Mass (grams): Mass_M1
93 ±
C15
87 ±
C15
92 ±
C15
161 ±
C15
152 ±
C15

Mass_M1/Mass_Total(%)
46.5% ±
C17
43% ±
C17
46% ±
C17
79% ±
C17
75 ±
C17

Second material Mass (grams): Mass_M2
83 ±
C19
71 ±
C19
91 ±
C19
4 ±
C19
3 ±
C19

Mass_M2/Mass_Total(%)
41.5% ±
C21
35% ±
C21
46% ±
C21
2% ±
C21
1.5% ±
C21

Third material Mass (grams): Mass_M3
24 ±
C23
45 ±
C23
17 ±
C23
38 ±
C23
48 ±
C23

Mass_M3/Mass_Total(%)
12% ±
C27
22% ±
C27
8.5% ±
C27
19% ±
C27
24% ±
C27

TABLE 12C

Example 36
Example 37

Total Volume of Material (cm{circumflex over ( )}3):
68 ±
C1
69 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
58 ±
C2
58.5 ±
C2

Vol_M1/Vol_Total(%)
85% ±
C3
85% ±
C3

Second material Volume (cm{circumflex over ( )}3): Vol_M2
7 ±
C4
7.5 ±
C4

Vol_M2/Vol_Total(%)
10% ±
C6
11% ±
C6

Third material Volume (cm{circumflex over ( )}3): Vol_M3
3 ±
C8
2.5 ±
C8

Vol_M3/Vol_Total(%)
5% ±
C11
4% ±
C11

Total Head Mass (grams): Mass_Total
203 ±
C14
203 ±
C14

First material Mass (grams): Mass_M1
133 ±
C15
126 ±
C15

Mass_M1/Mass_Total(%)
66% ±
C17
62% ±
C17

Second material Mass (grams): Mass_M2
33 ±
C19
33 ±
C19

Mass_M2/Mass_Total(%)
16% ±
C21
16% ±
C21

Third material Mass (grams): Mass_M3
37 ±
C23
44 ±
C23

Mass_M3/Mass_Total(%)
18% ±
C27
22% ±
C27

It is important to note that while the disclosed examples discuss the first material volume, first material mass, second material volume, second material mass, third material volume, and third material mass, each individual volume and mass stands on its own, or may be paired with another material volume and mass, or may be combined with the existence of all three material volumes and masses. Thus, the first material volume and first material mass may be claimed individually, or in relation to the total material volume or head mass, the second material volume or second material mass, and/or the third material volume or third material mass; and likewise for the second material volume and second material mass, and/or the third material volume or third material mass. In Tables 12A-12C constants are labeled C1-C29 and therefore enable ranges associated with the values listed in the table. Constant C1 is 8 cc, and in additional embodiments C1 is 7 cc, 6 cc, 5 cc, 4 cc, 3 cc, 2 cc, or 1 cc. Constant C2 is 7 cc, and in additional embodiments is 6 cc, 5 cc, 4 cc, 3 cc, 2 cc, or 1 cc. When constants are associated with a percentage the constant reflects an integer adjustment to the percentage, not a percentage adjustment of the listed percentage. For example, if constant C3 is 5%, the disclosed range for example 26 is 69% to 79%, not an adjustment of 5% of the listed 74%. Constant C3 is 5, and in additional embodiments is 4, 3, 2, or 1. Constant C4 is 3 cc, and in additional embodiments is 2 cc or 1 cc. Constance C5 is 0.5, and in additional embodiments 0.4, 0.3, 0.2, or 0.1. Constant C6 is 10, and in additional embodiments is 8, 6, 4, or 2. Constant C7 is 0.4, and in additional embodiments 0.3, 0.2, or 0.1. Constant C8 is 1.5 cc, and in additional embodiments 1.25 cc, 1 cc, 0.75 cc, 0.5 cc, or 0.25 cc. Constant C9 is 3 cc, and in additional embodiments 2.5 cc, 2 cc, 1.5 cc, 1 cc, or 0.5 cc. Constant C10 is 2 cc, and in additional embodiments 1.75 cc, 1.5 cc, 1.25 cc, 1 cc, 0.75 cc, 0.5 cc, or 0.25 cc. Constant C11 is 3, and in additional embodiments is 2.5, 2, 1.5, 1, or 0.5. Constant C12 is 5, and in additional embodiments is 4, 3, 2, or 1. Constant C13 is 3.5, and in additional embodiments is 3, 2.5, 2, 1.5, 1, or 0.5. Constant C14 is 5 grams, and in additional embodiments is 4 grams, 3 grams, 2 grams, or 1 gram. Constant C15 is 9 grams, and in additional embodiments is 7 grams, 5 grams, 3 grams, or 1 gram. Constant C16 is 13 grams, and in additional embodiments is 10 grams, 7 grams, 4 grams, or 1 gram. Constant C17 is 6, and in additional embodiments is 5, 4, 3, 2, or 1. Constant C18 is 8, and in additional embodiments is 6, 4, 2, or 1. Constant C19 is 8 grams, and in additional embodiments is 6 grams, 4 grams, 2 grams, or 1 gram. Constant C20 is 2 grams, and in additional embodiments is 1.5 grams, 1 gram, or 0.5 gram. Constant C21 is 6, and in additional embodiments is 5, 4, 3, 2, or 1. Constant C22 is 0.6, and in additional embodiments is 0.5, 0.4, 0.3, 0.2, or 0.1. Constant C23 is 5 grams, and in additional embodiments is 4 grams, 3 grams, 2 grams, or 1 gram. Constant C24 is 12 grams, and in additional embodiments is 10 grams, 8 grams, 6 grams, 4 grams, or 2 grams. Constant C25 is 7 grams, and in additional embodiments is 5 grams, 3 grams, or 1 gram. Constant C26 is 9 grams, and in additional embodiments is 7 grams, 5 grams, 3 grams, or 1 gram. Constant C27 is 10, and in additional embodiments is 8, 6, 4, or 2. Constant C28 is 20, and in additional embodiments is 16, 12, 8, 4, or 2. Constant C29 is 15, and in additional embodiments is 12, 9, 6, 3, or 1. While the values in Table 12A-12C are indicated as plus or minus the constant, the disclosure enables unbound ranges, as well as ranges bound only by zero. For example, in Example 26 the Vol_Totalis indicated as 78.2±C1, and in one embodiment C1 is 7 cc, therefore the disclosure includes individual lower bounds such as at least 71.2, as well as individual upper bounds such as no more than 85.2; and this applies to any variable disclosed herein with a plus or minus a constant.

Continuing with the examples, and consistent with the disclosure of Tables 10 and 11, Tables 13A-13C goes to further disclose further examples including variations of Examples 26-36 of Table 12A-12C, which are referred to as Examples 26A, 27A, 28A, 29A, 30A, 31A, 32A, 33A, 34A, 35A, 36A, and 37A, including fiber reinforced first material volumes (Vol_M1FR), fiber reinforced first material masses (Mass_M1FR), Vol_M1FR-to-Vol_M1ratios, and Mass_M1FR-to-Mass_M1ratios. As disclosed above, the first material has a first material density of 0.1 g/cc to 3.5 g/cc, and therefore may include metallic and nonmetallic material. For instance the first material may be an aluminum alloy, magnesium alloy, or other low density metal alloy, or it may be any of the disclosed nonmetallic materials within the density range. However, some embodiments further characterize the first material by the volume and mass of the first material that is a fiber containing first material, which includes either, or both, long-fiber first material and short-fiber first material. In other words, there are embodiments in which some of the components are composed of a first material that meets the density requirement but does not have fiber reinforcing, such as low density metal alloys, as well as some components that are formed of fiber containing first material.

TABLE 13A

Example
Example
Example
Example

26A
27A
28A
29A

Total Volume of Material (cm{circumflex over ( )}3):
78.2 ±
C1
75.1 ±
C1
75.9 ±
C1
79.3 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
57.6 ±
C2
61.9 ±
C2
66.8 ±
C2
71.8 ±
C2

Vol_M1/Vol_Total(%)
74% ±
C3
82% ±
C3
88% ±
C3
91% ±
C3

First material Mass (grams): Mass_M1
89 ±
C15
96 ±
C15
126 ±
C16
112 ±
C16

Mass_M1/Mass_Total(%)
43.4% ±
C17
48.0% ±
C17
63.3% ±
C18
56.0% ±
C18

Fiber reinforced first material volume
50.4 ±
C30
54.3 ±
C31
43.8 ±
C32
67.8 ±
C33

(cm{circumflex over ( )}3): Vol_M1FR

Vol_M1FR/Vol_M1(%)
87.5% ±
C34
87.7% ±
C35
65.6% ±
C36
94.4% ±
C37

Fiber reinforced first material mass
74 ±
C38
79 ±
C39
64 ±
C40
102 ±
C41

(grams): Mass_M1FR

Mass_M1FR/Mass_M1(%)
83.1% ±
C42
82.3% ±
C43
50.8% ±
C44
91.1% ±
C45

TABLE 13B

Example
Example
Example
Example
Example

31A
32A
33A
34A
35A

Total Volume of Material (cm{circumflex over ( )}3):
72 ±
C1
71 ±
C1
71 ±
C1
77 ±
C1
78 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
51 ±
C2
51 ±
C2
47 ±
C2
74 ±
C2
74 ±
C2

Vol_M1/Vol_Total(%)
71% ±
C3
72% ±
C3
66% ±
C3
96% ±
C3
95% ±
C3

First material Mass (grams): Mass_M1
93 ±
C15
87 ±
C15
92 ±
C15
161 ±
C15
152 ±
C15

Mass_M1/Mass_Total(%)
46.5% ±
C17
43% ±
C17
46% ±
C17
79% ±
C17
75 ±
C17

Fiber reinforced first material
41 ±
C30
41 ±
C30
40 ±
C30
41 ±
C30
42 ±
C30

volume (cm{circumflex over ( )}3): Vol_M1FR

Vol_M1FR/Vol_M1(%)
80% ±
C34
80% ±
C34
85% ±
C34
55% ±
C34
57% ±
C34

Fiber reinforced first material mass
78 ±
C38
75 ±
C38
75 ±
C38
76 ±
C38
78 ±
C38

(grams): Mass_M1FR

Mass_M1FR/Mass_M1(%)
84% ±
C42
86% ±
C42
82% ±
C42
47% ±
C42
51% ±
C42

TABLE 13C

Example
Example

36A
37A

Total Volume of Material (cm{circumflex over ( )}3):
68 ±
C1
69 ±
C1

Vol_Total

First material Volume (cm{circumflex over ( )}3): Vol_M1
58 ±
C2
58.5 ±
C2

Vol_M1/Vol_Total(%)
85% ±
C3
85% ±
C3

First material Mass (grams): Mass_M1
133 ±
C15
126 ±
C15

Mass_M1/Mass_Total(%)
66% ±
C17
62% ±
C17

Fiber reinforced first material volume
27 ±
C30
27 ±
C30

(cm{circumflex over ( )}3): Vol_M1FR

Vol_M1FR/Vol_M1(%)
47% ±
C34
46% ±
C34

Fiber reinforced first material mass
53 ±
C38
53 ±
C38

(grams): Mass_M1FR

Mass_M1FR/Mass_M1(%)
40% ±
C42
42% ±
C42

Constants C1-C29 have already been disclosed. In Tables 13A-13C constant C30 is 7.2 cc, and in additional embodiments is 6 cc, 5 cc, 4 cc, 3 cc, 2 cc, or 1 cc. Constant C31 is 7.6 cc, and in additional embodiments is 6 cc, 4 cc, 2 cc, or 1 cc. Constant C31 is 7.6 cc, and in additional embodiments is 6 cc, 4 cc, 2 cc, or 1 cc. Constant C32 is 23 cc, and in additional embodiments is 20 cc, 17 cc, 14 cc, 11 cc, 8 cc, 5 cc, 3 cc, or 1 cc. Constant C33 is 4 cc, and in additional embodiments is 3 cc, 2 cc, or 1 cc. Constant C34 is 12.5, and in additional embodiments is 10, 7.5, 5, or 2.5. Constant C35 is 12.3, and in additional embodiments is 10, 7.5, 5, or 2.5. Constant C36 is 34.4, and in additional embodiments is 30, 25, 20, 15, 10, 5, or 2.5. Constant C37 is 5.6, and in additional embodiments is 4, 3, 2, or 1. Constant C38 is 15 grams, and in additional embodiments is 12 grams, 9 grams, 6 grams, 3 grams, or 1 gram. Constant C39 is 17 grams, and in additional embodiments is 14 grams, 11, grams, 8 grams, 5 grams, or 2 grams. Constant C40 is 62 grams, and in additional embodiments is 50 grams, 40 grams, 30 grams, 20 grams, 15 grams, 10 grams, 7.5 grams, 5 grams, or 2.5 grams. Constant C41 is 10 grams, and in additional embodiments is 8 grams, 6 grams, 4 grams, or 2 grams. Constant C42 is 16.9, and in additional embodiments is 13, 10, 7, 4, or 1. Constant C43 is 17.7, and in additional embodiments is 13, 10, 7, 4, or 1. Constant C44 is 49.2, and in additional embodiments is 40, 30, 20, 15, 10, 7.5, 5, or 2.5. Constant C45 is 8.9, and in additional embodiments is 7, 5, 3, or 1.

In a further embodiment of Example 26A or 28A, the previously defined long-fiber first material mass is at least 1010% of the short-fiber first material mass, and in additional embodiments at least 120%, 140%, 160%, 180%, or 200%. In another embodiment Example 26A or 28A, the long-fiber first material mass is no more than 500% of the short-fiber first material mass, and in further embodiments no more than 475%, 450%, 425%, 400%, 375%, or 350%. In a further embodiment of Example 27A, the previously defined long-fiber first material mass is at least 101% of the short-fiber first material mass, and in additional embodiments at least 110%, 120%, or 130%. In another embodiment of Example 27A, the long-fiber first material mass is no more than 200% of the short-fiber first material mass, and in further embodiments no more than 190%, 180%, 170%, 160%, or 150%. In a further embodiment of Example 29A, the previously defined long-fiber first material mass is no more than 50% of the short-fiber first material mass, and in additional embodiments no more than 45%, 40%, 35%, 30%, or 25%. In an addition embodiment of Example 29A, the previously defined long-fiber first material mass is at least 10% of the short-fiber first material mass, and in additional embodiments at least 12.5%, 15%, 17.5%, 20%, or 22.5%.

In any of the disclosed embodiments the lightweight composite face plate 4610 has a face plate mass of less than 30 grams, and in further embodiments less than 28 grams, 26 grams, or 24 grams. In another embodiment the face plate mass is at least 16 grams, and in further embodiments at least 18 grams or 20 grams. In a further embodiment the lightweight composite face plate 4610 contains at least X layer(s) formed of continuous long-fiber material as defined herein, where X is at least 1 and therefore a mass of the entire face plate 4610 is included in the long-fiber first material mass. This includes embodiments where the face plate 4610 is primarily formed of short-fiber material but includes at least one layer containing continuous long-fiber material, whether attached to an interior or exterior surface, for embedded within the short-fiber material. In one embodiment X is at least 24, and in further embodiments is at least 28, 32, 36, 40, or 44. In a further embodiment X is no more than 64, and in further embodiments no more than 60, 56, 52, or 48.

In any of the disclosed embodiments where the crown 4620 is a separate component attached to a portion of the club head 4600, the lightweight composite crown 4620 has a crown mass of less than 20 grams, and in further embodiments less than 18 grams, 16 grams, or 14 grams. In another embodiment the crown mass is at least 8 grams, and in additional embodiments at least 10 grams or 12 grams. In a further embodiment the lightweight composite crown 4620 contains at least X layer(s) formed of continuous long-fiber material as defined herein, where X is at least 1 and therefore a mass of the entire crown 4620 insert is included in the long-fiber first material mass. This includes embodiments where the crown 4620 is primarily formed of short-fiber material but includes at least one layer containing continuous long-fiber material, whether attached to an interior or exterior surface, for embedded within the short-fiber material.

In any of the disclosed embodiments the lightweight composite sole plate 4640 has a sole plate mass of less than 30 grams, and in further embodiments less than 28 grams, 26 grams, 24 grams, 22 grams, or 20 grams. In another embodiment the sole plate mass is at least 8 grams, and in additional embodiments at least 10 grams or 12 grams. In a further embodiment the lightweight composite sole plate 4640 contains at least X layer(s) formed of continuous long-fiber material as defined herein, where X is at least 1 and therefore a mass of the entire sole plate 4640 is included in the long-fiber first material mass. This includes embodiments where the sole plate 4640 is primarily formed of short-fiber material but includes at least one layer containing continuous long-fiber material, whether attached to an interior or exterior surface, for embedded within the short-fiber material.

In an embodiment, the Examples 26 and 26A, Examples 32 and 32A, Examples 35 and 35A, and Examples 37 and 37A, of Tables 12 and 13 correspond to the mass properties of Examples 16-20 of Table 6 and the disclosure of FIGS. 160-175.

In an embodiment the Examples 27, 27A, 31, 31A, 34, 34A, 36, and 36A of Tables 12 and 13 correspond the mass properties of Examples 27B-27F, 31B-31F, 34B-34F, 36B-36F in Table 14 below, with the club head oriented with a face angle of 0 degrees. The mass listed in any mass property tables herein is the total head mass unless noted otherwise.

TABLE 14

Examples
Examples
Examples
Examples
Examples

27B, 31B,
27C, 31C,
27D, 31D,
27E, 31E,
27F, 31F,

34B, 36B
34C, 36C
34D, 36D
34E, 36E
34F, 36F

CGX
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2.5 to 2.5
mm
−1.5 to 1.5
mm

CGY
31-42
mm
32-41
mm
33-40
mm
34-39
mm
35-38
mm

CGZ
−13 to 0
mm
−13 to −2
mm
−12 to −4
mm
−11 to −6
mm
−10 to −8
mm

ZUP
16-30
mm
18-28
mm
20-27
mm
20-25
mm
21-23
mm

DELTA1
21-32
mm
22-31
mm
23-30
mm
24-29
mm
25-28
mm

DELTA2
30-40
mm
32-40
mm
33-39
mm
34-39
mm
35-39
mm

MASS
180-210
g
195-209
g
197-208
g
198-207
g
199-205
g

IXX
310-440
kg · mm²
320-430
kg · mm²
330-420
kg · mm²
340-410
kg · mm²
350-400
kg · mm²

IYY
230-325
kg · mm²
240-315
kg · mm²
240-305
kg · mm²
250-295
kg · mm²
260-285
kg · mm²

IZZ
470-595
kg · mm²
480-570
kg · mm²
490-560
kg · mm²
500-550
kg · mm²
510-540
kg · mm²

CFX
42-62
mm
44-60
mm
46-58
mm
47-54
mm
48-52
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
39-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2 to 2
mm
−1.5 to 1.5
mm

BODY LIE
52-63
degrees
53-62
degrees
54-62
degrees
55-61
degrees
56-60
degrees

(CASTING)

ASM LIE
49-59.5
degrees
50-59
degrees
51-58
degrees
52-57
degrees
53-56
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
420-470
cm³

As with all tables disclosed herein, when a range is disclosed the upper boundary and/or the lower boundary are enabled to stand on their own without association with the opposite boundary. For example, the Zup ranges in the table above include 16-30 mm, 18-28 mm, 20-27 mm, 20-25 mm, and 21-23 mm, however they enable embodiments of Zup at least 16, 18, 20, and 21, as well as embodiments of Zup no greater than 30, 28, 27, 25, and 23. Further, any of the disclosed lower bounds may be combined with any of the disclosed upper bounds; for example Table 14 enables a Zup range of 16-23, as well as any other variation of the disclosed values. Further, any discreet value within the disclosed ranges is fully enabled and may be claimed either as a value or as a boundary to a range. These principles apply to each variable disclosed, and the contents of each table. As previously noted, for the purposes of this disclosure, and in light of the 10 mm grid shown in many of FIGS. 160-222, the embodiments shown with the grids are illustrated to scale and the disclosed grid may be used to identify the location of all aspects of the club head, including, but not limited to, dimensions such as the head height, and head width, head depth, as well as the regions in which portions of the club head are located, and/or where interfaces of the various components occur. Unless noted otherwise, the disclosed values based upon the grid are ±5% and may be claimed as such, however in further embodiments the disclosed values based upon the grid are ±4%, ±3%, ±2%, or ±1%, and may be claimed as such. For example with a simple 2-D distance, a distance from the shaft axis vertical plane to the rearmost point of the club head is 97.5 mm, and this a range of 97.5±5% is enabled, disclosed, and may be claimed, as well any range associated with ±4%, ±3%, ±2%, or ±1%. This applies to any point on any portion of the club heads disclosed.

Further, the components and construction of one embodiment may be disclosed for a compact club head, but are equally disclosed for sizes of any of the other club heads. Further, components labeled in one figure apply to similar unlabeled components in the other figures.

In an embodiment the Examples 28, 28A, 31, 31A, 34, 34A, 36, and 36A of Tables 12 and 13 correspond the mass properties of Examples 28B-28F, 31B-31F, 34B-34F, 36B-36F in Table 15 below, with the club head oriented with a face angle of 0 degrees.

TABLE 15

Examples
Examples
Examples
Examples
Examples

28B, 31B,
28C, 31C,
28D, 31D,
28E, 31E,
28F, 31F,

34B, 36B
34C, 36C
34D, 36D
34E, 36E
34F, 36F

CGX
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2.5 to 2.5
mm
−1.5 to 1.5
mm

CGY
32-43
mm
33-42
mm
34-41
mm
35-41
mm
36-40
mm

CGZ
−10 to 0
mm
−9 to −1
mm
−8 to −2
mm
−7 to −3
mm
−6 to −4
mm

ZUP
20-30
mm
21-28.5
mm
21.5-28
mm
22-27.5
mm
23-27
mm

DELTA1
21-31
mm
22-30
mm
23-29
mm
24-28
mm
23-27
mm

DELTA2
30-40
mm
31-39
mm
32-38
mm
33-37
mm
34-36
mm

MASS
180-210
g
195-209
g
197-208
g
199-207
g
199-205
g

IXX
320-430
kg · mm²
330-420
kg · mm²
340-410
kg · mm²
350-400
kg · mm²
360-390
kg · mm²

IYY
245-310
kg · mm²
250-300
kg · mm²
255-295
kg · mm²
260-290
kg · mm²
265-285
kg · mm²

IZZ
470-595
kg · mm²
480-565
kg · mm²
490-555
kg · mm²
500-545
kg · mm²
510-535
kg · mm²

CFX
45-62
mm
47-59
mm
49-57
mm
50-56
mm
51-55
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
39-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2 to 2
mm
−1.5 to 1.5
mm

BODY LIE
51-63
degrees
52-61
degrees
52-60
degrees
53-59
degrees
54-58
degrees

(CASTING)

ASM LIE
49-59.5
degrees
50-59
degrees
51-58
degrees
52-57
degrees
53-56
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
430-465
cm³

Example 29 corresponds to the embodiments having a lightweight core frame 14000 that integrally includes the lightweight composite crown 4620, the lightweight composite sole plate 4640, and the lightweight rear ring portion 4630, all formed together as a single component with a front opening to receive a lightweight composite face plate 4610. The lightweight core frame 14000 may include at least one core port 14200, which in some embodiments has a core port sleeve 14300 for attachment of a front sole weight 4660, which may be secured by a fastener 4664. The illustrated embodiment includes a plurality of front sole weights 4660, which may be interchangeable. The rear weight 4650 and/or the forward weighted portion 13000 may be at least partially embedded within the lightweight core frame 14000, or attached to the lightweight core frame 14000. In one embodiment the lightweight core frame 14000 is a unitary molding of nonmetallic fiber reinforced material, which has a density less than 2 g/cc, and in further embodiments less than 1.8 g/cc, 1.6 g/cc, 1.4 g/cc, or 1 g/cc. In a further embodiment the forward weighted portion 13000 is formed of a steel alloy. In one embodiment the forward weighted portion 13000 has a forward weighted portion mass of at least 10 grams, and in further embodiments at least 14, 18, or 22 grams. In another embodiment the forward weighted portion mass is no more than 60 grams, and in further embodiments no more than 55, 50, 45, or 40 grams. In another embodiment, the forward weighted portion 13000 extends in the direction of the x-axis for a distance of at least 25 mm, and in further embodiments at least 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, or 60 mm. In embodiment the rear weight 4650 may include a secondary rear weight 4660, which may be interchangeable with the front sole weight 4660, and is secured to the rear weight 4650 by a fastener such as fastener 4664 or fastener 4652. Thus, the rear weight 4650 may incorporate a port of the same size and shape as the core port 14200.

In an embodiment the Examples 29, 29A, 31, 31A, 34, 34A, 36, and 36A of Tables 12 and 13 correspond the mass properties of Examples 29B-29F, 31B-31F, 34B-34F, 36B-36F in Table 16 below, with the club head oriented with a face angle of 0 degrees.

TABLE 16

Example 29B
Example 29C
Example 29D
Example 29E
Example 29F

CGX
−5 to 5
mm
−4.5 to 4
mm
−4 to 3
mm
−3.5 to 2.5
mm
−3 to 1.5
mm

CGY
25-40
mm
27-39
mm
28-38
mm
28-37
mm
28-36
mm

CGZ
−13 to −1
mm
−12 to −2
mm
−11 to −3
mm
−10 to −4
mm
−9 to −5
mm

ZUP
16-30
mm
18-28
mm
20-27
mm
20-25
mm
21-23
mm

DELTA1
24-35
mm
25-34
mm
26-33
mm
27-32
mm
26-31
mm

DELTA2
31-42
mm
32-41
mm
33-40
mm
34-39
mm
35-38
mm

MASS
180-210
g
195-207
g
196-206
g
197-204
g
198-204
g

IXX
310-400
kg · mm²
300-390
kg · mm²
310-380
kg · mm²
320-370
kg · mm²
330-360
kg · mm²

IYY
245-310
kg · mm²
250-300
kg · mm²
255-295
kg · mm²
260-290
kg · mm²
265-285
kg · mm²

IZZ
420-550
kg · mm²
430-540
kg · mm²
440-530
kg · mm²
450-520
kg · mm²
460-510
kg · mm²

CFX
45-62
mm
47-59
mm
49-57
mm
50-56
mm
51-55
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
39-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2 to 2
mm
−1.5 to 1.5
mm

BODY LIE
51-63
degrees
52-61
degrees
52-60
degrees
53-59
degrees
54-58
degrees

(CASTING)

ASM LIE
49-59.5
degrees
50-59
degrees
51-58
degrees
52-57
degrees
53-56
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
430-470
cm³

FIGS. 176-191 illustrate another embodiment without a forward weighted portion 13000, but including at least two front sole weights 4660 located in front body portion ports 4603. In this embodiment the front body portion 4602 is formed of the second material, but incorporates a separate lightweight rear ring portion 4630, a lightweight composite crown 4620, and a lightweight composite sole plate 4640 formed of the first material. The lightweight rear ring portion 4630 is shaped to establish important locations of atoe ring joint 4633 and a heel ring joint 4633, seen best in FIG. 186. In one embodiment the toe ring joint 4633 is located a toe joint distance from the shaft axis vertical plane (SAVP), and the heel ring joint 4633 is located a heel joint distance from the shaft axis vertical plane (SAVP), and the toe joint distance is not equal to the heel joint distance. This asymmetry aids in durability, stress distribution, and provides preferred deflection. In one embodiment the toe joint distance is at least 101% of the heel joint distance, and in additional embodiments is at least 105%, 110%, 115%, 120%, 125%, or 130%. In another embodiment the toe joint distance is no more than 200% of the heel joint distance, and no more than 190%, 180%, 170%, 160%, or 150% in additional embodiments. In another embodiment the lowest portion of the heel joint is located at a heel joint elevation, and the lowest portion of the toe joint is located at a toe joint elevation, seen in FIG. 188. In one embodiment the toe joint elevation is at least 130% of the heel joint elevation, and at least 135%, 140%, 145%, or 150% in additional embodiments. In one embodiment the front body portion 4602 is formed of titanium alloy.

Additionally, as seen in FIGS. 176 and 189, the club head 4600 components are configured to create a toe panel adjacency region 16000, having a forward toe region point 16010 and a rearward toe region point 16020, and a heel panel adjacency region 17000, having a forward heel region point 17010 and a rearward heel region point 17020. Withing the toe panel adjacency region 16000 and the heel panel adjacency region 17000, the lightweight composite sole plate 4640 and a lightweight composite crown 4620, in the form of an insert, have edges located within 3 mm of each other. In one embodiment a portion of both the front body portion 4602 and the lightweight rear ring portion 4630 are formed to facilitate this proximity, while still achieving the desired durability. In one embodiment the forward toe region point 16010 is located a FTRP distance behind the shaft axis vertical plane (SAVP), and the forward heel region point 17010 is located a FHRP distance behind the shaft axis vertical plane (SAVP). In one embodiment the FTRP distance is greater than the FHRP distance. In one embodiment the FHRP distance and/or the FTRP distance is at least 20 mm, and at least 24 mm or 28 mm in additional embodiments. The toe panel adjacency region 16000 has a y-axis TPAR distance between the forward toe region point 16010 and the rearward toe region point 16020, and the heel panel adjacency region 17000 has a HPAR distance between the forward heel region point 17010 and the rearward heel region point 17020. In another embodiment the TPAR distance and/or the HPAR distance is at least 20 mm, and at least 25 mm, 30 mm, 35 mm, or 40 mm in additional embodiments. In a further embodiment the TPAR distance and/or the HPAR distance is no more than 70 mm, and no more than 65 mm, 60 mm, 55 mm, or 50 mm in additional embodiments.

In an embodiment the disclosure of FIGS. 176-191 provides the mass properties of Examples 30A-30E in Table 17 below, as well as the mass properties of Example 33 of Tables 12 and 13, and variations of Example 31, 34, and 36 of Tables 12 and 13, with the club head oriented with a face angle of 0 degrees.

TABLE 17

Examples
Examples
Examples
Examples
Examples

30A, 33A,
30B, 33B,
30C, 33C,
30D, 33D,
30E, 33E,

31A, 34A,
31B, 34B,
31C, 34C,
31D, 34D,
31E, 34E,

36A
36B
36C
36D
36E

CGX
−5 to 5
mm
−4.5 to 4
mm
−4 to 3
mm
−3.5 to 2.5
mm
−3 to 1.5
mm

CGY
25-42
mm
26-41
mm
27-40
mm
28-38
mm
28-36
mm

CGZ
−11 to 0
mm
−10 to −1
mm
−9 to −2
mm
−8 to −3
mm
−7 to −3.5
mm

ZUP
20-30
mm
21-29
mm
22-28
mm
23-27
mm
24-26
mm

DELTA1
16-29
mm
17-28
mm
18-27
mm
19-26
mm
20-25
mm

DELTA2
31-41
mm
32-40
mm
33-39
mm
34-38
mm
35-37
mm

MASS
180-210
g
195-209
g
196-208
g
197-207
g
198-205
g

IXX
260-360
kg · mm²
270-350
kg · mm²
280-340
kg · mm²
285-330
kg · mm²
290-320
kg · mm²

IYY
245-310
kg · mm²
250-300
kg · mm²
255-295
kg · mm²
260-290
kg · mm²
265-290
kg · mm²

IZZ
430-530
kg · mm²
430-510
kg · mm²
430-490
kg · mm²
440-480
kg · mm²
450-470
kg · mm²

CFX
45-62
mm
47-59
mm
49-57
mm
50-56
mm
51-56
mm

CFY
9-18
mm
11-16
mm
12-15
mm
12.5-14.5
mm
13-14
mm

CFZ
35-45
mm
36-44
mm
37-43
mm
38-42
mm
38-41
mm

BP PROJ
−5 to 5
mm
−4 to 4
mm
−3 to 3
mm
−2 to 2
mm
−1.5 to 1.5
mm

BODY LIE
51-63
degrees
52-61
degrees
52-60
degrees
53-59
degrees
54-58
degrees

(CASTING)

ASM LIE
49-59.5
degrees
50-59
degrees
51-58
degrees
52-57
degrees
53-56
degrees

(FCT IN

STD)

LOFT
6-14
degrees
7-13
degrees
8-12
degrees
8.5-12
degrees
9-12
degrees

VOLUME
390-550
cm³
400-520
cm³
410-490
cm³
420-480
cm³
430-470
cm³

In one embodiment example 26 corresponds to an embodiment of FIGS. 160-175 having a front body portion 4602, a lightweight rear ring portion 4630, a lightweight composite face plate 4610, a lightweight composite crown 4620, and a lightweight composite sole plate 4640. In a further embodiment the lightweight composite crown 4620 is an oversized lightweight composite crown 4620 having any of the disclosed relationships regarding the proximity to the face plate 4610. In another embodiment the lightweight composite crown 4620 and/or the lightweight composite sole plate 4640 includes at least one layer of uni-directional fiber reinforcement that extends continuously between two points on a perimeter of the crown 4620 and/or sole plate 4640. In another embodiment the lightweight rear ring portion 4630 is formed of an aluminum alloy, magnesium alloy, or a nonmetallic composite material. In a further embodiment the lightweight rear ring portion 4630 is formed of a fiber-reinforced non-metallic composite material, which in a further embodiment has fibers of a length of less than 10 mm.

In an embodiment in which the front body portion 4602 is titanium alloy the second material mass (Mass_M2) is significantly higher than the values in Table 8, and in one embodiment is at least 60 grams, and at least 63, 66, 69, or 72 grams in further embodiments. In another embodiment in which the front body portion 4602 is titanium alloy the second material mass (Mass_M2) is significantly higher than the values in Table 8 but in one embodiment no more than 90 grams, and no more than 86, 82, 78, or 74 grams in further embodiments. Thus, in one titanium alloy front body portion 4602 embodiment the Mass_M2-to-Mass_Totalratio is at least 28%, and at least 30%, 32%, or 34% in further embodiments. In a further titanium alloy front body portion 4602 embodiment the Mass_M2-to-Mass_Totalratio is no more than 44%, and no more than 42%, 40%, or 38% in further embodiments.

In the previously disclosed embodiments the first material has a first material density of 0.1 g/cc to 3.5 g/cc, the second material has a second material density of 3.6 g/cc to 5.5 g/cc, and the third material has a third material density of 5.6 g/cc to 20.0 g/cc). A further series of embodiments narrows the range of the first material density to 0.6 g/cc to 2.8 g/cc. Additionally, a further series of embodiments narrows the range of the second material density to 4.2 g/cc to 4.9 g/cc. Further, another series of embodiments narrows the range of the third material density to 7.5 g/cc to 18.5 g/cc.

Now the mass distribution of another series of embodiments will be disclosed in detail. This series of embodiments describes the mass distribution of a club head having an aluminum alloy component, or components, that contribute a significant portion of the club head mass, which in one embodiment accounts for at least 17.5% of the club head mass associated with an aluminum alloy component, or components, referred to as the aluminum alloy mass percentage. All such embodiments are generally referred to as the significant aluminum alloy mass percentage embodiments. In further embodiments the aluminum alloy mass percentage is at least 22.5%, 27.5%, 32.5%, or 37.5%. In additional embodiments the aluminum alloy mass percentage is no more than 75%, 65%, 55%, or 45%. The aluminum alloy component, or components, create a total aluminum alloy mass, which aids in further describing embodiments and the location and range of the aluminum alloy component, or components.

For example, in one embodiment at least 10% of the total aluminum alloy mass is located between the 2R plane and the shaft axis vertical plane (SAVP), while in another embodiment at least 10% of the total aluminum alloy mass is located above the face center horizontal plane (FCHP), while in a further embodiment at least 10% of the total aluminum alloy mass is located below the face center horizontal plane (FCHP), while in still another embodiment at least 10% of the total aluminum alloy mass is located rearward of the 2R plane, or post-2R, while in still a further embodiment at least 5% of the total aluminum alloy mass is located forward of the SAVP, or pre-SAVP, while in still another embodiment at least 2.5% of the total aluminum alloy mass is located rearward of the 9R plane, or post-9R. In additional embodiments the % of the total aluminum alloy mass located between the 2R plane and the shaft axis vertical plane (SAVP) is increased to at least 12.5%, 15%, or 17.5%. Likewise, in additional embodiments the % of the total aluminum alloy mass located above the face center horizontal plane (FCHP) is increased to at least 12.5%, 15%, or 17.5%. Similarly, in additional embodiments the % of the total aluminum alloy mass located below the face center horizontal plane (FCHP) is increased to at least 12.5%, 15%, or 17.5%. In further embodiments the % of the total aluminum alloy mass located rearward of the 2R plane is increased to at least 12.5%, 15%, or 17.5%. In still further embodiments the % of the total aluminum alloy mass located rearward of the 2R plane, or post-2R, is increased to at least 12.5%, 15%, or 17.5%. In additional embodiments the % of the total aluminum alloy mass located forward of the SAVP, or pre-SAVP, is increased to at least 7.5%, 10%, or 12.5%. Finally, in still further embodiments the % of the total aluminum alloy mass located rearward of the 9R plane, or post-9R, is increased to at least 5%, 7.5%, or 10%.

In another embodiment no more than 50% of the total aluminum alloy mass is located between the 2R plane and the shaft axis vertical plane (SAVP), while in another embodiment no more than 60% of the total aluminum alloy mass is located above the face center horizontal plane (FCHP), while in a further embodiment no more than 70% of the total aluminum alloy mass is located below the face center horizontal plane (FCHP), while in still another embodiment no more than 35% of the total aluminum alloy mass is located rearward of the 2R plane, or post-2R, while in still a further embodiment no more than 35% of the total aluminum alloy mass is located forward of the SAVP, or pre-SAVP, while in still another embodiment no more than 15% of the total aluminum alloy mass is located rearward of the 9R plane, or post-9R. In additional embodiments the % of the total aluminum alloy mass located between the 2R plane and the shaft axis vertical plane (SAVP) is decreased to no more than 55%, 50%, 45%, 40%, or 35%. Likewise, in additional embodiments the % of the total aluminum alloy mass located above the face center horizontal plane (FCHP) is decreased to no more than 55%, 50%, 45%, or 40%. Similarly, in additional embodiments the % of the total aluminum alloy mass located below the face center horizontal plane (FCHP) is decreased to no more than 65%, 60%, or 55%. In further embodiments the % of the total aluminum alloy mass located rearward of the 2R plane is decreased to no more than 32.5%, 30%, 27.5%, 25%, or 22.5%. In additional embodiments the % of the total aluminum alloy mass located forward of the SAVP, or pre-SAVP, is decreased to no more than 32.5%, 30%, 27.5%, or 25%. Finally, in still further embodiments the % of the total aluminum alloy mass located rearward of the 9R plane, or post-9R, is decreased to no more than 12.5%, 10%, or 7.5%. As with all of the disclosure herein, any of these relationships may be used in singularity or in combination with any of the other relationships disclosed in these aluminum alloy component paragraphs, or elsewhere in the disclosure.

As previously disclosed, the body can also include a front opening 4696 that is covered by the face plate 4610. The face plate 4610 may be in the form of a face plate 4610 insert supported by the ledge wall 4690 or face support ledge wall 4690, and/or 4692, also referred to as the insert recess wall 4692, as seen in FIGS. 127 and 128, or the face plate 4610 may wrap onto an upper, lower, heel, and/or toe portion of the lightweight front body portion 4602 and/or forward ledge 4680 and thereby cover the face opening 4696, such as is shown in FIG. 63 with respect to strike plate 1143. Thus, in one embodiment the face plate 4610 comprises material that is different than the material of the portion of the body that supports at least a portion of the face plate 4610, and/or is different than the material of the portion of the body that the face plate 4610 is joined to; and in another embodiment the face plate 4610 is joined via adhesive bonding. Taken further, in one embodiment the ledge wall 4690 or face support ledge wall 4690, and/or 4692, also referred to as the insert recess wall 4692, seen in FIG. 128 is formed of aluminum alloy, and the face plate 4610 insert is formed of a non-metallic material or a metallic material that is not aluminum alloy, such as titanium alloy, magnesium alloy, and/or a steel alloy. Likewise, in another embodiment where the face plate 4610 wraps onto an upper, lower, heel, and/or toe portion of the lightweight front body portion 4602 and/or forward ledge 4680 and covers the face opening 4696, the portion of the front body portion 4602 located at the interface with the face plate 4610 is formed of aluminum alloy, while the wrapping face plate 4610 is formed of a non-metallic material or a metallic material that is not aluminum alloy, such as titanium alloy, magnesium alloy, and/or a steel alloy. Thus, at least a portion of the face plate 4610 is supported by an aluminum alloy component, which in one embodiment means at least 25%, 50%, 75%, or 100% of a perimeter of the face plate 4610 is supported by an aluminum alloy component. This is easily illustrated using the angles illustrated in FIG. 126, with the 0 degree line extending vertically upward from the origin 205, the 180 degree line extending downward from the origin 205, the 90 degree line extending horizontally toward the heel, and the 270 degree line extending horizontally toward the toe. One skilled in the art will appreciate that the face plate has a perimeter whether it is a simple face plate, as seen in FIG. 126, or a wrapping strike plate 1143, such as that illustrated in FIG. 63. In one embodiment at least 30 degrees of the face plate perimeter located in the quadrant between 0 degrees and 270 degrees is supported by an aluminum alloy component, while in further embodiments the amount is increased to at least 45, 60, 75, or 90 degrees. In another embodiment at least 30 degrees of the face plate perimeter located in the quadrant between 180 degrees and 270 degrees is supported by an aluminum alloy component, while in further embodiments the amount is increased to at least 45, 60, 75, or 90 degrees. In still a further embodiment at least 30 degrees of the face plate perimeter located in the quadrant between 0 degrees and 90 degrees is supported by an aluminum alloy component, while in further embodiments the amount is increased to at least 45, 60, 75, or 90 degrees. In yet another embodiment at least 30 degrees of the face plate perimeter located in the quadrant between 90 degrees and 180 degrees is supported by an aluminum alloy component, while in further embodiments the amount is increased to at least 45, 60, 75, or 90 degrees.

In another embodiment at least a portion of the face plate 4610 is adhesively bonded to an aluminum alloy component, which in one embodiment means a bond area between the face plate 4610 and the aluminum alloy component is at least 50 mm², and in further embodiments at least 100 mm², 150 mm², 200 mm², 250 mm², 300 mm², 350 mm², 400 mm², 450 mm², 500 mm², or 550 mm². In any of these embodiments a thickness of the aluminum alloy component within the bond area is no more than 2 mm, and in further embodiments no more than 1.75 mm, 1.5 mm, or 1.25 mm. For example, with reference to FIG. 128, at least a portion of the ledge wall thickness 4699, within the bond area, is no more than 2 mm, and in further embodiments no more than 1.75 mm, 1.5 mm, or 1.25 mm. While in a further embodiment the average ledge wall thickness 4699, within the bond area, is no more than 2 mm, and in further embodiments no more than 1.75 mm, 1.5 mm, or 1.25 mm. And in still another embodiment the maximum ledge wall thickness 4699, within the bond area, is no more than 2 mm, and in further embodiments no more than 1.75 mm, 1.5 mm, or 1.25 mm. The club head components composed of aluminum alloy include one or more of the following: the cup, the ring, the forward portion, the front body portion, the front portion, the hosel, the sole insert, the sole plate, the strike face, the upper cup piece, the lower cup piece, the FCT system, the FCT fastener, a portion of the body 1102, the lightweight core frame, and/or the forward weighted portion, as well as portions and/or components thereof.

Incorporating such large amounts of aluminum alloy, which in many embodiments is disbursed throughout many regions of the club head, introduces many new challenges that must be overcome to ensure durability, performance, and ease of manufacture, which is further complicated since the club head also incorporates significant portions constructed of non-metallic materials and/or different metallic alloys. For instance, the more low-density materials used to form the club head means that the total material volume, not club head volume, is greater than conventional golf club heads, such as those formed solely of titanium alloy and perhaps incorporating a low density composite crown. As with most variables in club head design, the increased total material volume introduces new challenges and potential benefits. For example, increases in total material volume can improve the sound of the golf club head, however it can also result in manufacturing challenges such as increasing the quantity of components and the associated joints, which have the potential to become additional failure points. Additionally, supporting face plate 4610 from, and/or joining the face plate 4610 to, an aluminum alloy component introduces challenges in the design of such a golf club head in order to ensure durability and performance. In fact, golf club makers have shied away from such widespread use of aluminum alloys in large components of a golf club head, particularly in high stress areas supporting a face plate 4610 comprising a different material, because of concerns regarding durability and performance.

Examples 34-37 of Tables 12B, 12C, 13B, and 13C are specific significant aluminum alloy mass percentage embodiments, and illustrate the interplay between the first, second, and third material volumes and masses, in comparison with the total material volume and mass, as well as the percentages of the first material volume and mass that are fiber reinforced. The associated mass properties of these significant aluminum alloy mass percentage embodiments are found in Tables 6, 14, 15, 16, and 17. Properly balancing the many tradeoffs associated with incorporating significant aluminum alloy mass percentages can produce not only a durable club head, but one that also improves performance and reduces cost. Performance improvements are not only obtained by freeing up mass from undesirable areas and relocating it to desirable areas, but also by reducing abrupt stiffness variations within the shell of the golf club head, which can improve face performance. Contrary to convention thinking that suggested that the high tensile strength and Young's modulus of titanium alloys were necessary to produce a durable driver type golf club head, the presently disclosed embodiments have shown that the opposite improve performance when the aluminum alloy components are carefully designed to achieve the relationships disclosed herein. Further, these relationships are not simply about mass distribution, rather they overcome undesirable deformation and stress concentration issues associated with the incorporation of significant aluminum alloy components in areas of the club head that are subjected to high stress. This issue is particularly acute when a golf ball is struck near the perimeter of the face plate 4610. In fact significant effort was required to overcome undesirable deformation in the lower portion of the lightweight front body portion 4602, namely the sole 130 portion seen in FIGS. 94 and 95B, and/or the upper portion of the lightweight front body portion 4602, namely the forward ledge 4680 seen in FIG. 135A and the associated forward ledge thickness 4681, seen in FIG. 136.

Now, building upon the prior disclosed relationships, but now tailored to the significant aluminum alloy mass percentage embodiments, one embodiment has a center-forward-to-HT mass ratio of 0.6-1.1, where the center-forward-to-HT mass ratio is a ratio of a 4T-4H, 1S-4C, pre-2R mass to the forward heel and toe mass, with the forward heel and toe mass being the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass. In a further embodiment the center-forward-to-HT mass ratio is at least 0.65, 0.70, 0.75, or 0.80 in additional embodiments. The center-forward-to-HT mass ratio is no more than 1.05 in another embodiment, and no more than 1.05, 1.00, 0.95, or 0.90 in still further embodiments. Having a center-forward-to-HT mass ratio close to unity, and often less than 1.0, provides stability at impact not found in club heads having conventional weight distribution, provides the ability to increase Izz and Ixx, and/or control Iyy, while reducing the elevation of the balance point projection and/or controlling the magnitude of the CGy value and/or delta1 value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 32 grams, and in further embodiments is less than 30 grams, 28 grams, or 26 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 18 grams, 20 grams, 22 grams, or 24 grams. In one embodiment the forward heel and toe mass is less than 38 grams, and in further embodiments is less than 36 grams, 34 grams, or 32 grams. In another embodiment the forward heel and toe mass is at least 22 grams, 24 grams, 26 grams, 28 grams, or 30 grams.

Another embodiment has a center-forward-to-mid-section mass ratio of 0.75-1.375, where the center-forward-to-mid-section mass ratio is a ratio of a 4T-4H, 1S-4C, pre-2R mass to a mid-section mass. Here the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. In an embodiment the center-forward-to-mid-section mass ratio is at least 0.80, and at least 0.85, 0.9, 0.95, 1.0, or 1.05 in further embodiments. The center-forward-to-mid-section mass ratio is no more than 1.325 in an embodiment, and is no more than 1.275, 1.225, 1.175, or 1.125 in further embodiments. Having a center-forward-to-mid-section mass ratio close to unity, and in some embodiments greater than 1.0, enhances impact stability compared to clubs with standard weight distribution, allowing for increased Izz and Ixx, or controlled Iyy, while simultaneously reducing the elevation of the balance point projection and managing the CGy value and delta1 value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In a further embodiment the mid-section mass is no more than 50% of a pre-SAVR mass, and no more than 48%, 46%, 44%, 42%, 40%, or 38% in further embodiments. The mid-section mass is at least 26% of the pre-SAVR mass in one embodiment, and is at least 26%, 28%, 30%, 32%, 34%, or 36% in additional embodiments. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 32 grams, and in further embodiments is less than 30 grams, 28 grams, or 26 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 18 grams, 20 grams, 22 grams, or 24 grams. In one embodiment the mid-section mass is less than 36 grams, and in further embodiments is less than 34 grams, 32 grams, 30 grams, 28 grams, or 26 grams. In another embodiment the mid-section mass is at least 18 grams, 20 grams, 22 grams, or 24 grams.

Still a further embodiment has a forward-HT-to-mid-section mass ratio of 0.9-1.65, where the forward-HT-to-mid-section mass ratio is a ratio of a forward heel and toe mass to a mid-section mass. Here the forward heel and toe mass is the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass; and the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. In one embodiment the forward-HT-to-mid-section mass ratio is at least 0.95, and at least 1.0, 1.05, 1.1, 1.15, 1.2, or 1.25 in further embodiments. The forward-HT-to-mid-section mass ratio is no more than 1.6 in an embodiment, and no more than 1.55, 1.45, 1.4, 1.35, or 1.3 in further embodiments. Having a forward-HT-to-mid-section mass ratio close to unity, and in some embodiments close to but greater than unity, delivers impact stability not typically found in clubs with traditional weight distribution providing the flexibility to boost Izz and/or Ixx, or regulate Iyy, while decreasing the elevation of the balance point projection and managing both the CGy and delta1 values, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. In one embodiment the forward heel and toe mass is less than 38 grams, and in further embodiments is less than 36 grams, 34 grams, or 32 grams. In another embodiment the forward heel and toe mass is at least 22 grams, 24 grams, 26 grams, 28 grams, or 30 grams.

A rear-center-to-forward-center mass ratio is at least 1.20, where the rear-center-to-forward-center mass ratio is a ratio of a rear center mass to a center-forward mass. Here the rear center mass is the 2T-2H, post-9R mass, and the center-forward mass is the 4T-4H, 1S-4C, pre-2R mass. The rear-center-to-forward-center mass ratio is at least 1.25 in one embodiment, and at least 1.3, 1.35, 1.4, 1.45, 1.5, 1.55, or 1.6 in further embodiments. The rear-center-to-forward-center mass ratio is no more than 2.1 in an embodiment, and no more than 2.0, 1.9, 1.8, or 1.7 in additional embodiments. Having a rear-center-to-forward-center mass ratio greater than unity provides unmatched stability upon impact, distinguishing it from clubs with conventional weight distribution, and affording the ability to enhance Izz and Ixx, or fine-tune Iyy, while concurrently minimizing the elevation of the balance point projection, and governing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625. The rear center mass is at least 30 grams in one embodiment, and at least 32.5, 35, 37.5, 40, or 42.5 grams in further embodiments. The rear center mass is no more than 55 grams in an embodiment, and no more than 52.5, 50, 47.5, or 45 grams in additional embodiments. In one embodiment the 4T-4H, 1S-4C, pre-2R mass is less than 32 grams, and in further embodiments is less than 30 grams, 28 grams, or 26 grams. In another embodiment the 4T-4H, 1S-4C, pre-2R mass is at least 18 grams, 20 grams, 22 grams, or 24 grams.

A rear-center-to-forward-HT mass ratio is at least 1.05, where the rear-center-to-forward-center mass ratio is a ratio of a rear center mass to a forward heel and toe mass. Here the rear center mass is the 2T-2H, post-9R mass, and the forward heel and toe mass is the sum of a 4H-8H, 1S-4C, pre-2R mass and a 4T-8T, 1S-4C, pre-2R mass. The rear-center-to-forward-HT mass ratio is at least 1.1 in one embodiment, and at least 1.15, 1.2, 1.25, 1.3, or 1.35 in further embodiments. The rear-center-to-forward-HT mass ratio is no more than 1.85 in an embodiment, and no more than 1.8, 1.75, 1.7, 1.65, 1.6, 1.55, 1.5, or 1.45 in additional embodiments. Having a rear-center-to-forward-HT mass ratio greater than unity provides improved stability and face performance at impact, while facilitating increased Izz and/or Ixx, and precise control over Iyy, all the while reducing the elevation of the balance point projection and managing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

A rear-center-to-mid-section mass ratio is at least 1.2, where the rear-center-to-mid-section mass ratio is a ratio of a rear center mass to a mid-section mass. Here the rear center mass is the 2T-2H, post-9R mass, and the mid-section mass is the sum of the 8R-7R mass, the 7R-6R mass, the 6R-5R mass, the 5R-4R mass, and the 4R-3R mass. The rear-center-to-mid-section mass ratio is at least 1.2 in one embodiment, and at least 1.3, 1.4, 1.5, 1.6, or 1.7 in further embodiments. The rear-center-to-mid-section mass ratio is no more than 2.25 in an embodiment, and no more than 2.15, 2.05, 1.95, 1.85, or 1.75 in additional embodiments. Having a rear-center-to-mid-section mass ratio significantly greater than unity provides preferred weight distribution and precise control of the elevation of the balance point projection, CGy, and delta1 values, while the controlling Iyy and achieving desirable ranges for Izz and Ixx, while improving face performance, and is achievable due to the disclosed lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

In one embodiment a rear-to-front mass ratio of a post-9R plane mass to a pre-SAVP mass is at least 0.475. The rear-to-front mass ratio is at least 0.525 in another embodiment, and at least 0.575, 0.625, or 0.675 in further embodiments. The rear-to-front mass ratio is no more than 0.925 in one embodiment, and no more than 0.9, 0.875, 0.85, 0.825, 0.775, 0.75, 0.725, or 0.700 in additional embodiments. A post-10R plane mass is at least 50% of the pre-1F plane mass in one embodiment, and is at least 52.5%, 55%, 57.5%, 60%, 62.5%, 65%, 67.5%, or 70% in further embodiments. A post-10R plane mass is no more than 90% of the pre-1F plane mass in one embodiment, and is no more than 85%, 80%, or 75% in additional embodiments. A post-10R plane mass is at least 200% of the pre-SAVR central-4 array mass in one embodiment, and is at least 225%, 250%, 275%, 300%, 325%, 350%, 375%, or 400% in further embodiments. The post-10R plane mass is no more than 700% of the pre-SAVR central-4 array mass in one embodiment, and is no more than 650%, 600%, 550%, 500%, or 450% in additional embodiments. The pre-SAVR central-4 array mass is less than 4 grams in one embodiment, and less than 3.75, 3.5, 3.25, 3.0, or 2.75 grams in further embodiments. Further, the pre-SAVR central-4 array mass is at least 1.5 grams in an embodiment, and at least 1.75, 2.0, or 2.25 grams in additional embodiments. In one embodiment the pre-SAVP mass is less than 82.5 grams, and is less than 80, 77.5, 75, 72.5, 70, or 67.5 in additional embodiments. In one embodiment the pre-SAVP mass is at least 47.5 grams, and at least 50, 52.5, 55, 57.5, 60, 62.5, or 65 grams in further embodiments. The pre-1F plane mass is at least 9 grams and less than 27.5 grams in an embodiment, while in further embodiments the pre-1F plane mass is no more than 25, 24, 23, 22, 21, 20, 19, 18, or 17 grams. The pre-1F plane mass is at least 5 grams in another embodiment, and at least 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 grams in additional embodiments.

In one embodiment at least one of the disclosed 10 mm×10 mm×10 mm cells of the club head has a cell mass that is 2.5 times the pre-SAVR central-4 array mass, and at least 3 times, 3.25 times, or 3.5 times in additional embodiments. In another embodiment a greatest cell mass of the golf club head is no more than 5 times the pre-SAVR central-4 array mass, and no more than 4.75 times, 4.5 times, 4.25 times, 4 times, or 3.75 times in additional embodiments. In one embodiment a heaviest cell associated with the greatest cell mass is located between the FCVP and the 4H plane, and in another embodiment between the FCVP and the 3H plane, and between the FCVP and the 2H plane in yet a further embodiment.

In one embodiment, at least one of the following are true: the pre-1F mass is 12-18 grams, the SAVP-1F mass is 43-65 grams, the 1R-SAVP mass is 32-42 grams, the 2R-1R mass is 12-20 grams, the 3R-2R mass is 5-10 grams, the 4R-3R mass is 3-7.5 grams, the 5R-4R mass is 3-7.5 grams, the 6R-5R mass is 3-7.5 grams, the 7R-6R mass is 3-7.5 grams, the 8R-7R mass is 3-7.5 grams, the 9R-8R mass is 4-11 grams, the 10R-9R mass is 26-42 grams, or the 11R-10R mass is 4-20 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. In another embodiment, at least one of the following are true: the pre-1F mass is 12.5-17.5 grams, the SAVP-1F mass is 45-63 grams, the 1R-SAVP mass is 30-40 grams, the 2R-1R mass is 13-19 grams, the 3R-2R mass is 6-9.5 grams, the 4R-3R mass is 4-7 grams, the 5R-4R mass is 4-7 grams, the 6R-5R mass is 4-7 grams, the 7R-6R mass is 4-7 grams, the 8R-7R mass is 4-7 grams, the 9R-8R mass is 5-10 grams, the 10R-9R mass is 28-40 grams, or the 11R-10R mass is 4.5-18 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. In still a further embodiment, at least one of the following are true: the pre-1F mass is 13-17 grams, the SAVP-1F mass is 47-60 grams, the 1R-SAVP mass is 31-39 grams, the 2R-1R mass is 14-18 grams, the 3R-2R mass is 6.5-9 grams, the 4R-3R mass is 4.5-6.7 grams, the 5R-4R mass is 4.5-6.7 grams, the 6R-5R mass is 4.5-6.7 grams, the 7R-6R mass is 4.5-6.7 grams, the 8R-7R mass is 4.5-6.7 grams, the 9R-8R mass is 6-9 grams, the 10R-9R mass is 30-38 grams, or the 11R-10R mass is 4.75-16 grams; whereas in further embodiment at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or all 13 are true. Having the disclosed rear-to-front mass ratio, the post-10R mass relationships, the pre-SAVP mass, the pre-1F plane mass, and/or the pre-SAVR central-4 array mass provides improved face performance and the ability to enhance Izz and/or Ixx, while meticulously controlling Iyy, all while lowering, and/or precisely positioning, the elevation of the balance point projection and managing the values of CGy and delta1, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

The disclosed goals and mass distribution are further achieved via extremely lightweight regions in the middle of the club head. For example, in one embodiment the 7R-6R plane mass is less than a grams and within β% of the 8R-7R plane mass. In additional embodiments the 6R-5R plane mass is less than a grams and within β% of the 5R-4R plane mass, the 4R-3R plane mass is less than a grams and within β% of the 5R-4R plane mass, and/or the 8R-7R plane mass and the 5R-4R plane mass are less than a grams. In one embodiment a is 7 grams, and in further embodiments is 6.5, 6.0, or 5.5 grams. In one embodiment β is 20, and in further embodiments is within 15, 10, or 5. Additionally, any of these plane masses may have a minimum value of at least 3.0 grams in one embodiment, and at least 3.5, 4.0, or 4.5 grams in additional embodiments. As seen in FIGS. 105 and 106, each of the disclosed slices of the club head has a section width 11000, measured in the top plan view, including a maximum section width and a minimum section width, and a section height 12000, measured in a side elevation view, including a maximum section height and a minimum section height. For instance, the portion of the club head between the 4R plane and the 3R plane, i.e. the 4R-3R region, has a 4R-3R section width 11000, as seen in FIG. 105, and a 4R-3R section height 12000, as seen in FIG. 106; and likewise for each region of the club head, namely the 1F-2F region, the SAVP-1F region, the 1R-SAVP region, the 2R-1R region, the 3R-2R region, the 4R-3R region, the 5R-4R region, the 6R-5R region, the 7R-6R region, the 8R-7R region, the 9R-8R region, the 10R-9R region, and the 11R-10R region. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 4R-3R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 4R-3R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 4R-3R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 4R-3R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%. In another embodiment the consistency of the disclosed plane masses is true even when a maximum 5R-4R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 5R-4R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 5R-4R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 5R-4R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%. In still a further embodiment the consistency of the disclosed plane masses is true even when a maximum 6R-5R section width is at least 20% greater than a minimum 8R-7R section width, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 6R-5R section width is no more than 40% greater than the minimum 8R-7R section width, and in further embodiments no more than 37.5%, 35%, or 32.5%. In one embodiment the consistency of the disclosed plane masses is true even when a maximum 6R-5R section height is at least 20% greater than a minimum 8R-7R section height, and in further embodiments at least 22.5%, 25%, 27.5%, or 30%. In another embodiment the maximum 6R-5R section height is no more than 50% greater than the minimum 8R-7R section height, and in further embodiments no more than 47.5%, 45%, 42.5%, or 40%.

Controlling the jump in mass in between the planes, aka regions, adjacent the lightweight mid-section is also very important to achieving the desired performance. Unless noted otherwise, the lightweight mid-section comprises adjacent sections, aka regions, where each region has a mass less than previously disclosed a grams. In one embodiment the lightweight mid-section includes at least N regions selected from the group of the 4R-3R region, the 5R-4R region, the 6R-5R region, the 7R-6R region, and the 8R-7R region, wherein in one embodiment N is 3, and in additional embodiments N is 4 or 5. It is worth noting that within the disclosure reference to a plane mass such as a 4R-3R plane mass is the same as a reference to a region mass such as a 4R-3R region mass. Thus, controlling the mass of the first forward region located in front of the lightweight mid-section and/or the first rearward region located behind the lightweight mid-section plays a significant role in achieving the disclosed goals. Thus, a leading-mid-section mass ratio is a ratio of the first forward region mass to the mass of the adjacent region within the lightweight mid-section; and a trailing-mid-section mass ratio is a ratio of the first rearward region mass to the mass of the adjacent region within the lightweight mid-section. The leading-mid-section mass ratio is no more than 1.55 in one embodiment, and no more than 1.5, 1.45, 1.4, 1.35, 1.3, 1.25, or 1.2 in additional embodiments. The leading-mid-section mass ratio is at least 0.8 in an embodiment, and is at least 0.85, 0.9, 0.95, 1.0, 1.05, or 1.1 in further embodiments. The trailing-mid-section mass ratio is no more than 1.7 in one embodiment, and no more than 1.6, 1.5, 1.4, or 1.3 in additional embodiments. In one embodiment the first forward region is the 3R-2R region. The trailing-mid-section mass ratio is at least 0.9 in an embodiment, and is at least 1, 1.1, or 1.2 in further embodiments. In one embodiment the first rearward region is the 9R-8R region.

Controlling the mass of a second forward region located in front of the first forward region also plays a significant role in achieving the disclosed goals, and likewise for a third forward region located in front of the second forward region. Thus, a second-leading-mid-section mass ratio is a ratio of the second forward region mass to the first forward region mass; and a third-leading-mid-section mass ratio is a ratio of the third forward region mass to the second forward region mass. The second-leading-mid-section mass ratio is no more than 2.9 in one embodiment, and no more than 2.8, 2.7, 2.6, 2.5, 2.4, or 2.3 in additional embodiments. The second-leading-mid-section mass ratio is at least 1.5 in an embodiment, and is at least 1.6, 1.7, 1.8, 1.9, 2.0, or 2.1 in further embodiments. The third-leading-mid-section mass ratio is no more than 3.5 in one embodiment, and no more than 3.4, 3.3, or 3.2 in additional embodiments. The third-leading-mid-section mass ratio is at least 2.05 in an embodiment, and is at least 2.15, 2.25, 2.35, 2.45, 2.55, 2.65, 2.75, 2.5, 2.95, or 3.05 in further embodiments. In one embodiment the second forward region is the 2R-1R region, and the third forward region is the 1R-SAVP region.

A LHR-forward-toe mass ratio is 0.9-1.3, where the LHR-forward-toe mass ratio is a ratio of a large forward toe region mass to a limited heel region mass. The large forward toe region mass is the 5T-8T, 3S-1C, 3R-1F mass, and the limited heel region mass is the 4H-6H, 2S-1C, 3R-SAVP mass. The LHR-forward-toe mass ratio is at least 2.0 in another embodiment, and at least 2.1, 2.2, 2.3, or 2.4 in further embodiments. The LHR-forward-toe mass ratio is no more than 3.2 in an embodiment, and no more than 3.1, 3.0, 2.9, 2.8, 2.7, or 2.6 in additional embodiments. The large forward toe region mass is at least 17 grams in an embodiment, and at least 18, 19, 20, 21, or 22 grams in additional embodiments. The large forward toe region mass is no more than 30 grams in an embodiment, and no more than 28, 26, or 24 grams in further embodiments. The limited heel region mass is no more than 16 grams in an embodiment, and no more than 14, 13, 12, 11, or 10 grams in further embodiments. The limited heel region mass is at least 6.5 grams in an embodiment, and at least 7, 7.5, 8, 8.5, or 9 grams in additional embodiments. This specifically identified and crafted LHR-forward-toe mass ratio, and associated masses, provides preferred mass distribution and the performance benefits associated with a preferred center of gravity window providing a reduced elevation of the balance point projection while maintaining preferred Izz and Ixx values, and/or controlled Iyy value, and is achievable due to the disclosed lightweight face plate 4610, lightweight front body portion 4602 and/or ledge 4680, which may include an integrally formed face plate and thus in one embodiment a lightweight nonmetallic front body portion 4602 in the form of a cup face, and/or placement of the crown leading edge 4625.

The disclosed relationships are significant in that they allow the achievement of the goals disclosed herein while presenting the user with a comfortable and confidence inspiring club head shape. In one embodiment the head shape is such that no portion of the club head is found in the 5H-7H, 3S-4C, post-7R region, and in further embodiments no portion of the club head is found in the 5H-7H, 3S-4C, post-6R region or the 5H-7H, 3S-4C, post-5R region. In another embodiment the head shape is such that no portion of the club head is found in the 6T-8T, 3S-4C, post-9R region, and in a further embodiment no portion of the club head is found in the 6T-8T, 3S-4C, post-8R region. In another embodiment the head shape is such that no portion of the club head is found in the 6T-8T, 3S-4C, pre-SAVP region, the 6T-8T, 3S-1S, 2F-11R region, the 4T-8T, 3S-2S, 2F-11R region, the 4H-8H, 3S-2S, 2F-11R region, the 6T-8T, 4C-3C, 2F-11R region, the 5T-8T, 4C-3C, 2F-11R region, the 4H-5H, 4C-2C, 2F-11R region, or the 5H-7H, 4C-3S, pre-1F region. Further, the shape of the club head may be as illustrated in FIGS. 105-136 with reference to the disclosed grid structure, but will not be repeated entirely in words herein. However, with reference to FIG. 105, in one embodiment at least a portion of the club head is located at least 100 mm behind the SAVP plane, meaning behind the 10R plane, and at least 102 mm, 104 mm, 106 mm, or 108 mm in additional embodiments. In another embodiment at least a portion of the club head is located at least 10 mm in front of the SAVP plane, meaning in front of the 1F plane, and at least 13 mm, 15 mm or 16 mm in further embodiments. No portion of the club head extends behind the 11R plane or in front of the 2F plane in still another embodiment.

In yet another significant aluminum alloy mass percentage embodiment, a lower-upper center-forward-to-HT mass ratio is no more than 2.5. The lower-upper center-forward-to-HT mass ratio is a ratio of a 4T-4H, below 1C, pre-2R mass to the forward heel and toe mass. The lower-upper center-forward-to-HT mass ratio is no more than 2.4 in another embodiment, and no more than 2.3, 2.2, 2.1, or 2.0 in further embodiments. The lower-upper center-forward-to-HT mass ratio is at least 1.3 in one embodiment, and at least 1.4, 1.5, 1.6, 1.7, or 1.8 in additional embodiments. Further, the 4T-4H, below 1C, pre-2R mass is no more than 77.5 grams in an embodiment, and no more than 75, 72.5, 70, 67.5, 65, 62.5, or 60 grams in additional embodiments. However, the 4T-4H, below 1C, pre-2R mass is at least 40 grams in an embodiment, and at least 42.5, 45, 47.5, 50, 52.5, 55, or 57.5 grams in additional embodiments. The forward heel and toe mass is no more than 42.5 in one embodiment, and no more than 40, 37.5, 35, and 32.5 grams in further embodiments. Additionally, the forward heel and toe mass is at least 20 grams in one embodiment, and at least 22.5, 25, 27.5, or 30 grams in further embodiments.

The forward heel and toe mass is at least 18% of the pre-2R mass in yet another embodiment, and at least 19%, 20%, 21%, 22%, 23%, or 24% in additional embodiments. However, in a further embodiment the forward heel and toe mass is no more than 33% of the pre-2R mass in one embodiment, and no more than 32%, 31%, 30%, 29%, 28%, or 27% in additional embodiments.

In yet another significant aluminum alloy mass percentage embodiment, an upper-lower center-forward-to-HT mass ratio is no more than 1.2. The upper-lower center-forward-to-HT mass ratio is a ratio of the 4T-4H, 1S-4C, pre-2R mass to a low forward heel and toe mass. The low forward heel and toe mass is a sum of the 4H-8H, below FCHP, pre-2R mass and the 4T-8T, below FCHP, pre-2R mass. In additional embodiments the upper-lower center-forward-to-HT mass ratio is no more than 1.1, 1.0, or 0.9. While in further embodiments the upper-lower center-forward-to-HT mass ratio is at least 0.625, 0.675, 0.725, 0.775, 0.825, 0.85, or 0.875. The 4T-4H, 1S-4C, pre-2R mass is no more than 37.5 grams in one embodiment, and in additional embodiments is no more than 35, 32.5, 30, or 27.5 grams. In further embodiments the 4T-4H, 1S-4C, pre-2R mass is at least 15, 17.5, 20, 22.5, or 25 grams. In another embodiment the 4H-8H, below FCHP, pre-2R mass is at least 60% of the 4T-8T, below FCHP, pre-2R mass; and in additional embodiments is at least 62.5%, 65%, or 67.5%. In another embodiment the 4H-8H, below FCHP, pre-2R mass is no more than 80% of the 4T-8T, below FCHP, pre-2R mass; and in additional embodiments is no more than 77.5%, 75%, 72.5%, or 70%. The 4H-8H, below FCHP, pre-2R mass is no more than 16.5 grams in one embodiment, and no more than 15.5, 14.5, 13.5, or 12.5 grams in additional embodiments. The 4T-8T, below FCHP, pre-2R mass is at least 10.5 grams in one embodiment, and at least 11.5, 12.5, 13.5, 14.5, 15.5, or 16.5 grams in additional embodiments. However, in a further series of embodiments the 4T-8T, below FCHP, pre-2R mass is no more than 24, 23, 22, 21, 20, 19, or 18 grams.

A further significant aluminum alloy mass percentage embodiment has a 4T-4H, below 1C, pre-2R mass that is no more than 67.5% of the pre-2R mass, which in additional embodiments is no more than 65%, 62.5%, 60%, 57.5%, 55%, 52.5%, or 50%. However, in another series of embodiments the 4T-4H, below 1C, pre-2R mass is at least 35% of the pre-2R mass, which in additional embodiments is at least 37.5%, 40%, 42.5%, 45%, or 47.5%.

The 4H-8H, below FCHP, pre-2R mass is no more than 14% of the pre-2R mass in yet another significant aluminum alloy mass percentage embodiment, and is no more than 13%, 12%, or 11% in further embodiments. Additionally, the 4H-8H, below FCHP, pre-2R mass is at least δ% of the pre-2R mass in yet another significant aluminum alloy mass percentage embodiment, and is at least 7%, 8%, or 9% in further embodiments.

Similarly, the 4T-8T, below FCHP, pre-2R mass is at least 10% of the pre-2R mass in yet another significant aluminum alloy mass percentage embodiment, and is at least 11%, 12%, 13%, or 15% in further embodiments. Additionally, the 4T-8T, below FCHP, pre-2R mass is no more than 20%, 19%, 18%, 17%, or 16% of the pre-2R mass in additional embodiments.

A further significant aluminum alloy mass percentage embodiment has a 4T-4H, below 1C, pre-2R mass that is no more than 160% of a post-9R mass, and no more than 155%, 150%, 145%, 140%, or 135% in additional embodiments. However, in a further series of embodiments the 4T-4H, below 1C, pre-2R mass is at least 100%, 105%, 110%, 115%, 120%, or 125% of the post-9R mass. Similarly, in another series of embodiments the 4H-8H, below FCHP, pre-2R mass is no more than 35%, 33%, 31%, 29%, or 27% of the post-9R mass. While in a further series of embodiments the 4H-8H, below FCHP, pre-2R mass is at least 18%, 20%, 22%, or 24% of the post-9R mass.

Many of the just disclosed relationships involve the pre-2R region of the club head, the following relationships disclose in more detail the 2R-SAVP mass distribution of significant aluminum alloy mass percentage embodiments. For instance, in one embodiment a 2R-SAVP lower-upper center-forward-to-HT mass ratio is no more than 1.6. The 2R-SAVP lower-upper center-forward-to-HT mass ratio is a ratio of a 4T-4H, below 1C, 2R-SAVP mass to a 2R-SAVP heel and toe mass. The 2R-SAVP heel and toe mass is a sum of a 4H-8H, 1S-4C, 2R-SAVP mass and a 4T-8T, 1S-4C, 2R-SAVP mass. In additional embodiments the 2R-SAVP lower-upper center-forward-to-HT mass ratio is no more than 1.5, 1.4, 1.3, or 1.2. While in a further series of embodiments the 2R-SAVP lower-upper center-forward-to-HT mass ratio is at least 0.8, 0.9, 1.0, or 1.1. In particularly light club head embodiments, such as those with a club head mass of 197 grams or less, one series of embodiments has the 2R-SAVP lower-upper center-forward-to-HT mass ratio is at least 0.5, 0.55, 0.6, 0.65, or 0.7; while a further series of embodiment introduces a cap such that the 2R-SAVP lower-upper center-forward-to-HT mass ratio is no more than 1.0, 0.9, or 0.8.

The 4T-4H, below 1C, 2R-SAVP mass is no more than 29 grams in an embodiment, and no more than 28, 27, 26, 25, 24, 23, or 22 grams in additional embodiments. While in another series of embodiments the 4T-4H, below 1C, 2R-SAVP mass is at least 15, 16, 17, 18, 19, or 20 grams. Further, the 2R-SAVP heel and toe mass is at least 12.5 grams in one embodiment, and at least 13.5, 14.5, 15.5, 16.5, or 17.5 grams in additional embodiments. While in a further series of embodiments the 2R-SAVP heel and toe mass is no more than 25, 24, 23, 22, 21, or 20 grams.

Additionally, the balance of the 4H-8H, 1S-4C, 2R-SAVP mass and the 4T-8T, 1S-4C, 2R-SAVP mass is essential to achieve the mass properties expected in a modern driver type golf club head. For instance, in one embodiment the 4H-8H, 1S-4C, 2R-SAVP mass is at least 105% of the 4T-8T, 1S-4C, 2R-SAVP mass, and at least 110%, 115%, 120%, 125%, or 130% in additional embodiments. While in another series of embodiments the 4H-8H, 1S-4C, 2R-SAVP mass is no more than 170%, 160%, 150%, or 140% of the 4T-8T, 1S-4C, 2R-SAVP mass. In some embodiments the 4H-8H, 1S-4C, 2R-SAVP mass is at least 7, 8, 9, or 10 grams, while in another series of embodiments the 4H-8H, 1S-4C, 2R-SAVP mass is no more than 15, 14, 13, 12, or 11 grams. Similarly, in some embodiments the 4T-8T, 1S-4C, 2R-SAVP mass is no more than 11, 10, 9, or 8 grams, while in another series of embodiments the 4T-8T, 1S-4C, 2R-SAVP mass is at least 4.5, 5.5, 6.5, or 7.5 grams.

Even further, in one embodiment the 4H-8H, 1S-4C, 2R-SAVP mass is at least 13.5% of the 2R-SAVP mass, which in further embodiments is increased to at least 14.5%, 15.5%, 16.5%, 17.5%, or 18.5%. In another series of embodiments the 4H-8H, 1S-4C, 2R-SAVP mass is no more than 26%, 25%, 24%, 23%, 22%, or 21% of the 2R-SAVP mass.

The 4T-8T, 1S-4C, 2R-SAVP mass is no more than 20%, 19%, 18%, 17%, 16%, or 15% of the 2R-SAVP mass in another series of embodiments. However, a further series of embodiments sets a floor such that the 4T-8T, 1S-4C, 2R-SAVP mass is at least 10%, 11%, 12%, 13%, or 14% of the 2R-SAVP mass.

In still a further significant aluminum alloy mass percentage embodiment the 4T-4H, below 1C, 2R-SAVP mass is at least 33% of the post-9R mass, which in increase to at least 36%, 39%, 42%, or 45% in additional embodiments. A further series of embodiments caps this relationship whereby the 4T-4H, below 1C, 2R-SAVP mass is no more than 60%, 58%, 56%, 54%, 52%, or 50% of the post-9R mass.

Further, the mass distribution associated with the post-9R region compared to the 2R-SAVP heel and toe region provides club head stability and prevents durability issues associated with large rearward masses within a lightweight shell behind the SAVP. For instance, in one series of embodiments the post-9R mass is at least 150%, 170%, 190%, 210%, 230%, or 245% of the 2R-SAVP heel and toe mass. While a further series of embodiments caps the relationship with the post-9R mass being no more than 350%, 330%, 310%, 290%, or 270% of the 2R-SAVP heel and toe mass.

Such relationships can be further associated with the post-10R region. For example, in one series of embodiments the post-10R mass is greater than the 4T-8T, 1S-4C, 2R-SAVP mass, while in further embodiments the post-10R mass is no more than 200%, 185%, 170%, 155%, or 140% of the 4T-8T, 1S-4C, 2R-SAVP mass. In further embodiments the post-10R mass is at least 85%, 90%, 95%, 100%, or 105% of the 4H-8H, 1S-4C, 2R-SAVP mass. While an additional series of embodiments caps this relationship such that the post-10R mass is no more than 150%, 140%, 130%, 120%, or 110% of the 4H-8H, 1S-4C, 2R-SAVP mass.

Still focusing on the 2R-SAVP region of significant aluminum alloy mass percentage embodiments, a 2R-SAVP upper-lower center-to-HT mass ratio is at least 0.20 in one embodiment. The 2R-SAVP upper-lower center-to-HT mass ratio is a ratio of a 4T-4H, 1S-4C, 2R-SAVP mass to a low 2R-SAVP heel and toe mass. The low 2R-SAVP heel and toe mass is a sum of a 4H-8H, below FCHP, 2R-SAVP mass and a 4T-8T, below FCHP, 2R-SAVP mass. In further embodiments the 2R-SAVP upper-lower center-to-HT mass ratio is at least 0.22, 0.24, 0.26, or 0.28; while a further series of embodiments caps the ratio such that the 2R-SAVP upper-lower center-to-HT mass ratio is no more than 0.44, 0.42, 0.40, 0.38, 0.36, 0.34, or 0.32.

In another embodiment the 4H-8H, below FCHP, 2R-SAVP mass is no more than 165% of the 4T-8T, below FCHP, 2R-SAVP mass, which is reduced in further embodiments to no more than 160%, 155%, 150%, 145%, 140%, 135%, or 130%. Another series of embodiments establishes a floor for this relationship whereby the 4H-8H, below FCHP, 2R-SAVP mass is at least 90%, 95%, 100%, 105%, 110%, 115%, or 120% of the 4T-8T, below FCHP, 2R-SAVP mass. In another embodiment the 4T-4H, 1S-4C, 2R-SAVP mass is no more than 8 grams, while this is reduced in further embodiments to no more than 7.5, 7, 6.5, or 6 grams. Another series of embodiments sets a floor whereby the 4T-4H, 1S-4C, 2R-SAVP mass is at least 3.75, 4, 4.25, 4.5, 4.75, 5, 5.25, 5.5, or 5.75 grams. Further, in another series of embodiments the low 2R-SAVP heel and toe mass is at least 12.75, 13.25, 13.75, 14.25, 14.75, 15.25, 15.75, 16.25, 16.75, 17.25, 17.75, 18.25, or 18.75 grams. Another series of embodiments establishes a cap such that the low 2R-SAVP heel and toe mass is no more than 27, 25, 23, or 21 grams.

In a further series of embodiments the 4H-8H, below FCHP, 2R-SAVP mass is no more than 15.5, 15, 14.5, 14, 13.5, 13, 12.5, 12, or 11.5 grams. While another series of embodiments sets a floor whereby the 4H-8H, below FCHP, 2R-SAVP mass is at least 7.5, 8.5, 9.5, or 10.5 grams. Similarly, but now looking at the toe side, in another series of embodiments the 4T-8T, below FCHP, 2R-SAVP mass is at least 5.5, 6.5, 7.5, or 8.5 grams. Further, another series of embodiments caps this value whereby the 4T-8T, below FCHP, 2R-SAVP mass is no more than 12, 11, 10, or 9 grams.

Additionally it is helpful to place these values into perspective with their contribution to the 2R-SAVP mass. For example, in one embodiment the 4T-4H, 1S-4C, 2R-SAVP mass is no more than 16% of the 2R-SAVP mass; while in a further series of embodiments the percentage is reduced to no more than 15%, 14%, 13%, or 12%. Additionally, another series of embodiments introduces a floor for the relationship whereby the 4T-4H, 1S-4C, 2R-SAVP mass is at least 7%, 8%, 9%, or 10% of the 2R-SAVP mass. Similarly, but now looking at the low heel side, in one embodiment the 4H-8H, below FCHP, 2R-SAVP mass is no more than 28% of the 2R-SAVP mass; while in a further series of embodiments the percentage is reduced to no more than 26%, 24%, or 22%. Additionally, another series of embodiments introduces a floor for the relationship whereby the 4H-8H, below FCHP, 2R-SAVP mass is at least 14%, 16%, 18%, or 20% of the 2R-SAVP mass. Similarly, but now looking at the low toe side, in one embodiment the 4T-8T, below FCHP, 2R-SAVP mass is at least 10% of the 2R-SAVP mass; while in a further series of embodiments the percentage is increased to at least 11%, 12%, 13%, 14%, or 15%. Additionally, another series of embodiments introduces a cap for the relationship whereby the 4T-8T, below FCHP, 2R-SAVP mass is no more than 22%, 21%, 20%, 19%, 18%, or 17% of the 2R-SAVP mass.

The 4H-8H, 1S-4C, 2R-SAVP mass is within 10% of the 4H-8H, below FCHP, 2R-SAVP mass in one embodiment; while in further embodiments the percentage is reduced to within 7.5% or 5%. In a still further embodiment the 4H-8H, 1S-4C, 2R-SAVP mass is less than the 4H-8H, below FCHP, 2R-SAVP mass. Similarly, the 4T-8T, 1S-4C, 2R-SAVP mass is within 15% of the 4T-8T, below FCHP, 2R-SAVP mass in one embodiment; while in further embodiments the percentage is reduced to within 12.5% or 10%. In still a further embodiment the 4T-8T, 1S-4C, 2R-SAVP mass is less than the 4T-8T, below FCHP, 2R-SAVP mass.

Still focusing on the 2R-SAVP region of significant aluminum alloy mass percentage embodiments and considering a high heel to low toe relationship, in another embodiment the 4H-8H, 1S-4C, 2R-SAVP mass is at least 105% of the 4T-8T, below FCHP, 2R-SAVP mass; while in further embodiments the percentage is increased to at least 108%, 111%, 114%, or 117%. Another series of embodiments placed a cap on the relationship whereby the 4H-8H, 1S-4C, 2R-SAVP mass is no more than 130%, 128%, 126%, 124%, or 122% of the 4T-8T, below FCHP, 2R-SAVP mass.

Now conversely considering a high toe to low heel relationship, in one embodiment the 4T-8T, 1S-4C, 2R-SAVP mass is no more than 95% of the 4H-8H, below FCHP, 2R-SAVP mass; while in further embodiments the percentage is reduced to no more than 90%, 85%, 80%, or 75%. Another series of embodiments establishes a floor for the relationship whereby the 4T-8T, 1S-4C, 2R-SAVP mass is at least 50%, 55%, 60%, 65%, or 70% of the 4H-8H, below FCHP, 2R-SAVP mass.

Additionally the post-10R mass is at least 150% of the 4T-4H, 1S-4C, 2R-SAVP mass in one embodiment, whereas further embodiments increase the percentage to at least 160%, 170%, 180%, or 190%. Another series of embodiments caps the relationship such that the post-10R mass is no more than 265%, 255%, 245%, 235%, 225%, 215%, 205%, or 195% of the 4T-4H, 1S-4C, 2R-SAVP mass

Further, the low 2r-SAVP heel and toe mass is at least 50% of the post-10R mass in an embodiment, and further embodiments increase the percentage to at least 55%, 60%, 65%, or 70%. Additionally, another series of embodiments caps the relationship such that the low 2r-SAVP heel and toe mass is no more than 125%, 115%, 105%, 95%, or 85% of the post-10R mass.

Now, similarly but with respect to the low toe region of the 2R-SAVP region, in one embodiment the post-10R mass is at least 95% of the 4T-8T, below FCHP, 2R-SAVP mass; whereas further embodiments increase the percentage to at least 105%, 110%, 115%, 120%, or 125%. A further series of embodiments caps the relationship such that the post-10R mass is no more than 165%, 155%, 145%, or 135% of the 4T-8T, below FCHP, 2R-SAVP mass.

Still focusing on the 2R-SAVP region of significant aluminum alloy mass percentage embodiments and considering a high heel to low toe relationship, but now distinguished by the FCHP, one embodiment has a 2R-SAVP HH-LT mass ratio of no more than 0.20; where HH-LT references high-heel and low-toe. The 2R-SAVP HH-LT mass ratio is a ratio of a 2R-SAVP high-heel mass to a 2R-SAVP low-toe mass; where the 2R-SAVP high-heel mass is the 4H-FCVP, FCHP-4C, 2R-SAVP mass, and the 2R-SAVP low-toe mass is the 8T-FCVP, below FCHP, 2R-SAVP mass. In a further series of embodiments the 2R-SAVP HH-LT mass ratio is no more than 0.19, 0.18, 0.17, or 0.16. A further series of embodiments sets a floor for the ratio whereby the 2R-SAVP HH-LT mass ratio is at least 0.1, 0.11, 0.12, 0.13, or 0.14. In particularly light club head embodiments, such as those with a club head mass of 197 grams or less, one series of embodiments has the 2R-SAVP HH-LT mass ratio adjusted higher such that it is no more than 0.27 in one embodiment, and no more than 0.26, 0.25, 0.24, or 0.23 in additional embodiments; while a further series of embodiments sets a floor such that the 2R-SAVP HH-LT mass ratio is at least 0.14, 0.16, 0.18, or 0.20.

The 2R-SAVP low-toe mass is no more than 49% of the 2R-SAVP mass in one embodiment, and in further embodiments the percentage is reduced to no more than 46%, 43%, 40%, or 37%. Another series of embodiments established a floor for this relationship whereby the 2R-SAVP low-toe mass is at least 25% of the 2R-SAVP mass in one embodiment, and in further embodiments the percentage is increased to at least 27%, 29%, 31%, 33%, or 35%. In one embodiment the 2R-SAVP high-heel mass is no more than 5 grams, and in further embodiments is no more than 4.5, 4, 3.5, or 3 grams. A further series of embodiments establishes a floor whereby the 2R-SAVP high-heel mass is at least 1.5, 1.75, 2, 2.25, 2.5, or 2.75 grams. In another embodiment the 2R-SAVP low-toe mass is at least 13 grams, and in further embodiments is at least 14, 15, 16, 17, or 18 grams. A further series of embodiments establishes a cap whereby the 2R-SAVP low-toe mass is no more than 27, 26, 25, 24, 23, 22, or 21 grams.

In yet another embodiment the 2R-SAVP high-heel mass is no more than 40% of the post-10R mass, while in further embodiments the percentage is reduced to no more than 37.5%, 35%, 32.5%, 30%, or 27.5%. Another series of embodiments sets a floor for the relationship with the 2R-SAVP high-heel mass being at least 10%, 15%, or 20% of the post-10R mass. The post-10R mass is at least 40% of the 2R-SAVP low-toe mass in an embodiment, and is at least 45%, 50%, or 55% in additional embodiments. The post-10R mass is no more than 85% of the 2R-SAVP low-toe mass in an embodiment, and in further embodiments is no more than 80%, 75%, or 70%.

Again focusing on the 2R-SAVP region of significant aluminum alloy mass percentage embodiments and considering a low heel to high toe relationship, still distinguished by the FCHP, one embodiment has a 2R-SAVP LH-HT mass ratio of no more than 1.5; where the LH-HT reference low-heel and high-toe. The 2R-SAVP LH-HT mass ratio is a ratio of a 2R-SAVP low-heel mass to a 2R-SAVP high-toe mass; where the 2R-SAVP low-heel mass is the 4H-FCVP, below FCHP, 2R-SAVP mass, and the 2R-SAVP high-toe mass is the 8T-FCVP, FCHP-4C, 2R-SAVP mass. In a further series of embodiments the 2R-SAVP LH-HT mass ratio is no more than 1.4, 1.3, or 1.2. A floor is established in another series of embodiments whereby the 2R-SAVP LH-HT mass ratio is at least 0.8, 0.9, 1.0, or 1.1. The 2R-SAVP low-heel mass is at least 101% of the 2R-SAVP high-toe mass in one embodiment, and at least 105%, 110%, or 115% in additional embodiments. A cap is established in a further series of embodiments whereby the 2R-SAVP low-heel mass is no more than 160%, 150%, 140%, 130%, or 120% of the 2R-SAVP high-toe mass. The 2R-SAVP low-heel mass is no more than 27% of the 2R-SAVP mass in another embodiment, which in a further series of embodiments is limited to no more than 25%, 23%, or 21%. Another series of embodiments establishes a floor for the relationship whereby the 2R-SAVP low-heel mass is at least 14%, 16%, or 18% of the 2R-SAVP mass. Similarly, but now with respect to the 2R-SAVP high-toe mass, in one embodiment the 2R-SAVP high-toe mass is at least 12% of the 2R-SAVP mass, while in further embodiments the percentage is increased to at least 13.5%, 15%, or 16.5%. Another series of embodiments caps this relationship such that the 2R-SAVP high-toe mass is no more than 24%, 22%, 20%, or 18% of the 2R-SAVP mass.

Still focusing on the 2R-SAVP region of significant aluminum alloy mass percentage embodiments and considering a low heel to high toe relationship, still distinguished by the FCHP, in one embodiment the post-10R mass is within 25% of the 2R-SAVP low-heel mass, while in further embodiments the percentage is reduced to within 20%, 15%, 10%, or 5%. In a further embodiment any of these relationships are true but also have the post-10R mass greater than the 2R-SAVP low-heel mass. Similarly, but now with respect to the 2R-SAVP high-toe mass, in one embodiment the post-10R mass is within 30% of the 2R-SAVP high-toe mass, while in further embodiments the percentage is reduced to within, 27%, 24%, or 21%. In a further embodiment any of these relationships are true but also have the post-10R mass greater than the 2R-SAVP high-toe mass. The 2R-SAVP low-heel mass is no more than 16 grams in one embodiment, and no more than 15, 14, 13, or 12 grams in additional embodiments. A floor is introduced in another series of embodiments whereby the 2R-SAVP low-heel mass is at least 7, 8, 9, or 10 grams. Similarly, the 2R-SAVP high-toe mass is at least 6 grams in one embodiment, and at least 7, 8, or 9 grams in additional embodiments. A cap is introduced in another series of embodiments whereby the 2R-SAVP high-toe mass is no more than 14, 13, 12, 11, or 10 grams.

Yet another series of significant aluminum alloy mass percentage embodiments compares a mid-heel region mass with the mass of other regions of the club head. The mid-heel region mass is a mass of the 4H-7H, above 2S, 1R-7R region.

In one embodiment the post-10R mass is at least 30% of the mid-heel region mass, while in further embodiments it is at least 35%, 40%, 45%, 50%, or 55%. Another series of embodiments caps the relationship such that the post-10R mass is no more than 70% of the mid-heel region mass, while further embodiments reduce the cap to no more than 67.5%, 65%, 62.5%, and 60%.

In another embodiment the post-9R mass is at least 150% of the mid-heel region mass, while in further embodiments it is at least 175%, 200%, or 225%. Another series of embodiments caps the relationship such that the post-9R mass is no more than 300% of the mid-heel region mass, while further embodiments reduce the cap to no more than 290%, 280%, 270%, 260%, 250%, or 240%.

Still a further embodiment has a 2T-2H, post-9R mass that is at least 140% of the mid-heel region mass, while in further embodiments it is at least 165%, 190%, or 215%. Another series of embodiments caps the relationship such that the 2T-2H, post-9R mass is no more than 285% of the mid-heel region mass, while further embodiments reduce the cap to no more than 275%, 265%, 255%, 245%, or 235%.

The forward heel and toe mass is at least 125% of the mid-heel region mass in another embodiment, and further embodiments increase this percentage to at least 135%, 145%, or 155%. Another series of embodiments caps the relationship such that the forward heel and toe mass is no more than 200%, 190%, 180%, or 170% of the mid-heel region mass.

In another embodiment the large forward toe region mass is at least 80% of the mid-heel region mass, which in further embodiments is increased to at least 90%, 100%, or 110%. Another series of embodiments caps the relationship such that the large forward toe region mass is no more than 160%, 150%, 140%, or 130% of the mid-heel region mass.

The 4T-4H, below 1C, pre-2R mass is at least 200% of the mid-heel region mass in another embodiment, which further embodiments increase the percentage to at least 225%, 250%, 275%, or 300%. Another series of embodiments caps the relationship such that the 4T-4H, below 1C, pre-2R mass is no more than 400%, 380%, 360%, 340%, or 320% of the mid-heel region mass. In particularly light club head embodiments, such as those with a club head mass of 197 grams or less, one series of embodiments has the 4T-4H, below 1C, pre-2R mass at no more than 300%, 290%, 280%, or 270% of the mid-heel region mass.

The 4T-4H, 1S-4C, pre-2R mass is no more than 175% of the mid-heel region mass in a further embodiment, while additional embodiments reduce the percentage to no more than 165%, 155%, or 145%. Another series of embodiments introduces a floor on the relationship such that the 4T-4H, 1S-4C, pre-2R mass is at least 100%, 110%, 120%, or 130% of the mid-heel region mass.

In another embodiment the low forward heel and toe mass is no more than 200% of the mid-heel region mass, while further embodiments reduce the percentage to no more than 190%, 180%, 170%, or 160%. Another series of embodiments introduces a floor on the relationship such that the low forward heel and toe mass is at least 125%, 135%, or 145% of the mid-heel region mass.

The 4H-8H, 1S-4C, 2R-SAVP mass is at least 42% of the mid-heel region mass in another embodiment, and additional embodiments increase the percentage to at least 44%, 46%, 48%, 50%, or 52%. Another series of embodiments introduces a cap on the relationship such that the 4H-8H, 1S-4C, 2R-SAVP mass is no more than 80%, 76%, 72%, 68%, 64%, 60%, or 56% of the mid-heel region mass.

Further, the 4T-8T, 1S-4C, 2R-SAVP mass is at least 30% of the mid-heel region mass in another embodiment, and additional embodiments increase the percentage to at least 33%, 36%, or 39%. Another series of embodiments introduces a cap on the relationship such that the 4T-8T, 1S-4C, 2R-SAVP mass is no more than 50%, 48%, 46%, 44%, or 42% of the mid-heel region mass.

Additionally, the 4T-4H, 1S-1C, 2R-SAVP mass is no more than 42% of the mid-heel region mass in a further embodiment, and additional embodiments reduce the percentage to no more than 40%, 38%, 36%, 34%, or 32%. Another series of embodiments introduces a floor to the relationship such that the 4T-4H, 1S-1C, 2R-SAVP mass is at least 26%, 27%, 28%, or 29% of the mid-heel region mass.

The 4H-4H, below FCHP, 2R-SAVP mass is no more than 68% of the mid-heel region mass in another embodiment, and further embodiments decrease the percentage to no more than 65%, 62%, or 59%. Another series of embodiments introduces a floor to the relationship such that the 4H-4H, below FCHP, 2R-SAVP mass is at least 45%, 48%, 51%, or 54% of the mid-heel region mass.

Additionally, the 4T-8T, below FCHP, 2R-SAVP mass is at least 26% of the mid-heel region mass in a further embodiment, while additional embodiments increase the percentage to at least 30%, 34%, 38%, or 42%. Another series of embodiments introduces a cap on the relationship whereby the 4T-8T, below FCHP, 2R-SAVP mass is no more than 60%, 57%, 54%, 51%, or 47% of the mid-heel region mass.

The 2R-SAVP low-toe mass, which is the 8T-FAVP, below FCHP, 2R-SAVP mass, is at least 40% of the mid-heel region mass in another embodiment, and further embodiments increase the percentage to at least 50%, 60%, 70%, 80%, or 90%. Another series of embodiments places a cap on the relationship whereby the 2R-SAVP low-toe mass is no more than 150%, 140%, 130%, 120%, or 110% of the mid-heel region mass. In particularly light club head embodiments, such as those with a club head mass of 197 grams or less, one series of embodiments has a 2R-SAVP low-toe mass of at least 40%, 45%, 50%, 55%, or 60% of the mid-heel region mass; while a further series of embodiments caps the relationship at lower percentages whereby the 2R-SAVP low-toe mass is no more than 90%, 85%, 80%, 75%, or 70% of the mid-heel region mass.

The 2R-SAVP mass is at least 180% of the mid-heel region mass in a further embodiment, and additional embodiments increase the percentage to at least 195%, 210%, 225%, 240%, 255%, or 270%. Another series of embodiments introduces a cap on the relationship whereby the 2R-SAVP mass is no more than 320%, 310%, 300%, or 290% of the mid-heel region mass.

Further, the pre-SAVP mass is at least 245% of the mid-heel region mass in a further embodiment, and additional embodiments increase the percentage to at least 260%, 275%, 290%, 305%, 320%, or 335%. Another series of embodiments introduces a cap on the relationship whereby the pre-SAVP mass is no more than 400%, 390%, 380%, 370%, or 360% of the mid-heel region mass.

Additionally, the 2R-SAVP low-heel mass, which is the 4H-FCVP, below FCHP, 2R-SAVP mass, is no more than 68% of the mid-heel region mass in a further embodiment, while additional embodiments reduce the percentage to no more than 66%, 64%, 62%, or 60%. Another series of embodiments sets a floor for the relationship whereby the 2R-SAVP low-heel mass is at least 48%, 50%, 52%, 54%, or 56% of the mid-heel region mass.

The 2R-SAVP high-toe mass, which is the 8T-FCVP, FCHP-4C, 2R-SAVP mass, is at least 34% of the mid-heel region mass in one embodiment, and further embodiments increase the percentage to at least 37%, 40%, 43%, or 46%. Additional embodiments set a cap for the relationship whereby the 2R-SAVP high-toe mass is no more than 60%, 57%, 54%, or 51% of the mid-heel region mass.

In one embodiment the mid-heel region mass is no more than 26 grams, and in further embodiments is no more than 24, 22, or 20 grams. In another embodiment the mid-heel region mass is at least 12 grams, and in further embodiments is at least 14, 16, or 18 grams.

Now focusing on the mass distribution of specific regions with respect to the total head mass, again for significant aluminum alloy mass percentage embodiments, in one embodiment the 2R-SAVP mass is no more than 34% of the total head mass, while in further embodiments the percentage is reduced to no more than 32%, 30%, or 28%. Another series of embodiments introduces a floor to this relationship whereby the 2R-SAVP mass is at least 18%, 20%, 22%, or 24% of the total head mass. In another embodiment the 2R-SAVP mass is within 25% of the post-9R mass, and is within 23%, 21%, or 19% in further embodiments; and in any of these embodiments the 2R-SAVP mass is greater than the post-9R mass. In still a further embodiment the 2R-SAVP mass is at least 105% of the post-9R mass, which is increased in additional embodiments to at least 107.5%, 110%, 112.5%, 115%, or 117.5%. Another series of embodiments caps the relationship whereby the 2R-SAVP mass is no more than 130%, 127%, 124%, or 121% of the post-9R mass. In another embodiment the pre-2R mass is no more than 75% of the total head mass, while in further embodiments the percentage is no more than 72%, 69%, 66%, 63%, or 60%. Another series of embodiments introduces a floor for the relationship whereby the pre-2R mass is at least 40%, 43%, 46%, 49%, 52%, 55%, or 58% of the total head mass. In still another embodiment the pre-SAVP mass is no more than 43% of the total head mass, which in further embodiments is reduced to no more than 41%, 39%, 37%, 35%, or 33%. Another series of embodiments introduces a floor to this relationship whereby the pre-SAVP mass is at least 23%, 25%, 27%, 29%, or 31% of the total head mass.

Again focusing on the aluminum alloy mass distribution of specific regions within significant aluminum alloy mass percentage embodiments, in one embodiment no more than 60% of the pre-1F mass is associated with aluminum alloy within the pre-1F region, while further embodiments reduce the percentage to no more than 55%, 50%, 45%, 40%, 35%, 30%, or 25%. Another series of embodiments introduces a floor to the relationship such that at least 2.5%, 5%, or 7.5% of the pre-1F mass is associated with aluminum alloy within the pre-1F region. Similarly, in another series of embodiments at least 20%, 25%, 30%, 35%, 40%, 45%, or 50% of the SAVP-1F mass is associated with aluminum alloy in the SAVP-1F region. While in another series of embodiments no more than 95%, 90%, 85%, or 80% of the SAVP-1F mass is associated with aluminum alloy in the SAVP-1F region. Likewise, in another series of embodiments at least 25%, 35%, 45%, 55%, or 65% of the 1R-SAVP mass is associated with aluminum alloy in the 1R-SAVP region. In one embodiment 100% of the 1R-SAVP mass is associated with aluminum alloy in the 1R-SAVP region, however in a further series of embodiments no more than 97.5%, 95%, 92.5%, or 90% of the 1R-SAVP mass is associated with aluminum alloy in the 1R-SAVP region. In another series of embodiments at least 30%, 40%, 50%, 60%, or 70% of the 2R-1R mass is associated with aluminum alloy in the 2R-1R region. In one embodiment 100% of the 2R-1R mass is associated with aluminum alloy in the 2R-1R region, however in a further series of embodiments no more than 97.5%, 95%, 92.5%, 90%, 87.5%, or 85% of the 2R-1R mass is associated with aluminum alloy in the 2R-1R region. In still a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 3R-2R mass is associated with aluminum alloy in the 3R-2R region. In one embodiment 100% of the 3R-2R mass is associated with aluminum alloy in the 3R-2R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 3R-2R mass is associated with aluminum alloy in the 3R-2R region. Similarly, in yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 4R-3R mass is associated with aluminum alloy in the 4R-3R region. In one embodiment 100% of the 4R-3R mass is associated with aluminum alloy in the 4R-3R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 4R-3R mass is associated with aluminum alloy in the 4R-3R region. Similarly, in yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 5R-4R mass is associated with aluminum alloy in the 5R-4R region. In one embodiment 100% of the 5R-4R mass is associated with aluminum alloy in the 5R-4R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 5R-4R mass is associated with aluminum alloy in the 5R-4R region. Similarly, in yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 6R-5R mass is associated with aluminum alloy in the 6R-5R region. In one embodiment 100% of the 6R-5R mass is associated with aluminum alloy in the 6R-5R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 6R-5R mass is associated with aluminum alloy in the 6R-5R region. In yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 7R-6R mass is associated with aluminum alloy in the 7R-6R region. In one embodiment 100% of the 7R-6R mass is associated with aluminum alloy in the 7R-6R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 7R-6R mass is associated with aluminum alloy in the 7R-6R region. In yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 8R-7R mass is associated with aluminum alloy in the 8R-7R region. In one embodiment 100% of the 8R-7R mass is associated with aluminum alloy in the 8R-7R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 8R-7R mass is associated with aluminum alloy in the 8R-7R region. In yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 9R-8R mass is associated with aluminum alloy in the 9R-8R region. In one embodiment 100% of the 9R-8R mass is associated with aluminum alloy in the 9R-8R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 9R-8R mass is associated with aluminum alloy in the 9R-8R region. In yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 10R-9R mass is associated with aluminum alloy in the 10R-9R region. In one embodiment 100% of the 10R-9R mass is associated with aluminum alloy in the 10R-9R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 10R-9R mass is associated with aluminum alloy in the 10R-9R region. In yet a further series of embodiments at least 2.5%, 5%, 7.5%, or 10% of the 11R-10R mass is associated with aluminum alloy in the 11R-10R region. In one embodiment 100% of the 11R-10R mass is associated with aluminum alloy in the 11R-10R region, however in a further series of embodiments no more than 95%, 85%, 75%, 65%, 55%, 45%, or 35% of the 11R-10R mass is associated with aluminum alloy in the 11R-10R region. As with all of the disclosure, any of these individual region aluminum alloy mass percentages may stand on their own or be used with any, or all, of the other region specific aluminum alloy mass percentages; which includes as open ended ranges bound at the bottom or top, and/or closed ended ranges whereby the upper and lower bounds are selected from any of the individual values for the specific region.

Again focusing on the significant aluminum alloy mass percentage embodiments, any of the prior disclosure, Tables, and mass properties associated with Example 34 (and variations), Example 35 (and variations), Example 36 (and variations), and Example 37 (and variations) may be combined with any of the significant aluminum alloy mass percentage embodiments.

Now referring to any of the disclosed embodiments, not limited to just the significant aluminum alloy mass percentage embodiments, in one embodiment at least N of the following are true: the pre-1F mass is 6-9% of the club head mass, the pre-SAVP mass is 29-36% of the club head mass, the pre-1R mass is 47-55% of the club head mass, the pre-2R mass is 56-62% of the club head mass, the pre-3R mass is 59-66% of the club head mass, the pre-4R mass is 62-69% of the club head mass, the pre-5R mass is 65-71% of the club head mass, the pre-6R mass is 67-74% of the club head mass, the pre-7R mass is 69-75% of the club head mass, the pre-8R mass is 72-78% of the club head mass, the pre-9R mass is 74-81% of the club head mass, the pre-10R mass is 92-100% of the club head mass; where the value of N is at least 2 in one embodiment, and at least 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 in further embodiments.

Again referring to any of the disclosed embodiments, not limited to just the significant aluminum alloy mass percentage embodiments, in another embodiment at least P of the following are true: the pre-1F mass is 7-8% of the club head mass, the pre-SAVP mass is 30-34% of the club head mass, the pre-1R mass is 49-53% of the club head mass, the pre-2R mass is 57-61% of the club head mass, the pre-3R mass is 60-64% of the club head mass, the pre-4R mass is 63-68% of the club head mass, the pre-5R mass is 66-70% of the club head mass, the pre-6R mass is 69-72% of the club head mass, the pre-7R mass is 71-74% of the club head mass, the pre-8R mass is 73-77% of the club head mass, the pre-9R mass is 75-79% of the club head mass, the pre-10R mass is 93-100% of the club head mass; where the value of P is at least 2 in one embodiment, and at least 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 in further embodiments.

Still referring to any of the disclosed embodiments, not limited to just the significant aluminum alloy mass percentage embodiments, in another embodiment at least Q of the following are true: the pre-1F mass is 13-19 grams, the pre-SAVP mass is 62-71 grams, the pre-1R mass is 100-108 grams, the pre-2R mass is 115-125 grams, the pre-3R mass is 122-132 grams, the pre-4R mass is 128-138 grams, the pre-5R mass is 132-142 grams, the pre-6R mass is 139-149 grams, the pre-7R mass is 143-153 grams, the pre-8R mass is 147-157 grams, the pre-9R mass is 152-162 grams, the pre-10R mass is at least 187 grams; where the value of Q is at least 2 in one embodiment, and at least 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 in further embodiments.

Additionally, and still referring to any of the disclosed embodiments, not limited to just the significant aluminum alloy mass percentage embodiments, in another embodiment at least β of the following are true: the pre-1F mass is 14-18 grams, the pre-SAVP mass is 64-70 grams, the pre-1R mass is 101-107 grams, the pre-2R mass is 117-123 grams, the pre-3R mass is 124-130 grams, the pre-4R mass is 130-136 grams, the pre-5R mass is 134-140 grams, the pre-6R mass is 140-147 grams, the pre-7R mass is 145-151 grams, the pre-8R mass is 148-155 grams, the pre-9R mass is 154-160 grams, the pre-10R mass is at least 189 grams; where the value of R is at least 2 in one embodiment, and at least 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 in further embodiments.

In one significant aluminum alloy mass percentage embodiment the front body portion 4602 is formed of aluminum alloy and does not extend behind the 5R plane, while in further embodiments it does not extend behind the 4R plane, the 3R plane, the 2R plane, or the 1R plane. While in another embodiment at least a portion of the front body portion 4602 extends in front of the SAVP, and in a further embodiment at least a portion of the front body portion 4602 extends in front of the crown leading edge 4625, while in another embodiment at least a portion of the front body portion 4602 extends in front of the center face 205, and in still another embodiment the front body portion 4602 extends to the sole plate leading edge 4641, of FIG. 141, and/or the club head leading edge 1170, of FIG. 70A. In another embodiment a portion of the front body portion 4602 extends above the 1C plane and below the 1S plane, and in a further embodiment a portion of the front body portion 4602 extends above the 2C plane and/or below the 2S plane. The aluminum alloy front body portion 4602 has a front body portion mass that is less than 45% of the club head mass in one embodiment, and less than 42.5%, 40%, or 37.5% in additional embodiments. While another series of embodiments establishes a floor with the front body portion mass being at least 12.5%, 17.5%, 22.5%, 27.5%, 32.5%, or 35%. While the aluminum alloy front body portion 4602 may be completely covered by other components of the club head such that no portion is visible in a finished club head, in another embodiment at least 100 mm²of the front body portion 4602 is exposed to the external environment in the finished club head, and in further embodiments the exposed front body portion surface area is increased to at least 200 mm², 300 mm², 400 mm², 500 mm², 600 mm², 700 mm², or 800 mm²; while a further series of embodiments caps the exposed front body portion surface area to no more than 6000 mm², 5500 mm², 5000 mm², 4500 mm², or 4000 mm². In one embodiment the front body portion mass is greater than at least one of the following: 150% of the mid-heel region mass; 250% of the post-10R mass; the forward heel and toe mass; the 2T-2H, post-9R mass; the post-9R mass; the large forward toe region mass; the 4T-4H, 1S-1C, pre-2R mass; the low forward heel and toe mass; the 2R-SAVP mass; the 4T-4H, below 1C, pre-2R mass; and/or the pre-SAVP mass. In further embodiments at least 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11 of the relationships in the prior sentence are true. In another embodiment the front body portion mass is less than at least one of the following: 8.5 times the limited heel region mass; 2.5 times the forward heel and toe mass; 3 times the mid-section mass; 180% of the 2T-2H, post-9R mass; 120% of the pre-SAVP mass; 130% of the 4T-4H, below 1C, pre-2R mass; and/or 2.8 times the low forward heel and toe mass. In further embodiments at least 2, 3, 4, 5, 6, or 7 of the relationships in the prior sentence are true.

As previously disclosed, the body can also include a front opening 4696 that is covered by the face plate 4610, where the face plate 4610 may be in the form of a face plate 4610 insert supported by the ledge wall 4690 or face support ledge wall 4690, and/or 4692, also referred to as the insert recess wall 4692, as seen in FIGS. 127 and 128, or the face plate 4610 may wrap onto an upper and/or lower portion of the lightweight front body portion 4602 and/or forward ledge 4680 and thereby cover the face opening 4696. Regardless of geometry and/or material, the face plate 4610 has a face plate mass that is not uniformly distributed about the origin 205, and impacts the face performance as well as the overall club head mass properties, and thus club head performance.

In one embodiment the face plate mass is less than at least one of the following: the 2R-SAVP mass; the post-9R mass; the 2T-2F post-9R mass; 20% of the club head mass; 47.5% of the front body portion mass; the forward heel and toe mass; the 4T-4H, 1S-4C, pre-2R mass; 50% of the pre-SAVP mass; a sum of the large forward toe region mass and the limited heel region mass; 50% of the 4T-4H, below 1C, pre-2R mass; the low forward heel and toe mass; the mid-section mass; and/or 200% of the mid-heel region mass. In further embodiments at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or 13 of the relationships in the prior sentence are true.

In another embodiment the face plate mass is greater than at least one of the following: 30% of the pre-SAVP mass; 55% of the 2T-2H, post-9R mass; 75% of the 4T-4H, 1S-4C, pre-2R mass; 75% of the mid-section mass; 60% of the forward heel and toe mass; the large forward toe region mass; 35% of the 4T-4H, below 1C, pre-2R mass; 75% of the low forward heel and toe mass; the 4T-8T, below FCHP, pre-2R mass; 155% of the 4H-8H, below FCHP, pre-2R mass; the 4T-4H, below 1C, 2R-SAVP mass; the 2R-SAVP heel and toe mass; the 4T-4H, below 1C, 2R-SAVP mass; 175% of the post-10R mass; the low 2R-SAVP heel and toe mass; the 2R-SAVP low-toe mass; 32.5% of the 2R-SAVP mass; 42.5% of the post-9R mass; 15% of the pre-2R mass; and/or the mid-heel region mass. In further embodiments at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 of the relationships in the prior sentence are true.

In another embodiment the front body portion mass is greater than the face plate mass; while in further embodiments the front body portion mass is at least 115%, 130%, 145%, 160%, 175%, 190%, or 205% of the face plate mass. In a further series of embodiments the front body portion mass is no more than 330%, 320%, 310%, or 300% of the face plate mass.

One skilled in the art will appreciate how additional planes may be introduced to further describe aspects of the club head. For example, the 1R plane is 10 mm behind the SAVP, and similarly a 0.75R plane is located 7.5 mm behind the SAVP, a 0.5R plane is located 5 mm behind the SAVP, and a 0.25R plane is located 2.5 mm behind the SAVP. Likewise, the 1F plane is 10 mm in front of the SAVP, and similarly a 0.75F plane is located 7.5 mm in front of the SAVP, a 0.5F plane is located 5 mm in front of the SAVP, and a 0.25F plane is located 2.5 mm in front of the SAVP. This same methodology may be applied to the heel-toe planes and the sole-crown planes.

The 0.75R plane is significant because it generally passes just behind a rear edge of the hosel and thus encompasses an area of the club head exposed to significant stresses. The region of the club head in front of the 0.75R plane is referred to as a pre-0.75R region that has a pre-0.75R mass, and the amount of aluminum alloy in the pre-0.75R region is a pre-0.75R aluminum alloy mass. A pre-0.75R AA mass ratio is a ratio of the pre-0.75R aluminum alloy mass to the pre-0.75R mass, which in one embodiment is 0.16-0.67. In a further series of embodiments the pre-0.75R AA mass ratio is at least 0.20, 0.24, 0.28, 0.32, 0.36, 0.40, 0.44, or 0.48. In another embodiment the pre-0.75R AA mass ratio is no more than 0.64, 0.61, 0.58, or 0.55. Conventional golf club head design thinking often suggests that a heavier pre-0.75R mass can potentially generate more ball speed and distance when struck properly because a well-designed pre-0.75R region face can provide increased energy transfer to the ball, resulting in higher initial ball velocity. Further, conventional thinking suggests that a heavier pre-0.75R region may enhance forgiveness by reducing the chances of the clubhead twisting or rotating upon impact, and thereby maintain a more consistent ball flight. However, recent research suggests that a lighter pre-0.75R region results in less moving mass as the face is deflected at impact, and therefore an increase in the coefficient of restitution (COR) and an ability to improve a weighted COR, which is disclosed later in detail. Thus, in another embodiment the pre-0.75R mass is less than 52% of the club head mass, and in further embodiments less than 51%, 50%, 49%, or 48%. Another series of embodiments establishes a floor whereby the pre-0.75R mass is at least 42%, 43%, 44%, or 45% of the club head mass. However, in another embodiment the pre-0.75R aluminum alloy mass is greater than the post-10R mass; while in a further embodiment the pre-0.75R aluminum alloy mass is no more than 110% of the post-9R mass, while in further embodiments the pre-0.75R aluminum alloy mass is no more than 105%, 100%, 95%, 90%, 85%, or 80% of the post-9R mass.

While the front body portion 4602 may include the hosel when described and claimed as such, in other embodiments the hosel is associated with a separate and distinct component that is attached to the front body portion 4602. However, one skilled in the art will appreciate that in an alternative embodiment the forward weighted portion 13000 may be formed of aluminum alloy and is considered the aluminum alloy front body portion 4602, and thus would not include a hosel, yet all of the significant aluminum alloy mass percentage embodiments, disclosure, and relationships would still apply. Likewise for the embodiment illustrated in FIG. 18 whereby the lower cup piece 304B may be the aluminum alloy front body portion 4602.

The disclosed aluminum alloy front body portion 4602 may be joined to a rear cap component, such as those disclosed in U.S. Ser. No. 15/504,887, filed Nov. 8, 2023, U.S. Ser. No. 18/124,325, filed Mar. 21, 2023, and U.S. Ser. No. 18/913,535, filed Oct. 11, 2024, each of which is incorporated by reference in the entirety. Further, any of the attributes of the disclosed aluminum alloy front body portion 4602 may be combined with the disclosure of U.S. Ser. No. 18/647,379, filed Apr. 26, 2024, U.S. Ser. No. 18/957,619, filed Nov. 22, 2024, and U.S. Ser. No. 63/740,603, filed Dec. 31, 2024, each of which is incorporated by reference in the entirety.

In one embodiment the coefficient of restitution (COR) at the location of the greatest ball speed is at least γ, and/or the characteristic time (CT) at the location of the greatest ball speed is at least δ, and/or a ball speed preservation area on the striking face is at least a mm². The ball speed preservation area is the surface area on the exterior of the striking face where the second ball speed is within 0.5 mph of the greatest ball speed. In one embodiment γ is 0.810, and is 0.815, 0.820, or 0.825 in further embodiments. In another embodiment δ is 245, and is 247, 249, 251, or 253 in further embodiments. In still another embodiment—is 180, and is 190, 200, 210, 220, 230, or 240 in further embodiments. The γ is less than 0.840 in one embodiment, and less than 0.835 or 0.830 in further embodiments; and the δ is less than 275 in one embodiment, and less than 270, 265, or 260 in further embodiments; and the ε is less than 350 in one embodiment, and less than 340, 330, 320, 310, 300, or 290 in further embodiments.

The disclosure contains a delicate interplay of relationships of the various components, variables within each component as well, as relationships across the components, which impact the performance, sound, feel, durability, and manufacturability of the golf club head. The disclosed relationships are more than mere optimization, maximization, or minimization of a single characteristic or variable, and are often contrary to conventional design thinking, yet have been found to achieve a unique balance of the trade-offs associated with competing criteria such as durability, acoustics, vibration, fatigue resistance, weight, and ease of manufacture. The relationships disclosed do more than maximize or minimize a single characteristic such as characteristic time (CT), coefficient of restitution (COR) at a single point such as face center or offset/distributed COR, moments of inertia, deflection of a single component, rigidity of a single component, ductility of a single component, stiffness of the overall club head, deflection of a single component, frequency of a single components, damping, and/or changes in mode frequencies of the individual components, rather, the relationships achieve a unique balance among these characteristics, which are often conflicting, to produce a club head that has improved feel, sound, durability, and/or performance. After all, the interaction of the numerous components of the present golf club head, particularly when they have such varied material properties, has the potential to adversely impact the sound and feel of the golf club head, as well as its durability, manufacturability, and overall performance. The aforementioned balance requires trade-offs among the competing characteristics recognizing key points of diminishing returns. Further, it is important to recognize that all the associated disclosure and relationships apply equally to all embodiments and should not be interpreted as being limited to the particular embodiment being discussed when a relationship is mentioned. The aforementioned balances require trade-offs among the competing characteristics recognizing key points of diminishing returns, as often disclosed with respect to open and closed ranges for particular variables and relationships. Proper functioning of each component, and the overall club head, on each and every shot, over thousands of impacts during the life of a golf club, is critical. Therefore, this disclosure contains unique combinations of components and relationships that achieve these goals. While the relationships of the various features and dimensions of a single component play an essential role in achieving the goals, the relationships of features and/or characteristics across multiple components are just as critical, if not more critical, to achieving the goals. Further, the relative length, width, thickness, geometry, and material properties of various components, and their relationships to one another and the other design variables disclosed herein, influence the performance, durability, feel, sound, safety, and ease of manufacture. Additionally, many embodiments have identified upper and/or lower limits ranges of relationships when extension outside the range the performance may suffer and adversely impact the goals. While some relationships may appear unrelated, durability of a crown extending to the extent disclosed herein has been avoided in the past due to durability issues, despite obvious advantages regarding creation of a topline, reduction in the thickness of portions of the forward body portion and the associated weight savings that permits more discretionary mass to be located as desired to achieve the disclosed mass properties, as well as the elimination of unsightly joints and seams when looking down on the club head at address. For instance the curvature of the crown near the crown leading edge, the extent to which it extends below the crown apex, particularly near the hosel portion, and/or the proud nature of the crown leading edge with respect to the face, or the proud nature of the crown perimeter edge with respect to the rear ring portion—namely the intermediary stepped down wall 4638, the relation of the crown leading edge to the vertical forward hosel plane, the extent to which the crown creates the perimeter of the club head, the elevation of the heel-side crown-to-face junction point and toe-side crown-to-face junction point, and/or the intersection of the heel-side stepped down wall and toe-side stepped down wall with the insert recess wall, as well as the associated elevations of the intersection, the notch and its size and associated thickness variations, the insert recess wall and face support ledge wall characterises and relationships to the face plate and crown, the material properties of the various club head components and bonding agents, all play a significant role in the durability of the crown, the face plate, the forward body portion, and the club head in general.

Central Region

Any of the embodiments herein may further include the performance attributes of the striking face disclosed in U.S. Ser. No. 18/888,500, filed Sep. 18, 2024, which is incorporated by reference in its entirety, including, but not limited to, the weighted COR, balance point COR, COR area, and characteristic time attributes. The disclosed front body portion 4602 attributes, as well as the mass distribution disclosed, has demonstrated unexpected improvements to the performance attributes of the striking face.

FIG. 216 illustrates a front elevation view of a golf club head 700 with striking locations 701, 702, 703, 704, 705 within a central region 720 positioned on the striking face 710. For example, the strike or striking face 710 can include the central region 720 centered on a geometric center of the striking face 710. In some embodiments, the central region 720 is centered on a different location on the face, such as the location of the club head center of gravity (CG) projected onto the striking face 710 or another location. The central region 720 can be defined by a 40 millimeter (mm) by 20 mm rectangular area centered on the striking face 710. The central region can be elongated in a heel-to-toe direction, such as tangential to the face 710 and parallel to a ground plane (GP). In some embodiments, the central region 720 is elongated at an angle with respect to the GP, such as elongated at a 45 degree angle to GP and extending from low-to-high in a heel-to-toe direction or in another direction. In some embodiments, the central region 720 can be defined by a larger or smaller rectangular area, defined by a different shape, such as a circular region, an octagonal region, a square region, a diamond shaped region, or another in another shape.

FIG. 217 illustrates the central region 720. For example, the central region 720 includes striking locations 701, 702, 703, 704, 705 for a right-handed golf club head. The central region 720 includes a first striking location 701 positioned at the geometric center of the striking face 710 corresponding to an (x, y) coordinate of (0, 0). The central region 720 includes a second striking location 702 positioned 10 mm above the geometric center of the striking face 710 corresponding to an (x, y) coordinate of (0, 10). The central region 720 includes a third striking location 703 positioned 10 mm below the geometric center of the striking face 710 corresponding to an (x, y) coordinate of (0, −10). The central region 720 includes a fourth striking location 704 positioned 20 mm toe-ward of the geometric center of the striking face 710 corresponding to an (x, y) coordinate of (−20, 0). The central region 720 includes a fifth striking location 705 positioned 20 mm heel-ward of the geometric center of the striking face 710 corresponding to an (x, y) coordinate of (20, 0). The above coordinates are provided in a 1 mm scale, but other scales can be used.

In some embodiments, additional or different striking locations can be used, such as striking locations corresponding to (x, y) coordinates of (0, 0), (−20, 10), (20, 10), (−20, −10), and (20, −10). Additional and different striking locations may also be used, such as for central regions of different shapes and/or sizes.

COR Weighting Factors and Values

Referring to FIGS. 216-217, each striking location 701, 702, 703, 704, 705 has a weighting factor and a COR value. The weighting factors are selected based on historical data on the impact locations where golfers most often impact the golf ball on the striking face 710. To selectively increase or optimize COR at likely impact locations on the striking face of the golf club heads, weighting factors are selected for each of the striking locations 701, 702, 703, 704, 705. The weighting factors and COR values are then used to calculate a weighted COR value for the golf club head.

In some embodiments, historical data for all golfers is used to select the weighting factors. Using historical data for all golfers, weighting factors can be selected to fit a large percentage of golfers, including golfers of different skill levels and with different tendencies in striking the golf ball outside of the ideal striking location. In other embodiments, a subset of historical data can be used, such as data for low handicap golfers, high handicap golfers, high lateral dispersion golfers (e.g., for higher MOI heads), low lateral dispersion golfers (e.g., for lower MOI heads), low swing speed golfers, high swings speed golfers, high spin golfers (e.g., for forward CG heads), low spin golfers (e.g., for rearward CG heads), golfers with similar swing flaws (e.g., draw bias heads for over the top producing a slice), golfers with similar shot shapes (e.g., draw, fade, slice, and hook) or another subset of golfers. Using a smaller subset of golfers, weighting factors can be selected to better fit golfers who are categorized as having tendencies fitting the subset.

In some embodiments, personalized data for an individual golfer is used to select the weighting factors. For example, a golfer can hit a number of golf balls (e.g., 100 balls or another number) and weighting factors can be selected based on the golfer's individual tendencies. Using data for the individual golfer, such as gathered during club fitting, a custom golf club head can be manufactured according to the weighting factors, such as with individualized COR, bulge and roll, and twist profiles for the golfer.

Ideally, golfers would always strike the golf ball at the geometric center of the face on every impact. However, in practice, golfers tend to strike the golf ball in similar locations outside of the geometric center of the face. For example, many golfers tend to strike the golf ball high and toe-ward on the striking face. Thus, the weighting factors apply more weight to the second striking location 102 higher on the and the fourth striking location toe-ward on the striking face. In this example, the first striking location corresponding to the geometric center of the striking face weighted highest, and the weighting factors can be summed to total 1 (i.e., 100%).

In some embodiments, the first COR weighting factor at the first striking location 701 is between 0.3 and 0.4, preferably greater than 0.3, more preferably between 0.32 and 0.33, more preferably 0.3267. The second COR weighting factor at the second striking location 702 is between 0.2 and 0.3, preferably greater than 0.2, more preferably between 0.22 and 0.23, more preferably 0.2256. The third COR weighting factor at the third striking location 703 is between 0.1 and 0.2, preferably greater than 0.1, more preferably between 0.135 and 0.145, more preferably 0.1395. The fourth COR weighting factor at the fourth striking location 704 is between 0.2 and 0.3, preferably greater than 0.2, more preferably between 0.22 and 0.23, more preferably 0.2263. The fifth COR weighting factor at the first striking location 705 is between 0.075 and 0.090, preferably greater than 0.08, more preferably between 0.0815 and 0.0824, more preferably 0.0819.

As discussed above, in some embodiments, the first COR weighting factor can be greater than all other weighting factors. The second COR weighting factor can be greater than the third COR weighting factor, such as between 0.05 and 0.2 greater than the third weighting factor. The fourth COR weighting factor can be greater than the fifth COR weighting factor, such as between 0.001 and 0.2 greater than the fifth weighting factor. The fourth COR weighting factor can be at least two times greater than the fifth COR weighting factor, such as between 0.1 and 0.2 greater than fifth COR weighting factor. The first COR weighting factor can be at least three times greater than the fifth COR weighting factor, such as between 0.2 and 0.3 greater than fifth COR weighting factor. The first COR weighting factor can be at least two times greater than the third COR weighting factor, such as between 0.1 and 0.3 greater than the third COR weighting factor. The first COR weighting factor can be no more than two times greater than the fourth COR weighting factor, such as between 0.01 and 0.3 greater than the fourth COR weighting factor. The third COR weighting factor can be greater than the fifth COR weighting factor, such as between 0.01 and 0.1 greater than the fifth COR weighting factor.

Each striking location 701, 702, 703, 704, 705 has corresponding COR values. In some embodiments, the first COR value at the first striking location 701 is between 0.805 and 0.840, preferably no less than 0.817, and in some embodiments at least 0.810, 0.820, 0.825, or 0.830. A second COR value at the second striking location 702 is between 0.780 and 0.830, preferably no less than 0.805, and in some embodiments at least 0.810, 0.815, or 0.820. A third COR value at the third striking location 703 is between 0.750 and 0.810, preferably no less than 0.775, 0.785, 0.795, or 0.800. A fourth COR value at the fourth striking location 704 is between 0.760 and 0.815, preferably no less than 0.770, 0.775, 0.780, 0.785, or 0.790. A fifth COR value at the fifth striking location 705 is between 0.720 and 0.800, preferably no less than 0.730, 0.740, 0.750, or 0.760.

In some embodiments, the second COR value plus the fourth COR value minus the third COR value minus the fifth COR value is greater than zero, such as between 0.0 and 0.165, preferably at least 0.015 COR points. The fourth COR value minus the fifth COR value is at least 0.015 COR points, such as between 0.015 and 0.095. The second COR value minus the fourth COR value is at least 0.007 COR points, such as between 0.007 and 0.060. The third COR value minus the fifth COR value is at least 0.004 COR points, such as between 0.004 and 0.085. In some embodiments, the fourth COR value can be greater than fifth COR value, second COR value can be greater than the fourth COR value, and the second COR value can be greater than the third COR value.

Weighted COR

As discussed above, the weighting factors and COR values can be used to calculate a weighted COR value for the golf club head. In some embodiments, the weight COR value can be a summation of each of the weighting factors multiplied by its corresponding COR value. For example, the weighted COR value can be equal to the first weighting factor multiplied by the first COR value, plus the second weighting factor multiplied by the second COR value, plus the third weighting factor multiplied by the third COR value, plus the fourth weighting factor multiplied by the fourth COR value, and plus the fifth weighting factor multiplied by the fifth COR value.

In some embodiments, the weighted COR value is no less than 0.800, such as between 0.800 and 0.840. In one embodiment the weighted COR value is at least 0.802, while in further embodiments it is at least 0.804, 0.806, 0.808, or 0.810. Another series of embodiments caps the weighted COR value to no more than 0.835, 0.830, 0.825, 0.820, or 0.815. In some embodiments, the weighted COR is between about 0.800 and about 0.815, preferably between 0.801 and 0.814, preferably between 0.802 and 0.813, preferably between 0.803 to 0.812.

Below is a table of weighted COR values for exemplary club heads:

701
702
703
704
705
Weighted

Example
COR
COR
COR
COR
COR
COR

1
0.829
0.802
0.802
0.790
0.771
0.806

2
0.830
0.802
0.802
0.792
0.761
0.806

3
0.828
0.799
0.795
0.791
0.775
0.804

4
0.830
0.802
0.802
0.792
0.761
0.806

5
0.830
0.801
0.803
0.799
0.780
0.809

6
0.830
0.801
0.802
0.799
0.775
0.808

7
0.830
0.815
0.810
0.799
0.785
0.813

8
0.830
0.815
0.810
0.795
0.785
0.812

9
0.830
0.811
0.805
0.795
0.785
0.811

10
0.830
0.813
0.805
0.801
0.799
0.814

11
0.830
0.811
0.802
0.799
0.790
0.812

12
0.830
0.821
0.804
0.825
0.799
0.821

13
0.830
0.825
0.804
0.819
0.799
0.820

14
0.829
0.802
0.802
0.790
0.771
0.806

15
0.828
0.801
0.795
0.791
0.775
0.805

16
0.822
0.807
0.804
0.792
0.770
0.805

Balance Point COR

The disclosed embodiments have also achieved unexpected balance point (BP) COR values. The BP COR corresponds to the BP location of the club head where the club head center of gravity (CG) projects onto the strike face. In such embodiments, the strike face has a balance point (BP) COR between 0.810 and about 0.840, preferably no less than 0.812, 0.814, 0.816, 0.818, 0.820, 0.822, 0.824, 0.826, 0.828, or 0.830. In some embodiments, the BP location does not correspond to the geometric center of the strike face. In some embodiments, the BP location is toe-ward of the geometric center of the strike face (i.e., at a negative location on the x-axis). In some embodiments, the BP location is upward of the geometric center of the strike face (i.e., at a positive location on the y-axis) or lower than the geometric center of the strike face (i.e., at a negative location on the y-axis). Referring back to the tables above, Examples 1, 2, and 3 have a BP COR values of 0.831, 0.830, and 0.829, respectively. In one embodiment the BP location is at least 1 mm from the center face striking location 701, and the balance point (BP) COR is within 0.002 of the center face striking location 701 COR, and is within 0.001 in another embodiment. Similarly, in a further embodiment the BP location is at least 1.5 mm from the center face striking location 701, and the balance point (BP) COR is within 0.002 of the center face striking location 701 COR, and is within 0.001 in another embodiment

COR Area

FIGS. 218-219 illustrate plots of COR values on the striking face of two different golf clubs. For example, each point on the plots represents a location on the striking face with a COR above 0.800. Four quadrants Q1, Q2, Q3, Q4 are defined with respect to the geometric center of the striking face 110. In this example, Q1 is defined high (from 0 to 15 mm on the y-axis) and heelward (0 to 20 mm on the x-axis). Q2 is defined high (from 0 to 15 mm on the y-axis) and toeward (0 to −25 mm on the x-axis). Q3 is defined low (from 0 to −10 mm on the y-axis) and toeward (0 to −25 mm on the x-axis). Q4 is defined low (from 0 to −10 mm on the y-axis) and heelward (0 to 20 mm on the x-axis). Additional or different quadrants can be used. The above quadrants Q1, Q2, Q3, Q4 refer to a right-handed golf club.

FIG. 218 illustrates COR area plots for two club heads: Club Head 1; and Club Head 2. In this example, Club Head 1 was designed using traditional processes and Club Head 2 was designed using the COR weighting factors and weighted COR. As depicted, the total COR area of Club Head 1 is smaller than the COR area of club head 2. The total COR area of Club Head 1 can be between 380 mm²and 450 mm², such as about 415 mm². Using the COR weighting factors and weighted COR, the total COR area of Club Head 2 can be increased to a value between 560 mm²and 635 mm², such as at least 570 mm², 580 mm², 590 mm², or about 594 mm². In some embodiments, the total COR area of Club Head 2 is at least 450 mm², more preferably at least 500 mm², more preferably at least 550 mm², more preferably at least 600 mm², more preferably at least 650 mm². A similar increase in COR area is illustrated in FIG. 219 by COR area plots for two different club heads: Club Head 3 and Club Head 4.

In addition to increasing the overall COR area of the striking face 710, the COR area can be increased in more beneficial locations based on the COR weighting factors, resulting in an asymmetric COR area. For example, the COR area can be increased in Q2 (i.e., high and toward), resulting in a COR area that is asymmetric about a vertical axis and shifted toeward, with a majority of the increase in COR area toeward of the vertical axis through center face. In some embodiments, the COR area can also be increased above a horizontal axis through center face.

Based on the weighting factors, the COR area of each of the quadrants Q1, Q2, Q3, Q4 can be different. For example, the COR area of Q2 can be greater than Q1, the COR area of Q2 can be greater than Q3, and the COR area of Q2 can be greater than Q4. The combined COR area of Q1 and Q2 can be greater than the combined COR area of Q3 and Q4. The combined COR area of Q2 and Q3 can be greater than the combined COR area of Q1 and Q4. The combined COR area of Q2 and Q4 can be greater than the combined COR area of Q1 and Q3.

The COR values in each of the quadrants Q1, Q2, Q3, Q4 can also be based on the weighting factors. For example, locations in Q2, such as a first location −10 mm toward and a second location −20 mm toward, can have COR values greater than 0.793, such as between about 0.780 and 0.830. In some embodiments, locations in Q2 and Q3 have COR values greater than Q1 and Q2. In an example, a location −20 mm toeward can have a COR value at least 0.100 greater than 20 mm heelward, while an average COR of the two locations is at least 0.750.

Club Head Testing for Weighted COR

A method of testing a club head for weighted COR is provided. The method begins by performing initial testing properties of the golf club head, such as inertia, mass properties, center of gravity z-axis (Izz), center of gravity x-axis (Ixx), and displaced water volume.

Next, the club head is measured for COR values at each of the five striking locations 701, 702, 703, 704, 705. In some embodiments, using the measured COR values (COR_N) and corresponding weighting factors (WF_N) for the five striking locations 701, 702, 703, 704, 705, and a weighted COR can be calculated using the following equation:

${COR}_{101} * {WF}_{101} + {COR}_{102} * {WF}_{102} + {COR}_{103} * {WF}_{103} + {COR}_{104} * {WF}_{104} + {COR}_{105} * {WF}_{105} = Weighted COR$

In the above equation, the weighting factors can be 0.3267, 0.2256, 0.1395, 0.2263, and 0.0819 for the striking locations 701, 702, 703, 704, 705, respectively. In other embodiments, different weighting factors can be used.

Next, durability testing can be performed on the club head. For example, an initial CT value can be measured at the geometric center of the strike face (e.g., striking location 701). In some embodiments, the initial CT value is at least 236 microseconds (μs) and no more than 257 μs. In further embodiments the initial CT value at striking location 701 is at least 237 μs, 238 μs, 239 μs, 240 μs, 241 μs, 242 μs, 243 μs, 244 μs, 245 μs, or 246 μs. In some embodiments, initial CT values can be measured at other striking locations, such as striking locations 702, 703, 704, 705 and/or other striking locations. The CT testing can be performed within the central region 720, which can be defined by the 40 millimeter (mm) by 20 mm rectangular area centered on the striking face 710, and there is a highest initial CT within the central region 720 and a lowest initial CT within the central region 720, with a CT delta being the difference between the highest initial CT within the central region 720 and the initial CT at the center face striking location 701. In one embodiment the CT delta is no more than 6 μs, while in further embodiments is no more than 5 μs, 4 μs, 3 μs, or 2 μs. These relationships are significantly more than just maximizing one variable, or multiple variables, but rather are a unique balance of tradeoffs enabled by the disclosed construction and mass distribution of the embodiments. For instance, in one embodiment the initial CT at the center face striking location 701 is at least 237 μs, while the highest initial CT within the central region 720 is no more than 254 μs, 252 μs, or 250 μs, while the weighted COR is 0.804-0.812, all while the BP COR is 0.827-0.832 with the BP location at least 1.0 mm from the center face, and while the balance point (BP) COR is within 0.002 of the center face striking location 701 COR.

After measuring initial CT value(s), the club head it exposed to 500 golf ball impacts at the geometric center of the strike face. The golf ball impacts are performed with a golf ball speed of 52 meters per second. After the 500 golf ball impacts, the central region 720 is golf club head is measured to determine if a change in CT has occurred. For example, different striking locations on the striking face of the club head are tested to determine if any CT values of the striking locations within the central region 720 are greater than 256 μs. Additionally, a 500 impact CT value at the geometric center of the striking face can be measured and compared to the initial CT value to determine an increase CT resulting from the impacts. For example, after 500 impacts, the 500 impact CT value can be larger than the initial CT value, such as by no more than five (5.0) CT points than the initial CT value, preferably no more than four (4.0) CT points greater than the initial CT value, preferably no more than three (3.0) CT points greater than the initial CT value, preferably no more than four (2.0) CT points greater than the initial CT value, preferably no more than one (1.0) CT points greater than the initial CT value, more preferably no more than zero (0.0) CT points greater than the initial CT value. Thus, the disclosed construction and mass distribution of the embodiments may aid in controlling CT creep, or the difference between the 500 impact CT value at a particular location and the initial CT value at the same location.

The durability testing can be repeated with additional sets of 500 golf ball of impacts, such as after 1000 golf ball of impacts, 1500 golf ball of impacts, 2000 golf ball of impacts, 2500 golf ball of impacts, and 3000 golf ball of impacts. A CT value is measured after each series of golf ball impacts, and each CT value is compared to the initial CT value to determine further increases in CT resulting from the additional impacts. For example, after series of impacts, the measured CT value can be larger than the initial CT value, such as by no more than six (6.0) points, preferably no more than five (5.0) CT points, more preferably no more than four (4.0) CT points greater than the initial CT value. After each test, all measured CT values are less than 257 μs.

Industry standard values disclosed herein are to be determined via methodologies known to one skilled in the art, and when appropriate via the rules, procedures, and protocols set forth by the United States Golf Association in the versions in effect as of Nov. 20, 2024, including but not limited to the following:

R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE CLUBHEAD SIZE OF WOOD CLUBS, TPX3003, Rev. 2.1, 9 Apr. 2019.

R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE FLEXIBLITY OF A GOLF CLUBHEAD, TPX3004, Rev. 2.0, 9 Apr. 2019.

R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE MOMENT OF INERTIA OF GOLF CLUBHEADS, TPX3005, Rev. 2.0, 1 Dec. 2020.

R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING THE COEFFICIENT OF RESTITUTION OF A CLUBHEAD RELATIVE TO A BASELINE PLATE, TPX3009, Rev. 2.0, 9 Apr. 2019.

R&A Rules Limited and United States Golf Association, PROTOCOL FOR MEASURING IMPACT AREA MARKINGS OF GOLF CLUBS, TPX3001, Rev. 2.0, 1 Dec. 2020.

United States Golf Association and R&A Rules Limited, PROCEDURE FOR MEASURING THE LENGTH OF GOLF CLUBS (Excluding Putters), USGA-TPX3002, Revision 1.0.0, Jan. 2, 2007.

R&A Rules Limited and United States Golf Association, OVERALL DISTANCE STANDARD AND SYMMETRY TEST PROTOCOL, TPX3006, Rev. 3.0, 9 Apr. 2019.

R&A Rules Limited and United States Golf Association, INITIAL VELOCITY TEST PROTOCOL, TPX3007, Rev. 2.1, 9 Apr. 2019.

R&A Rules Limited and United States Golf Association, GOLF BALL WEIGHT AND SIZE TEST PROTOCOL, TPX3008, Rev. 2.0, 1 Dec. 2020.

With respect to coefficient of restitution, test equipment shall be manufactured by Automated Design Corporation, Romeoville, IL, Model: Club Head COR Tester, or equivalent.

The club head origin coordinate system is again illustrated in FIGS. 220-224 to further explain attributes achieved via the significant aluminum alloy mass percentage embodiments. The club head has a club head center-of-gravity (CG). A club head origin 205 is illustrated at the geometric center of the face.

The head origin coordinate system defined with respect to the head origin 205 includes three axes: an origin z-axis extending through the head origin 205 in a vertical direction relative to the ground plane (GP) when the club head is at the normal address position; an origin x-axis extending through the head origin 205 in a toe-to-heel direction parallel to the face, e.g., generally tangential to the face at the origin 205, and perpendicular to the origin z-axis; and an origin y-axis extending through the head origin 205 in a front-to-back direction and perpendicular to the origin x-axis and to the origin z-axis. The origin x-axis and the origin y-axis both extend in horizontal directions relative to the ground plane (GP) when the club head is at normal address position. The origin x-axis extends in a positive direction from the origin 205 to the heel of the club head. The origin y-axis extends in a positive direction from the origin 205 towards the rear of the club head. The origin z-axis extends in a positive direction from the origin 205 towards the crown. Thus, if the club head CG is located 5 mm toward the heel from the head origin 205, and 5 mm below the head origin 205, and 25 mm behind the head origin 205, the head origin x-axis (CGx) coordinate would be 5 mm, the head origin y-axis (CGy) coordinate would be 25 mm, and the head origin z-axis (CGz) coordinate would be −5 mm.

As used herein, “Zup” refers to the height of the CG above the ground plane (GP). Another alternative coordinate system uses the club head center-of-gravity (CG) as the origin when the club head is at normal address position. Each center-of-gravity axis passes through the CG. For example, the CG x-axis passes through the center-of-gravity parallel to the ground plane (GP) and parallel to the origin x-axis when the club head is at the normal address position. Similarly, the CG y-axis passes through the center-of-gravity CG parallel to the ground plane (GP) and generally parallel to the origin y-axis, and the CG z-axis passes through the center-of-gravity CG perpendicular to the ground plane (GP) and generally parallel to the origin z-axis when the club head is at normal address position.

The moment of inertia about the CG z-axis (Izz) is an indication of the ability of a golf club head to resist twisting about the CG z-axis. Greater moments of inertia about the CG z-axis (Izz) provide the golf club head with greater forgiveness on toe-ward or heel-ward off-center impacts with a golf ball. In other words, a golf ball hit by a golf club head on a location of the striking face between the toe and the origin 205 tends to cause the golf club head to twist rearwardly and the golf ball to draw (e.g., to have a curving trajectory from right-to-left for a right-handed swing). Similarly, a golf ball hit by a golf club head on a location of the striking face between the heel and the origin 205 causes the golf club head to twist forwardly and the golf ball to slice (e.g., to have a curving trajectory from left-to-right for a right-handed swing). Increasing the moment of inertia about the CG z-axis (Izz) reduces forward or rearward twisting of the club head, reducing the negative effects of heel or toe mis-hits.

As the moment of inertia about the CG z-axis (Izz) is an indication of the ability of a club head to resist twisting about the CG z-axis, the moment of inertia about the CG x-axis (Ixx) is an indication of the ability of the club head to resist twisting about the CG x-axis. In general, greater moments of inertia about the CG x-axis (Ixx) improve the forgiveness of the club head on high and low off-center impacts with a golf ball. In other words, a golf ball hit by a club head on a location of the striking surface above the origin 205 causes the club head to twist upwardly and the golf ball to have a higher trajectory than desired. Similarly, a golf ball hit by a club head on a location of the striking face below the origin 205 causes the club head to twist downwardly and the golf ball to have a lower trajectory than desired. Increasing the moment of inertia about the CG x-axis (Ixx) reduces upward and downward twisting of the club head, reducing the negative effects of high and low mis-hits.

A moment of inertia about the golf club head shaft axis is referred to as the hosel axis moment of inertia (Ih) and is calculated in a similar manner and is an indication of the ability of the club head to resist twisting about the shaft axis, and also serves as a measure of the resistance a golfer senses during a golf swing as they attempt to bring the club head back to a square position to impact a golf ball. In addition to redistributing mass within a particular club head envelope as discussed immediately above, the club head center-of-gravity CG location can also be tuned by modifying the club head external envelope. Referring now to FIGS. 222 and 223, the club head has a maximum club head height Hch defined as the maximum above ground z-axis coordinate of the outer surface of the crown. Similarly, a maximum club head width Wch can be defined as the distance between the maximum extents of the heel and toe portions of the body measured along an axis parallel to the x-axis when the club head is at normal address position, where per the USGA the heel measurement point is deemed to be 0.875 inches (22.23 mm) above the horizontal ground plane. A maximum club head depth Deh, or length, defined as the distance between the forwardmost and rearwardmost points on the surface of the body measured along an axis parallel to the y-axis when the club head is at normal address position. Generally, the height and width of the club head should be measured according to the USGA “Procedure for Measuring the Clubhead Size of Wood Clubs”, TPX3003, Rev. 2.1, 9 Apr. 2019. The heel portion of the club head is broadly defined as the portion of the club head from a vertical plane passing through the origin y-axis toward the hosel, while the toe portion is that portion of the on the opposite side of the vertical plane passing through the origin y-axis.

A club head origin coordinate system can be defined such that the location of various features of the club head including a club head center-of-gravity (CG).

In some embodiments the CG location preferentially affects the Z-axis gear effect. As seen in FIG. 221, a loft plane contacts the origin 205 and is parallel to the origin x-axis. An imaginary line (IL) originates at the CG and extends forward to intersect the loft plane at a 90 degree angle. A projected CG point, abbreviated Proj. CG point in the figures, is located at the intersection of the imaginary line (IL) and the loft plane, seen in FIGS. 221 and 222. A BP projection distance, abbreviated BP Proj. and often referred to as BP projection, or BP proj for short, is the vertical distance measured parallel to the origin z-axis from the origin x-axis to the elevation of the projected CG point. The BP projection is positive when the projected CG point is above the origin, and is negative when the projected CG point is below the origin. The impact efficiency of the club head, as well as the ball launch characteristics, are influenced by the location of the projected CG point and the magnitude of the BP projection. The imaginary line also defines a BP Plane, illustrated in FIG. 221. The BP Plane contains the imaginary line, and thus the CG and the Proj. CG Point, and extends throughout the club head in the x-direction parallel to the imaginary line. The BP Plane is used to divide the club head into two sections, namely an above-BP-Plane portion of the club head and a below-BP-Plane portion of the club head. The above-BP-Plane portion of the club head has an above-BP-Plane portion mass, and the below-BP-Plane portion of the club head has a below-BP-Plane portion mass. In one embodiment the above-BP-Plane portion mass and the below-BP-Plane portion mass differ by less than 5% of the total club head mass, while in further embodiments they differ by less than 4.5%, 4%, 3.5%, 3%, or 2.5% of the total club head mass. In another embodiment the above-BP-Plane portion mass is greater than the below-BP-Plane portion mass. Further, the above-BP-Plane portion of the club head has an above-BP-Plane portion material volume and an average above-BP-Plane portion density, which is the above-BP-Plane portion mass divided by the above-BP-Plane portion material volume. Likewise, the below-BP-Plane portion of the club head has a below-BP-Plane portion material volume and an average below-BP-Plane portion density, which is the below-BP-Plane portion mass divided by the below-BP-Plane portion material volume. In one embodiment the average above-BP-Plane portion density is less than the average below-BP-Plane portion density. In another embodiment the average above-BP-Plane portion density is at least 5% less than the average below-BP-Plane portion density, and in further embodiments the percentage is increased to 7%, 9%, or 11%. However, another series of embodiments limits this relationship whereby the average above-BP-Plane portion density is at least 75% of the average below-BP-Plane portion density, and in further embodiments the average above-BP-Plane portion density is at least 77.5%, 80%, 82.5%, or 85% of the average below-BP-Plane portion density.

The below-BP-Plane portion of the club head has a below-BP-Plane portion Izz about the CG z-axis, as well as a below-BP-Plane portion Ixx about the CG x-axis. The above-BP-Plane portion of the club head has an above-BP-Plane portion Izz about the CG z-axis, as well as an above-BP-Plane portion Ixx about the CG x-axis. The above-BP-Plane portion Izz is at least 15% greater than the below-BP-Plane portion Izz in one embodiment, and the percentage is increased to at least 17.5%, 20%, 22.5%, or 25% in additional embodiments. However, another series of embodiments caps this relationship such that the above-BP-Plane portion Izz is no more than 35%, 32.5%, 30%, or 27.5% greater than the below-BP-Plane portion Izz. The above-BP-Plane portion Ixx is at least 7.5% greater than the below-BP-Plane portion Ixx in one embodiment, and the percentage is increased to at least 10% or 12.5% in additional embodiments. However, another series of embodiments caps this relationship such that the above-BP-Plane portion Ixx is no more than 25%, 22.5%, 20%, or 17.5% greater than the below-BP-Plane portion Ixx.

If the projected CG point on the ball striking club face is closer to the sole than the geometric center, when the golf club is swung such that the club head impacts a golf ball at the origin 205, the impact is “off center” from the projected CG point, creating torque that causes the body of the golf club head to rotate (or twist) about the CG x-axis. The rotation of the club face creates a “z-axis gear effect.” More specifically, the rotation of the club head about the CG x-axis tends to induce a component of spin on the ball. In particular, the backward rotation of the face that occurs as the golf ball is compressed against the face during impact causes the ball to rotate in a direction opposite to the rotation of the face, much like two gears interfacing with one another. Thus, the backward rotation of the club face during impact creates a component of forward rotation in the golf ball. This effect is termed the “z-axis gear effect.” Because the loft of a golf club head also creates a significant amount of backspin in a ball impacted by the golf club head, the forward rotation resulting from the z-axis gear effect is typically not enough to completely eliminate the backspin of the golf ball, but instead reduces the backspin from that which would normally be experienced by the golf ball. In general, the forward rotation (or topspin) component resulting from the z-axis gear effect is increased as the impact point of a golf ball moves upward from (or higher above) the projected CG point on the ball striking club face, and having a large club head and face may promote strikes high on the face. Additionally, the effective loft of the golf club head that is experienced by the golf ball and that determines the launch conditions of the golf ball can be different than the static loft of the golf club head. The difference between the golf club head's effective loft at impact and its static loft angle at address is referred to as “dynamic loft” and can result from a number of factors. In general, however, the effective loft of a golf club head is increased from the static loft as the impact point of a golf ball moves upward from (or higher than) the projected CG point on the ball striking club face. Thus, a club head with a low CG, or relatively small Zup value, and associated low projected CG point has preferred z-axis gear effect particularly when combined with an increased face height Hss that tends to promote impacts higher on the face. In a further embodiment the static loft angle is at 8-15 degrees, while in another embodiment it is 91-14 degrees, and in yet a further embodiment it is 9-13 degrees.

The trajectory of a golf ball hit by a club head having a projected CG that coincides with the geometric center of the striking surface typically includes a low launch angle and a significant amount of backspin. The backspin on the ball causes it to quickly rise in altitude and obtain a more vertical trajectory, “ballooning” into the sky. Consequently, the ball tends to quickly lose its forward momentum as it is transferred to vertical momentum, eventually resulting in a steep downward trajectory that does not create a significant amount of roll. Even though some backspin can be beneficial to a golf ball's trajectory by allowing it to “rise” vertically and resist a parabolic trajectory, too much backspin can cause the golf ball to lose distance by transferring too much of its forward momentum into vertical momentum.

In contrast, the trajectory of a golf ball hit by a large club head having a lower center of gravity has a higher launch angle and less backspin relative to the club head having a projected CG that coincides with the geometric center of the striking surface, and the trajectory includes less “ballooning” but still has enough backspin for the ball to have some rise and to generally maintain its launch trajectory longer than a ball with no backspin. As a result, the golf ball carries further because the horizontal momentum of the golf ball is greater, which also increases the roll-out upon landing.

As seen in FIG. 221, Delta1 is a measure of how far rearward in the club head body the CG is located behind the SAVP; and Zup is a measure of the vertical distance that the CG is located above the ground plane (GP). Smaller values of Delta1 result in a lower projected CG. In some embodiments of the disclosed golf club heads the projected CG is lower than the geometric center, reducing Delta1 can lower the projected CG and increase the distance between the geometric center and the projected CG. Recall also that a lower projected CG creates a higher dynamic loft and more reduction in backspin due to the z-axis gear effect. Thus, for particular embodiments of the disclosed golf club heads, the Delta1 values are relatively low, thereby reducing the amount of backspin on the golf ball and helping the golf ball obtain the desired high launch, low spin trajectory.

Adjusting the location of the discretionary mass in a golf club head, the shape of the club head, and/or multi-component and multi-material construction can provide the desired Delta1 value. For instance, Delta1 can be manipulated by varying the mass in front of the CG (closer to the face) with respect to the mass behind the CG. That is, by increasing the mass behind the CG with respect to the mass in front of the CG, Delta1 can be increased. In a similar manner, by increasing the mass in front of the CG with the respect to the mass behind the CG, Delta1 can be decreased. The shape of the body may include any of the embodiments disclosed in U.S. patent application Ser. No. 18/653,254, filed May 2, 2024, and Ser. No. 18/822,842, filed Sep. 3, 2024, and U.S. patent Ser. No. 10/463,929, issued Nov. 5, 2019, which are incorporated herein by reference. Additionally, one embodiment the club head avoids the high CG locations by incorporating a low-density material in at least a portion of the crown, which may be metallic or non-metallic. As such, one particular embodiment has an average crown density of less than 4 g/cc, while in another embodiment the average crown density is less than 3 g/cc, and in yet another embodiment the average crown density is less than 2 g/cc. In one particular embodiment at least 50% of the crown area is composed of non-metallic material. In another embodiment at least 75% of the crown area is composed of non-metallic material. In another embodiment at least 50% of the exposed surface area of the club head located above the height of the origin 205 is formed of non-metallic materials, while in an even further embodiment the non-metallic surface area located above the height of the origin 205 is at least 7500 mm², and in another embodiment the mass of the non-metallic portions located above the height of the origin is 25-50 grams, while the mass is 30-45 grams in another embodiment. In another embodiment at least 50% of the exposed surface area of the club head located below the height of the origin 205 is formed of non-metallic materials, while in an even further embodiment the non-metallic surface area located below the height of the origin 205 is at least 7500 mm², and in another embodiment the mass of the non-metallic portions located below the height of the origin 205 is 15-50 grams, while the mass is 20-45 grams in another embodiment.

As seen in FIG. 222, a Delta2 value is another important dimension used in quantifying the location of the center of gravity CG, which also influences the performance of the club head. First, project the center of gravity CG forward, along the CG y axis, until it strikes the SAVP thereby defining a point referred to as the D2 point. The shortest distance from the D2 point to the shaft axis SA is the Delta2 value, thus the Delta2 value is the distance from the D2 point to a shaft-axis-intersection point within the SAVP. Therefore, an imaginary triangle may be created starting at the center of gravity CG with a first leg along the CG y axis with a magnitude of the Delta1 value; a second leg within the SAVP extends from the D2 point to the shaft-axis-intersection point, and has a magnitude of the Delta2 value; and the hypotenuse of the triangle extends from the shaft-axis-intersection point to the center of gravity CG. The CG angle is the angle between the second leg and the hypotenuse. Therefore, the tangent of the CG angle is equal to the D1 value divided by the D2 value, allowing for easy calculation of the CG angle.

Simply maximizing or minimizing one attribute of a club head's mass properties generally produces a club head that is difficult for a novice golfer to maneuver and return to a square position. Such surprising and unique relationships include variations of Delta1, Delta2, CG angle, moments of inertia, volume, face dimensions, bulge, roll, and club head dimensions, as well as unique and unexpected ratios of such variables that box in unexpected characteristics to achieve the goals disclosed herein.

Another unexpected ratio that is a good indicator of the feel and difficulty a novice golfer is going to have controlling the club head throughout the swing, while avoiding the previously explained unstable feeling associated with mis-hits struck far from the geometric center of the face, is a delta2-hosel-axis ratio of the hosel axis moment of inertia (Ih) to the Delta2 value. In one embodiment the delta2-hosel-axis ratio is at least 24 kg-mm, while in further embodiments it is at least 25, 26, or 27 kg-mm. Another series of embodiments caps the delta2-hosel-axis ratio to no more than 31, 30, 29, or 28 kg-mm.

In one particular embodiment the hosel axis moment of inertia (Ih) is at least 900 kg·mm², while in further embodiments it is at least 920, 940, 960, 980, or 1000 kg·mm², while in yet another embodiment it is no more than 1100 kg·mm², and in an even further embodiments it is no more than 1090, 1080, 1070, 1060, 1050, 1040, or 1030 kg·mm². Likewise, in another preferred series of embodiments an Ih-to-Zup ratio of the hosel axis moment of inertia (Ih) to the Zup value is at least 34 kg·mm, while in a further embodiment it is at least 36 kg·mm, and in yet another embodiment it is at least 38 kg·mm, and in still another embodiment it is at least 40 kg·mm. In an even further series of embodiments the Ih-to-Zup ratio is no more than 45 kg·mm, while in another embodiment it is no more than 44 kg·mm, and in yet a further embodiment it is no more than 43 kg·mm, and in yet a further embodiment it is no more than 42 kg·mm. The disclosed ratios and ranges unexpectedly produce preferred launch conditions while not sacrificing playability and feel of the golf club in the hands of a novice golfer.

An extreme forward CG location in a large club head depths Dch club head often results in a feeling of club head instability upon mis-hits struck far from the origin 205, due in part to moments of inertia that are too small for the size of the club head. While a degree of club head twisting is sensed by a novice golfer using a golf club head having a club head depths Dch of 115 mm or less, when a golf ball is struck at the extreme toe or heel portion of the face, it is significantly more noticeable when using a club head having a club head depths Dch of 120 mm or more, particularly on shots struck high on the face or low on the face, which is virtually unperceivable to a novice golfer using a club head having a club head depths Dch of 115 mm or less.

In one particular embodiment the club head depths Dch is at least 120, 121, 122, 123, or 124 mm, and the Ixx value is at least 360 kg·mm², while in further embodiments the Ixx value is at least 370, 380, 390, 400, or 410 kg·mm². Another series of embodiments introduces new limits on the Ixx value range to ensure the desired z-axis gear effect is not reduced or negated. For instance, in one embodiment the Ixx value is no more than 455 kg·mm², while in further embodiments the Ixx value is no more than 445, 435, or 425 kg·mm². A ratio of the Ixx value to the Izz value is also critical to achieving the goals. Thus, in one embodiment the Ixx-Izz ratio is at least 0.68, and in further embodiments is at least 0.69, 0.70, or 0.71. Another series of embodiments caps the Ixx-Izz ratio to no more than 0.75, 0.74, 0.73, or 0.72. In another particular embodiment Iyy value is at least 265 kg·mm², while in a further embodiment the Iyy value is at least 275 kg·mm², and in yet another embodiment the Iyy value is at least 285 kg·mm². Another series of embodiments introduces new limits on the Iyy value range to promote a natural feeling when the club head is moved throughout the range of motion of a golf swing by a novice golfer. For instance, in one embodiment the Iyy value is no more than 325 kg·mm², while in another embodiment the Iyy value is no more than 315 kg·mm², and in yet another embodiment the Iyy value is no more than 305, or 295 kg·mm². In another particular embodiment the Izz value is at least 560 kg·mm²thereby reducing the feeling of the club head spinning open or closed when mis-hits are struck on the extreme toe or heel size of the face, while in a further embodiment the Izz value is at least 570 kg·mm², and in yet another embodiment the Izz value is at least 580, or 590 kg·mm². Another series of embodiments introduces new limits on the Izz value range so that a novice golfer does not feel as though they need to introduce additional rotation of their hands and the grip to square the face at impact with the golf ball. For instance, in one embodiment the Izz value is no more than 700 kg·mm², while in another embodiment the Izz value is no more than 650 kg·mm², and in yet another embodiment the Izz value is no more than 625, or 600 kg·mm². Still further embodiments of the oversized club head 2 may incorporate any of the ratios, relationships, and/or features disclosed in U.S. patent application Ser. No. 18/202,025, filed May 25, 2023, which is incorporated by reference herein.

Additionally, the location of the CG may be used to further the goal of assisting the novice golfer maneuver the club head throughout the swing and promote the return to the square position at impact with the golf ball. In one such example the CGx value is less than 0 mm, meaning the CG is located on the toe side of the origin 205 and thus the CGx value is negative, while in further embodiments the CGx value is less than −0.5 mm, −1.0 mm, −1.5 mm, −2 mm, −2.5 mm, or −3.0 mm. Another series of embodiments establishes a floor for the CGx value with it being no less than −7 mm, −6 mm, −5 mm, or −4 mm. In a further embodiment the CGx value is negative and within 30% of the absolute value of the BP projection distance multiplied by negative one, while in further embodiments the percentage is reduced to 25%, 20%, 15%, or 10%. In yet another embodiment the CGx value is negative, but greater than the absolute value of the BP projection distance multiplied by negative one. However, having a large GCx value, either negative or positive, may negatively influence performance, reduce impact efficiency, produce an undesirably feel when a ball is struck a significant distance from the origin 205, and result in a tendency of the golfer to have the face open, or closed, at impact (i.e. difficult to reliably bring the face to square during the swing).

As previously explained, Delta1 is a measure of how far rearward in the club head the CG is located behind a vertical plane containing the shaft axis, also referred to as the VSAP, further a center face progression CFP, also referred to as CFY, is a measure of how far the geometric face center, or origin, is in front of the VSAP, and the CGy value is the sum of Delta1 and CFP. As noted with several other variables, the center face progression CFP is particularly important when the maximum club head depth Dch is large, meaning at least 120 mm, 121 mm, 122 mm, 123 mm, or 124 mm. In one such embodiment the CFP is no more than 44% of Delta1, and/or the CFP is no more than 35.5% of Delta2. In a further embodiment the CFP is no more than 43.5% of Delta1; while further embodiments establish a floor for the relationship whereby the CFP is at least 41%, 41.5%, 42%, 42.5%, or 43% of Delta1. Similarly, in further embodiments the CFP is no more than 35.25%, 35%, or 34.75% of Delta2; while additional embodiments establish a floor for the relationship whereby CFP is at least 33%, 33.5%, 34%, or 34.5% of Delta2. In an even further embodiment the CFP is no more than 14 mm, and in additional embodiments the CFP is no more than 13.9 mm, 13.8 mm, or 13.7 mm. A further series of embodiments establishes a floor whereby the CFP is at least 12 mm, 12.5 mm, 13 mm, or 13.5 mm. The CFP influences the mass properties of the club head, but also must achieve a delicate balance with the mass properties to achieve a club head that is easy to control. This is achieved in part by carefully controlling the magnitudes of the BP projection, Delta1, Delta2, and/or Zup.

For example, in one embodiment the Delta2 value is at least 13 times the absolute value of the BP projection, while in further embodiments it is at least 13.1, 13.2, or 13.3 times the absolute value of the BP projection. Further, the difference between the Delta2 value and the Delta1 value, referred to as the Delta2-1 differential, is critical variable to control, often in association with other relationships. For example, in one embodiment the absolute value of the BP projection is less than 40% of the Delta2-1 differential, and in further embodiments the percentage is reduced to less than 39% or 38%. A further series of embodiments establishes a floor for the relationship whereby the absolute value of the BP projection is at least 30%, 31%, or 32% of the Delta2-1 differential. In another embodiment the Delta2-1 differential is less than 10 mm, and in additional embodiments is less than 9.5 mm, 9 mm, 8.5 mm, or 8 mm. While another series of embodiments establishes a floor for this relationship whereby the Delta2-1 differential is at least 5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, or 7.5 mm. Delta2, and the relationships associated therewith, may be used to manipulate impact location with a golf ball. For example, increasing Delta2 produces more toe droop during the golf swing, meaning there is a tendency of the toe to be more downward or closer to the ground at impact with a golf ball, which promotes a higher impact location on the strike face, which promotes an increased launch angle and/or lower spin on the golf ball after impact. However, simply maximizing Delta2 would produce a poor performing club head, as impact efficiency decreases as the impact location gets further from the origin 205. The unique relationships disclosed herein produce a club head that benefits most amateur golfers in ease of use, returning the club face to square at impact, and promoting impacts higher on the strike face, while still improving the performance in terms of resistance to twisting on off-center impacts and face performance via COR, weighted average COR, BP COR, and/or other performance factors disclosed herein.

A Zup-Delta1 ratio is a ratio of the Zup value to the Delta1 value, which in one embodiment is less than 0.815, which is further embodiments is reduced to less than 0.805 or 0.795. Another series of embodiments establishes a floor for this relationship whereby the Zup-Delta1 ratio is at least 0.65, 0.675, 0.7, 0.725, or 0.75. In another embodiment the CGy value is less than 47 mm, and is less than 46.5 mm, 46 mm, or 45.5 mm in additional embodiments. The CGy value is at least 40 mm in a further embodiment, at is at least 41 mm, 42 mm, 43 mm, or 44 mm in further embodiments. Additionally, the Delta1 value is less than 33 mm in an embodiment, and is less than 32.5 mm, 32 mm, or 31.5 mm in further embodiments. In another series of embodiments the Delta1 value is at least 27 mm, 27.5 mm, 28 mm, or 28.5 mm. The delicate balancing of pros and cons associated with mass distribution, construction, and CG placement, is also influenced by the CGz value to achieve a desired z-axis gear effect and launch characteristics, which in some embodiments is less than −3.5 mm, −3.75 mm, −4 mm, −4.25 mm, or −4.5 mm. Another series of embodiments establishes a floor for the CGz value whereby it is no less than −7 mm, −6.5 mm, −6 mm, −5.5 mm, or −5 mm. This is also true for the value of Zup, which is less than 27 mm in an embodiment, and in further embodiments is less than 26.5 mm, 26.25 mm, 26 mm, 25.75 mm, 25.5 mm, or 25.25 mm. In another series of embodiment the Zup value is at least 23 mm, 23.5 mm, 24 mm, or 24.5 mm.

In yet another embodiment the golf club head may include any of the ratios, products, relationships, and/or embodiments found in U.S. patent application Ser. No. 18/595,140, filed Mar. 4, 2024, Ser. No. 18/376,179, filed Oct. 3, 2023, 13/839,727, filed Mar. 15, 2013, and Ser. No. 18/379,512, filed Oct. 12, 2023, which are incorporated by reference herein.

Another important influencer of z-axis gear effect is the curvature of the face. Bulge and roll are golf club face properties that are generally used to compensate for gear effect. The term “bulge” on a golf club head refers to the rounded properties of the golf club face from the heel to the toe of the club face. The term “roll” on a golf club head refers to the rounded properties of the golf club face from the crown to the sole of the club face. The roll radius R refers to the radius of a circle having an arc that corresponds to the arc along the z-axis of the ball striking club face. Curvature is the inverse of radius and is defined as 1/R, where R is the radius of the circle having an arc corresponding to the arc along the z-axis of the ball striking club face. As an example, a roll with a curvature of 0.0050 mm²corresponds to a roll with a radius of 200 mm. The process for measure bulge and roll is disclosed later herein.

The roll of the golf club head can contribute to the amount of backspin that the golf ball acquires when it is struck by the club head at a point on the club face either above or below the projected CG of the club head. For example, shots struck at a point on the club face above the projected CG have less backspin than shots struck at or below the projected CG. If the roll radius of the club head is decreased, there will be a decreased variance between backspin for shots struck above the projected CG of the golf club face and shots struck below the projected CG of the ball striking club face. A Zup-to-Roll ratio is a ratio of the Zup value to the roll, and in an embodiment the Zup-to-Roll ratio is less than 0.13, while in further embodiments it is less than 0.128, 0.126, or 0.124. Another series of embodiments establishes a floor for this relationship whereby the Zup-to-Roll ratio is at least 0.1, 0.125, 0.15, 0.175, 0.12, or 0.122. The bulge also influences the performance and is at least 30% greater than the roll in one embodiment, while further embodiments increase the percentage to at least 35%, 40%, or 45% greater than the roll. In another embodiment the roll is less than 250 mm, while in additional embodiments it is less than 240 mm, 230 mm, 220 mm, or 210 mm. However, another series of embodiments introduces a floor for the roll whereby the roll is at least 180 mm, 185 mm, 190 mm, 195 mm, or 200 mm.

Taking advantage of the roll to influence z-axis gear effect is particularly important in club heads having large club head depths Deh, head heights, Hch, face heights, Hss, moments of inertia, and/or the disclosed relationships. One such embodiment has a roll-to-FH ratio of the roll (mm) to the face height Hss (mm) of less than 4.25, thereby promoting preferred z-axis gear effect, launch conditions, and trajectory. In a further embodiment the roll-to-FH ratio is no more than 4.05, while in an even further embodiment it no more than 3.95. Another series of embodiments discovers that a lower limit of this roll-to-FH ratio promotes preferred z-axis gear effect, launch conditions, and trajectory associated with large club head depths Dch club heads. For instance, in one embodiment the roll-to-FH ratio is at least 3.25, while in another embodiment the roll-to-FH ratio is at least 3.5, and in yet a further embodiment the roll-to-FH ratio is at least 3.75. The roll-to-FH ratio achieves both a visually attractive face when standing over a ball at address, and also yields preferred spin and trajectory.

Often the Delta1 values of the club heads having large club head depths Dch are not ideal. In one present embodiment, preferred z-axis gear effect and trajectory are achieved in a large club head depths Dch club head when the Delta1 value is less than 62% of the face height Hss, while in a further embodiment the Delta1 value is less than 61.5% of the face height Hss, and in yet a further embodiment the Delta1 value is less than 61% of the face height Hss, or even when it is less than 60.5%. In a further series of embodiments preferred performance is achieved when the Delta1 value lies within a tight range of relationships to face height Hss. For instance in one embodiment the Delta1 value is at least 57% of the face height Hss, while in a further embodiment the Delta1 value is at least 58% of the face height Hss, or even at least 59%. Similarly, in another embodiment the Delta2 value is less than 82.5% of the face height Hss, while in further embodiments the percentage is reduced to less than 80.5%, 78.5%, or 77%. Another series of embodiments sets a floor for the relationship whereby the Delta2 value is at least 60% of the face height Hss, which in further embodiments is increased to at least 65% or 70%. In another embodiment the face height Hss is at least 49 mm, which is increased in additional embodiments to at least 50 mm or 51 mm. In another series of embodiments the face height Hss is capped whereby it is no more than 56 mm, 55 mm, 54 mm, or 53 mm.

The method used to obtain the bulge and roll values in the present disclosure is the optical comparator method. The club face includes a series of score lines which traverse the width of the club face generally along the X-axis of the club head. In the optical comparator method, the club head is mounted face down and generally horizontal on a V-block mounted on an optical comparator. The club head is oriented such that the score lines are generally parallel with the X-axis of the optical comparator. Measurements are then taken at the geometric center point on the club face. Further measurements are then taken 20 millimeters away from the geometric center point of the club face on either side of the geometric center point 5a and along the X-axis of the club head, and 30 millimeters away from the geometric center point of the club face on either side of the center point and along the X-axis of the club head. An arc is fit through these five measure points, for example by using the radius function on the machine. This arc corresponds to the circumference of a circle with a given radius. This measurement of radius is what is meant by the bulge radius, or just simply bulge.

To measure the roll, the club head is rotated by 90 degrees such that the Z-axis of the club head is generally parallel to the X-axis of the machine. Measurements are taken at the geometric center point of the club face. Further measurements are then taken 15 millimeters away from the geometric center point and along the Z-axis of the club face on either side of the center point, and 20 millimeters away from the geometric center point and along the Z-axis of the club face on either side of the geometric center point. An arc is fit through these five measurement points. This arc corresponds to the circumference of a circle with a given radius. This measurement of radius is what is meant by the roll radius, or just simply roll. As previously expressed, aerodynamic drag associated with a large club head depth Dch is significant compared to a smaller golf club head, to the point that it not only may reduce the swing speed but also impacts a golfers ability to consistently return the club face to the square position at the time of impact with the golf ball. Therefore, the club head may incorporate any of the aerodynamic features, contours, and elements described in U.S. patent application Ser. No. 18/800,504, filed Aug. 12, 2024, Ser. No. 18/814,646, filed Aug. 26, 2024, Ser. No. 18/911,709, filed Oct. 10, 2024, Ser. No. 18/207,276, filed Jun. 8, 2023, and U.S. patent Ser. No. 10/463,929, issued Nov. 5, 2019, and others disclosed herein, which are incorporated herein by reference. Additionally, as explained in detail in U.S. patent Ser. No. 10/569,144, issued Feb. 25, 2020, which is incorporated herein by reference, preferential aerodynamic shaping of the body, and particularly the crown, tend to result in a high center of gravity, and thus a large Zup dimension. Further, as explained above, traditional large club head depth Dch club heads have produced a moment of inertia about the golf club head CG z-axis, Izz, that is less than ideal. An embodiment of the present invention unexpectedly discovered that a unique relationship of the Zup value relative to ½ of the maximum club head height Hch provides a preferred balance of aerodynamic performance, launch characteristic performance, forgiveness, and feel, provided a sufficient Izz is maintained. One embodiment achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5 mm, while in another embodiment the differential is less than −6 mm, and in still a further embodiment the differential is less than −7 mm. The preferred balance of aerodynamic performance, launch characteristic performance, forgiveness, and feel, are further provided in embodiments with sufficient Izz; for example, one embodiment has an Izz value of at least 550 kg·mm²and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5.0 mm. In a further embodiment the Izz value is at least 575 kg·mm²and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −5.0 mm; while in yet another embodiment the Izz value is at least 585 kg·mm²and achieves a differential between the Zup value and ½ the value of the maximum club head height Hch that is less than −6.0 mm. Another series of embodiments identifies a floor for the differential and a ceiling for the Izz value that lead to desirable improvements and avoid diminishing returns, here the differential between the Zup value and ½ the value of the maximum club head height Hch that is greater than −12.0 mm and the Izz value is no more than 615 kg·mm², while in a further embodiment the differential is greater than −10 mm and the Izz value is no more than 600 kg·mm².

Preferably, the overall frequency of the golf club head, i.e., the average of the first mode frequencies of the crown, sole, and skirt portions of the club head, generated upon impact with a golf ball is greater than 3,000 Hz. Frequencies above 3,000 Hz provide a user of the oversized golf club with an enhanced feel and satisfactory auditory feedback, while in some embodiments frequencies above 3,200 Hz are obtained and preferred. However, a golf club head having relatively thin walls and/or a thin bulbous crown, can reduce the first mode vibration frequencies to undesirable levels. The club head may incorporate a plurality of ribs positioned on an internal surface to achieve the desired frequency, such as, but not limited to, those disclosed in U.S. patent application Ser. No. 18/808,923, filed Aug. 19, 2024, and U.S. Pat. No. 9,358,436, issued Jun. 7, 2016, which are incorporated herein by reference. In still a further embodiment the oversized club head 2 has a surface covering including any of those disclosed in U.S. Pat. No. 9,630,068, issued Apr. 25, 2017, which is incorporated herein by reference.

Achieving a resistance to squaring a large club head depth Dch club head 2 during the golf swing that is comfortable to the novice golfer, and feels like a conventional depth golf club, and avoids a sense of instability during off-center impacts, is important and not easily achieved. This is achieved in part via establishing a proper center of gravity location to result in the desired magnitude of the Delta1 and Delta2 values, CG angle, moments of inertia, and the associated ratios, relationships, and club head mass property characteristics and mass distribution influenced by these variables, but they must take into account the aerodynamic drag associated with large club head depth Dch club heads, large face height Hss and/or widths Wss, and/or large club head heights Hch. The disclosed relationships and ratios accomplish this delicate balance were not found through mere experimentation, as most of the disclosed relationships and ratios are not even considerations in convention club head design, rather they were discovered to be surprisingly important and critical in the design of the disclosed golf club head and yielded unexpected results.

In addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the following features:

- 1. movable weight features including those described in more detail in U.S. Pat. Nos. 6,773,360, 7,166,040, 7,452,285, 7,628,707, 7,186,190, 7,591,738, 7,963,861, 7,621,823, 7,448,963, 7,568,985, 7,578,753, 7,717,804, 7,717,805, 7,530,904, 7,540,811, 7,407,447, 7,632,194, 7,846,041, 7,419,441, 7,713,142, 7,744,484, 7,223,180, 7,410,425 and 7,410,426, the entire contents of each of which are incorporated by reference in their entirety herein;
- 2. slidable weight features including those described in more detail in U.S. Pat. Nos. 7,775,905 and 8,444,505, U.S. patent application Ser. No. 13/898,313 filed on May 20, 2013, U.S. patent application Ser. No. 14/047,880 filed on Oct. 7, 2013, the entire contents of each of which are hereby incorporated by reference herein in their entirety;
- 3. aerodynamic shape features including those described in more detail in U.S. Patent Publication No. 2013/0123040A1, the entire contents of which are incorporated by reference herein in their entirety;
- 4. removable shaft features including those described in more detail in U.S. Pat. No. 8,303,431, the contents of which are incorporated by reference herein in in their entirety;
- 5. adjustable loft/lie features including those described in more detail in U.S. Pat. Nos. 8,025,587, 8,235,831, 8,337,319, U.S. Patent Publication No. 2011/0312437A1, U.S. Patent Publication No. 2012/0258818A1, U.S. Patent Publication No. 2012/0122601A1, U.S. Patent Publication No. 2012/0071264A1, U.S. patent application Ser. No. 13/686,677, the entire contents of which are incorporated by reference herein in their entirety; and
- 6. adjustable sole features including those described in more detail in U.S. Pat. No. 8,337,319, U.S. Patent Publication Nos. US2011/0152000A1, US2011/0312437, US2012/0122601A1, and U.S. patent application Ser. No. 13/686,677, the entire contents of each of which are incorporated by reference herein in their entirety.

The technology described herein may also be combined with other features and technologies for golf clubs, such as:

- 1. variable thickness face features described in more detail in U.S. patent application Ser. No. 12/006,060, U.S. Pat. Nos. 6,997,820, 6,800,038, and 6,824,475, which are incorporated herein by reference in their entirety;
- 2. composite face plate features described in more detail in U.S. patent application Ser. Nos. 11/998,435, 11/642,310, 11/825,138, 11/823,638, 12/004,386, 12/004,387, 11/960,609, 11/960,610 and U.S. Pat. No. 7,267,620, which are herein incorporated by reference in their entirety.

Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. No. 17/560,054, filed Dec. 22, 2021, 17/505511, filed Oct. 19, 2021, 17/389167, filed Jul. 19, 2021, 17/321315, filed May 14, 2021, 18/179848, filed Mar. 7, 2023, 17/124134, filed Dec. 16, 2020, 17/137151, filed Dec. 29, 2020, 17/691649, filed Mar. 10, 2022, 18/510476, filed Nov. 15, 2023, 17/228511, filed Apr. 12, 2021, 17/224026, filed Apr. 6, 2021, 17/564077, filed Dec. 28, 2021, 63/292,708, filed Dec. 22, 2021, 63/478,107, filed Dec. 30, 2022, 63/433,380, filed Dec. 16, 2022, 14/694998, filed Apr. 23, 2015, 18/068347, filed Dec. 19, 2022, 17/547519, filed Dec. 10, 2021, 17/360179, filed Jun. 28, 2021, 17/531979, filed Nov. 22, 2021, 17/722748, filed Apr. 18, 2022, 17/006561, filed Aug. 28, 2020, 16/806254, filed Mar. 2, 2020, 17/696664, filed Mar. 16, 2022, 17/565580, filed Dec. 30, 2021, 17/727963, filed Apr. 25, 2022, 16/288499, filed Feb. 28, 2019, 17/530331, filed Nov. 18, 2021, 17/586960, filed Jan. 28, 2022, 17/884027, filed Aug. 9, 2022, 13/842011, filed Mar. 15, 2013, 16/817311, filed Mar. 12, 2020, 17/355642, filed Jun. 23, 2021, 17/132645, filed Dec. 23, 2020, 17/390615, filed Jul. 30, 2021, 17/164033, filed Feb. 1, 2021, 17/107474, filed Nov. 30, 2020, 17/526981, filed Nov. 15, 2021, 16/352537, filed Mar. 13, 2019, 17/156205, filed Jan. 22, 2021, 17/132541, filed Dec. 23, 2020, 17/824727, filed May 25, 2022, 17/722632, filed Apr. 18, 2022, 17/712041, filed Apr. 1, 2022, 17/695194, filed Mar. 15, 2022, 17/686181, filed Mar. 3, 2022, 63/305,777, filed Feb. 2, 2022, 17/577943, filed Jan. 18, 2022, 17/570613, filed Jan. 7, 2022, 17/569810, filed Jan. 6, 2022, 17/566833, filed Dec. 31, 2021, 17/566131, filed Dec. 30, 2021, 17/566263, filed Dec. 30, 2021, 17/557759, filed Dec. 21, 2021, 17/558387, filed Dec. 21, 2021, 17/645033, filed Dec. 17, 2021, 17/541107, filed Dec. 2, 2021, 17/526855, filed Nov. 15, 2021, 17/524056, filed Nov. 11, 2021, 17/522560, filed Nov. 9, 2021, 17/515112, filed Oct. 29, 2021, 17/513716, filed Oct. 28, 2021, 17/504335, filed Oct. 18, 2021, 17/504327, filed Oct. 18, 2021, 17/494416, filed Oct. 5, 2021, 17/493604, filed Oct. 4, 2021, 63/261,457, filed Sep. 21, 2021, 17/479785, filed Sep. 20, 2021, 17/476839, filed Sep. 16, 2021, 17/477258, filed Sep. 16, 2021, 17/476025, filed Sep. 15, 2021, 17/467709, filed Sep. 7, 2021, 17/403516, filed Aug. 16,2021, 17/399823, filed Aug. 11, 2021, 63/227,889, filed Jul. 30, 2021, 17/387181, filed Jul. 28, 2021, 17/378407, filed Jul. 16, 2021, 17/368520, filed Jul. 6, 2021, 17/330033, filed May 25, 2021, 17/235533, filed Apr. 20, 2021, 17/233201, filed Apr. 16, 2021, 17/216185, filed Mar. 29, 2021, 17/198030, filed Mar. 10, 2021, 17/191617, filed Mar. 3, 2021, 17/190864, filed Mar. 3, 2021, 17/183905, filed Feb. 24, 2021, 17/183057, filed Feb. 23, 2021, 17/181923, filed Feb. 22, 2021, 17/171678, filed Feb. 9, 2021, 17/171656, filed Feb. 9, 2021, 17/107447, filed Nov. 30, 2020, and 63/338,818, filed May 5, 2022, all of which are herein incorporated by reference in their entirety. Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. Patent Numbers 9610479, issued Apr. 4, 2017, U.S. Pat. No. 11,213,726, issued Jan. 4, 2022, U.S. Pat. No. 8,777,776, issued Jul. 15, 2014, U.S. Pat. No. 7,278,928, issued Oct. 9, 2007, U.S. Pat. No. 7,445,561, issued Nov. 4, 2008, U.S. Pat. No. 9,409,066, issued Aug. 9, 2016, U.S. Pat. No. 8,303,435, issued Nov. 6, 2012, U.S. Pat. No. 7,874,937, issued Jan. 25, 2011, U.S. Pat. No. 8,628,434, issued Jan. 14, 2014, U.S. Pat. No. 8,608,591, issued Dec. 17, 2013, U.S. Pat. No. 8,740,719, issued Jun. 3, 2014, U.S. Pat. No. 9,694,253, issued Jul. 4, 2017, U.S. Pat. No. 9,683,301, issued Jun. 20, 2017, U.S. Pat. No. 9,468,816, issued Oct. 18, 2016, U.S. Pat. No. 8,262,509, issued Sep. 11, 2012, U.S. Pat. No. 7,901,299, issued Mar. 8, 2011, U.S. Pat. No. 8,119,714, issued Feb. 21, 2012, U.S. Pat. No. 8,764,586, issued Jul. 1, 2014, U.S. Pat. No. 8,227,545, issued Jul. 24, 2012, U.S. Pat. No. 8,066,581, issued Nov. 29, 2011, 10052530, issued Aug. 21, 2018, 10195497, issued Feb. 5, 2019, 10086240, issued Oct. 2, 2018, U.S. Pat. No. 9,914,027, issued Mar. 13, 2018, U.S. Pat. No. 9,174,099, issued Nov. 3, 2015, and U.S. Pat. No. 11,219,803, issued Jan. 11, 2022, all of which are herein incorporated by reference in their entirety.

The above-described embodiments are just examples of possible implementations of the disclosed technologies, and are set forth for a clear understanding of the principles of the present disclosure. Any process descriptions or blocks in flow diagrams should be understood as representing modules, segments, or portions of processes for implementing specific functions or steps in the process, and alternate implementations are included in which functions may not be included or executed at all, may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present disclosure.

Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure includes any and all combinations and sub-combinations of all elements, features, and aspects disclosed herein and in the documents that are incorporated by reference. All such combinations, modifications, and variations are included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

Any embodiments of the club head may include an electronic display, as disclosed in U.S. Ser. No. 17/878,734, filed Aug. 1, 2022, U.S. application Ser. No. 16/352,537, filed Mar. 13, 2019, and U.S. application Ser. No. 17/695,194, filed Mar. 15, 2022, which are all incorporated by reference herein in their entirety. In one such embodiment an electronic display is located on the frame top 10300 and at least partially on the thin wall crown region 10600. In addition to the various features described herein, any of the features of the golf club heads disclosed herein may also incorporate additional features, which can include any of the following features found in the following, which are all incorporated by reference herein in their entirety: U.S. Pat. Nos. 11,179,608; 10,874,928; 10,391,369; 10,052,530; 9,827,479; 9,522,313; 9,468,817; 9,375,619; 9,220,960; 8,328,654; 8,066,581; 7,648,425; 7,594,865; 7,465,240; 7,438,648; 7,396,295; 7,278,926; 6,929,564; U.S. Ser. No. 18/534,512, filed Dec. 8, 2023; U.S. Ser. No. 17/878,734, filed Aug. 1, 2022; U.S. Ser. No. 17/645,033, filed Dec. 17, 2021; U.S. Ser. No. 17/974,279, filed Oct. 26, 2022; U.S. Ser. No. 17/566,263, filed Mar. 16, 2022; U.S. Ser. No. 18/068,347, filed Dec. 19, 2022; U.S. Ser. No. 17/722,632, filed Apr. 18, 2022; U.S. Ser. No. 17/691,649, filed Mar. 10, 2022; U.S. Ser. No. 17/577,943, filed Jan. 18, 2022; U.S. Ser. No. 17/107,490, filed Nov. 30, 2020; U.S. Ser. No. 17/505,511, filed Oct. 19, 2021; U.S. Ser. No. 17/736,766, filed May 4, 2022; U.S. Ser. No. 17/963,491, filed Oct. 11, 2022; U.S. Pat. No. 9,468,817, issued Oct. 18, 2016; U.S. Pat. No. 9,375,619, issued Jun. 28, 2016; U.S. Pat. No. 9,522,313, issued Dec. 20, 2016; U.S. Pat. No. 8,758,155, issued Jun. 24, 2014; U.S. Pat. No. 9,375,619, issued Jun. 28, 2016; U.S. Pat. No. 9,220,960, issued Dec. 29, 2015; U.S. Pat. No. 7,465,240, issued Dec. 16,2008; U.S. Provisional Patent Application No. 63/436,330, filed Dec. 30, 2022; U.S. Provisional Patent Application No. 63/433,380, filed Dec. 27, 2022; U.S. Pat. No. D925,677, issued Jul. 20, 2021; U.S. Patent No. D924,991, issued Jul. 13, 2021; and U.S. Patent No. D924992, issued Jul. 13, 2021.

In addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the following features:

- movable weight features including those described in more detail in U.S. Pat. Nos. 6,773,360, 7,166,040, 7,452,285, 7,628,707, 7,186,190, 7,591,738, 7,963,861, 7,621,823, 7,448,963, 7,568,985, 7,578,753, 7,717,804, 7,717,805, 7,530,904, 7,540,811, 7,407,447, 7,632,194, 7,846,041, 7,419,441, 7,713,142, 7,744,484, 7,223,180, 7,410,425 and 7,410,426, the entire contents of each of which are incorporated by reference in their entirety herein;
- slidable weight features including those described in more detail in U.S. Pat. Nos. 7,775,905 and 8,444,505, U.S. patent application Ser. No. 13/898,313 filed on May 20, 2013, U.S. patent application Ser. No. 14/047,880 filed on Oct. 7, 2013, the entire contents of each of which are hereby incorporated by reference herein in their entirety;
- aerodynamic shape features including those described in more detail in U.S. Patent Publication No. 2013/0123040A1, the entire contents of which are incorporated by reference herein in their entirety;
- removable shaft features including those described in more detail in U.S. Pat. No. 8,303,431, the contents of which are incorporated by reference herein in in their entirety;
- adjustable loft/lie features including those described in more detail in U.S. Pat. Nos. 8,025,587, 8,235,831, 8,337,319, U.S. Patent Publication No. 2011/0312437A1, U.S. Patent Publication No. 2012/0258818A1, U.S. Patent Publication No. 2012/0122601A1, U.S. Patent Publication No. 2012/0071264A1, U.S. patent application Ser. No. 13/686,677, the entire contents of which are incorporated by reference herein in their entirety; and
- adjustable sole features including those described in more detail in U.S. Pat. No. 8,337,319, U. S. Patent Publication Nos. US2011/0152000A1, US2011/0312437, US2012/0122601A1, and U.S. patent application Ser. No. 13/686,677, the entire contents of each of which are incorporated by reference herein in their entirety.

The technology described herein may also be combined with other features and technologies for golf clubs, such as:

- variable thickness face features described in more detail in U.S. patent application Ser. No. 12/006,060, U.S. Pat. Nos. 6,997,820, 6,800,038, and 6,824,475, which are incorporated herein by reference in their entirety;
- composite face plate features described in more detail in U.S. patent application Ser. Nos. 11/998,435, 11/642,310, 11/825,138, 11/823,638, 12/004,386, 12/004,387, 11/960,609, 11/960,610 and U.S. Pat. No. 7,267,620, which are herein incorporated by reference in their entirety.

Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. No. 18/827,140, filed on Sep. 6, 2024, Ser. No. 18/888,500, filed on Sep. 18, 2024, Ser. No. 17/124,134, filed Dec. 16, 2020, 17/560054, filed Dec. 22, 2021, 17/505511, filed Oct. 19, 2021, 17/389167, filed Jul. 19, 2021, 17/321315, filed May 14, 2021, 18/179848, filed Mar. 7, 2023, 17/124134, filed Dec. 16, 2020, 17/137151, filed Dec. 29, 2020, 17/691649, filed Mar. 10, 2022, 18/510476, filed Nov. 15, 2023, 17/228511, filed Apr. 12, 2021, 17/224026, filed Apr. 6, 2021, 17/564077, filed Dec. 28, 2021, 63/292,708, filed Dec. 22, 2021, 63/478,107, filed Dec. 30, 2022, 63/433,380, filed Dec. 16, 2022, 14/694998, filed Apr. 23, 2015, 18/068347, filed Dec. 19, 2022, 17/547519, filed Dec. 10, 2021, 17/360179, filed Jun. 28, 2021, 17/531979, filed Nov. 22, 2021, 17/722748, filed Apr. 18, 2022, 17/006561, filed Aug. 28, 2020, 16/806254, filed Mar. 2, 2020, 17/696664, filed Mar. 16, 2022, 17/565580, filed Dec. 30, 2021, 17/727963, filed Apr. 25, 2022, 16/288499, filed Feb. 28, 2019, 17/530331, filed Nov. 18, 2021, 17/586960, filed Jan. 28, 2022, 17/884027, filed Aug. 9, 2022, 13/842011, filed Mar. 15, 2013, 16/817311, filed Mar. 12, 2020, 17/355642, filed Jun. 23, 2021, 17/132645, filed Dec. 23, 2020, 17/390615, filed Jul. 30, 2021, 17/164033, filed Feb. 1, 2021, 17/107474, filed Nov. 30, 2020, 17/526981, filed Nov. 15, 2021, 16/352537, filed Mar. 13, 2019, 17/156205, filed Jan. 22, 2021, 17/132541, filed Dec. 23, 2020, 17/824727, filed May 25, 2022, 17/722632, filed Apr. 18, 2022, 17/712041, filed Apr. 1, 2022, 17/695194, filed Mar. 15, 2022, 17/686181, filed Mar. 3, 2022, 63/305,777, filed Feb. 2, 2022, 17/577943, filed Jan. 18, 2022, 17/570613, filed Jan. 7, 2022, 17/569810, filed Jan. 6, 2022, 17/566833, filed Dec. 31, 2021, 17/566131, filed Dec. 30, 2021, 17/566263, filed Dec. 30, 2021, 17/557759, filed Dec. 21, 2021, 17/558387, filed Dec. 21, 2021, 17/645033, filed Dec. 17, 2021, 17/541107, filed Dec. 2, 2021, 17/526855, filed Nov. 15, 2021, 17/524056, filed Nov. 11, 2021, 17/522560, filed Nov. 9, 2021, 17/515112, filed Oct. 29, 2021, 17/513716, filed Oct. 28, 2021, 17/504335, filed Oct. 18, 2021, 17/504327, filed Oct. 18, 2021, 17/494416, filed Oct. 5, 2021, 17/493604, filed Oct. 4, 2021, 63/261,457, filed Sep. 21, 2021, 17/479785, filed Sep. 20, 2021, 17/476839, filed Sep. 16, 2021, 17/477258, filed Sep. 16, 2021, 17/476025, filed Sep. 15, 2021, 17/467709, filed Sep. 7, 2021, 17/403516, filed Aug. 16,2021, 17/399823, filed Aug. 11, 2021, 63/227,889, filed Jul. 30, 2021, 17/387181, filed Jul. 28, 2021, 17/378407, filed Jul. 16, 2021, 17/368520, filed Jul. 6, 2021, 17/330033, filed May 25, 2021, 17/235533, filed Apr. 20, 2021, 17/233201, filed Apr. 16, 2021, 17/216185, filed Mar. 29, 2021, 17/198030, filed Mar. 10, 2021, 17/191617, filed Mar. 3, 2021, 17/190864, filed Mar. 3, 2021, 17/183905, filed Feb. 24, 2021, 17/183057, filed Feb. 23, 2021, 17/181923, filed Feb. 22, 2021, 17/171678, filed Feb. 9, 2021, 17/171656, filed Feb. 9, 2021, 17/107447, filed Nov. 30, 2020, and 63/338,818, filed May 5, 2022, all of which are herein incorporated by reference in their entirety. Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. PatentNumbers 9610479, issued Apr. 4, 2017, U.S. Pat. No. 11,213,726, issued Jan. 4, 2022, U.S. Pat. No. 8,777,776, issued Jul. 15, 2014, U.S. Pat. No. 7,278,928, issued Oct. 9, 2007, U.S. Pat. No. 7,445,561, issued Nov. 4, 2008, U.S. Pat. No. 9,409,066, issued Aug. 9, 2016, U.S. Pat. No. 8,303,435, issued Nov. 6, 2012, U.S. Pat. No. 7,874,937, issued Jan. 25, 2011, U.S. Pat. No. 8,628,434, issued Jan. 14, 2014, U.S. Pat. No. 8,608,591, issued Dec. 17, 2013, U.S. Pat. No. 8,740,719, issued Jun. 3, 2014, U.S. Pat. No. 9,694,253, issued Jul. 4, 2017, U.S. Pat. No. 9,683,301, issued Jun. 20, 2017, U.S. Pat. No. 9,468,816, issued Oct. 18, 2016, U.S. Pat. No. 8,262,509, issued Sep. 11, 2012, U.S. Pat. No. 7,901,299, issued Mar. 8, 2011, U.S. Pat. No. 8,119,714, issued Feb. 21, 2012, U.S. Pat. No. 8,764,586, issued Jul. 1, 2014, U.S. Pat. No. 8,227,545, issued Jul. 24, 2012, U.S. Pat. No. 8,066,581, issued Nov. 29, 2011, 10052530, issued Aug. 21, 2018, 10195497, issued Feb. 5, 2019, 10086240, issued Oct. 2, 2018, U.S. Pat. No. 9,914,027, issued Mar. 13, 2018, U.S. Pat. No. 9,174,099, issued Nov. 3, 2015, and U.S. Pat. No. 11,219,803, issued Jan. 11, 2022, all of which are herein incorporated by reference in their entirety.

Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. patent application Ser. No. 18/807,487, filed Aug. 16, 2024, 18/102001, filed Jan. 26, 2023, 18/077794, filed Dec. 8, 2022, 17/963491, filed Oct. 11, 2022, 18/397351, filed Dec. 27, 2023, 18/898332, filed Sep. 26, 2024, 18/540571, filed Dec. 14, 2023, 18/662372, filed May 13, 2024, 18/468273, filed Sep. 15, 2023, 18/743971, filed Jun. 14, 2024, 18/657023, filed May 7, 2024, 18/595140, filed Mar. 4, 2024, 18/355384, filed Jul. 19, 2023, 18/791808, filed Aug. 1, 2024, 18/764001, filed Jul. 3, 2024, 18/939302, filed Nov. 6, 2024, 17/164033, filed Feb. 1, 2021, 18/830380, filed Sep. 10, 2024, 18/892181, filed Sep. 20, 2024, 17/100273, filed Nov. 20, 2020, 18/197594, filed May 15, 2023, 18/604909, filed Mar. 14, 2024, 18/212861, filed Jun. 22, 2023, 18/436878, filed Feb. 8, 2024, 18/534985, filed Dec. 11, 2023, 17/974279, filed Oct. 26, 2022, 17/504327, filed Oct. 18, 2021, 18/822842, filed Sep. 3, 2024, 18/761819, filed Jul. 2, 2024, 17/010395, filed Sep. 2, 2020, 17/878661, filed Aug. 1, 2022, 18/478155, filed Sep. 29, 2023, 18/436841, filed Feb. 8, 2024, 18/504887, filed Nov. 8, 2023, 17/515112, filed Oct. 29, 2021, 18/913535, filed Oct. 11, 2024, 18/124325, filed Mar. 21, 2023, 17/570613, filed Jan. 7, 2022, 18/612969, filed Mar. 21, 2024, 18/468304, filed Sep. 15, 2023, 18/376179, filed Oct. 3, 2023, 18/531430, filed Dec. 6, 2023, 2024-154117, filed Sep. 6, 2024, JP2020100117A, filed Jun. 9, 2020, 17/107447, filed Nov. 30, 2020, 18/815207, filed Aug. 26, 2024, 18/792777, filed Aug. 2, 2024, 18/807320, filed Aug. 16, 2024, 18/784461, filed Jul. 25, 2024, 17/526855, filed Nov. 15, 2021, 18/379512, filed Oct. 12, 2023, 17/105109, filed Nov. 25, 2020, 18/110636, filed Feb. 16, 2023, 18/502408, filed Nov. 6, 2023, 18/211751, filed Jun. 20, 2023, 18/135502, filed Apr. 17, 2023, 18/135463, filed Apr. 17, 2023, 18/808923, filed Aug. 19, 2024, 18/825926, filed Sep. 5, 2024, 18/370314, filed Sep. 19, 2023, 18/332099, filed Jun. 9, 2023, 17/975150, filed Oct. 27, 2022, 18/653254, filed May 2, 2024, 18/515737, filed Nov. 21, 2023, 18/936651, filed Nov. 4, 2024, 18/889078, filed Sep. 18, 2024, Ser. No. 18/943,215, filed Nov. 11, 2024, Ser. No. 18/911,709, filed Oct. 10, 2024, Ser. No. 18/888,500, filed Sep. 18, 2024, Ser. No. 18/827,140, filed Sep. 6, 2024, Ser. No. 18/817,539, filed Aug. 28, 2024, Ser. No. 18/814,646, filed Aug. 26, 2024, Ser. No. 18/808,224, filed Aug. 19, 2024, Ser. No. 18/800,504, filed Aug. 12, 2024, Ser. No. 18/796,753, filed Aug. 7, 2024, Ser. No. 18/777,649, filed Jul. 19, 2024, Ser. No. 18/736,758, filed Jun. 7, 2024, Ser. No. 18/736,646, filed Jun. 7, 2024, Ser. No. 18/647,379, filed Apr. 26, 2024, Ser. No. 18/544,301, filed Dec. 18, 2023, Ser. No. 18/534,512, filed Dec. 8, 2023, Ser. No. 18/519,327, filed Nov. 27, 2023, Ser. No. 18/518,013, filed Nov. 22, 2023, Ser. No. 18/444,811, filed Feb. 19, 2024, Ser. No. 18/414,128, filed Jan. 16, 2024, Ser. No. 18/406,312, filed Jan. 8, 2024, Ser. No. 18/375,888, filed Oct. 2, 2023, Ser. No. 18/226,294, filed Jul. 26, 2023, Ser. No. 18/207,276, filed Jun. 8, 2023, Ser. No. 18/082,735, filed Dec. 16, 2022, Ser. No. 18/082,271, filed Dec. 15, 2022, Ser. No. 17/734,185, filed May 2, 2022, Ser. No. 17/668,902, filed Feb. 10, 2022, and Ser. No. 17/068,355, filed Oct. 12, 2020, all of which are herein incorporated by reference in their entirety.

Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. Patent Application Ser. Nos. 63/433,380, 18/082,735, Ser. Nos. 18/082,271, 63/292,708, 17/547519, 17/360179, 17/560054, 17/124134, 17531979, 17/722748, 17/505511, 17/560054, 17/389167, 17/006561, 17/137151, 16/806254, 17/321315, 17/696664, 17/565580, 17/727963, 16/288499, 17/530331, 17/586960, 17/884027, 13/842011, 16/817311, 17/355642, 17/722748, 17/132645, 17/696664, 17/884027, 17/390615, 17/586960, 17/691649, 17/224026, 17/560054, 17/164033, 17/107474, 17/526981, 16/352537, 17/156205, 17/132541, 17/565580, 17/360179, 17/355642, 17/727963, 17/824727, 17/722632, 17/712041, 17/696664, 17/695194, 17/691649, 17/686181, 63/305777, 17/577943, 17/570613, 17/569810, 17/566833, 17/565580, 17/566131, 17/566263, 17/564077, 17/560054, 63/292708, 17/557759, 17/558387, 17/645033, 17/547519, 17/541107, 17/530331, 17/526981, 17/526855, 17/524056, 17/522560, 17/515112, 17/513716, 17/505511, 17/504335, 17/504327, 17/494416, 17/493604, 63/261457, 17/479785, 17/476839, 17/477258, 17/476025, 17/467709, 17/403516, 17/399823, 17/390615, 63/227889, 17/389167, 17/387181, 17/378407, 17/368520, 17/360179, 17/355642, 17/330033, 17/235533, 17/233201, 17/228511, 17/224026, 17/216185, 17/198030, 17/191617, 17/190864, 17/183905, 17/183057, 17/181923, 17/171678, 17/171656, 17/164033, 17/156205, 17/564077, 17/124134, 17/107447, 63/292708, 63/305777, and 63/338,818, all of which are herein incorporated by reference in their entirety. Additionally, in addition to the various features described herein, any of the golf club heads disclosed herein may also incorporate additional features, which can include any of the features disclosed in U.S. Pat. Nos. 11,213,726, 8,777,776, 7,278,928, 7,445,561, 9,409,066, 8,303,435, 7,874,937, 8,628,434, 8,608,591, 8,740,719, 8,777,776, 9,694,253, 9,683,301, 9,468,816, 8,777,776, 8,262,509, 7,901,299, 8,119,714, 8,764,586, 8,227,545, 8,066,581, 9,409,066, 10,052,530, 10,195,497, 10,086,240, 9,914,027, 9,174,099, and 11,219,803, all of which are herein incorporated by reference in their entirety.

Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more embodiments.

In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.” The term “about” in some embodiments, can be defined to mean within +/−5% of a given value, however in additional embodiments any disclosure of “about” may be further narrowed and claimed to mean within +/−4% of a given value, within +/−3% of a given value, within +/−2% of a given value, within +/−1% of a given value, or the exact given value. Further, when at least two values of a variable are disclosed, such disclosure is specifically intended to include the range between the two values regardless of whether they are disclosed with respect to separate embodiments or examples, and specifically intended to include the range of at least the smaller of the two values and/or no more than the larger of the two values. Additionally, when at least three values of a variable are disclosed, such disclosure is specifically intended to include the range between any two of the values regardless of whether they are disclosed with respect to separate embodiments or examples, and specifically intended to include the range of at least the A value and/or no more than the B value, where A may be any of the disclosed values other than the largest disclosed value, and B may be any of the disclosed values other than the smallest disclosed value. Any tables and/or examples and/or embodiments disclosed herein that give exact values, are to be interpreted as also disclosing an embodiment where each of the values is ±10% of the value indicated, and in further embodiments each of the values is ±7.5%, 5%, ±2.5%, or ±0%, thereby disclosing distinct upper values for each, distinct lower values for each, as well as closed ranges having upper and lower limiting values. Throughout the disclosure embodiments are described often with one embodiment setting a minimum value for variable or relationship, followed by an embodiment setting a maximum value for a variable or relationship. For example, in one sentence the disclosure states: “in another embodiment the frame mass is at least 250 grams, while in further embodiments is at least 260, 270, 280, 290, 300, or 310 grams.” In another sentence the disclosure states: “The frame mass is no more than 370 grams in an embodiment, and is no more than 360, 350, 340, 330, or 320 grams in additional embodiments.” In any such disclosure, any integer value meeting these limitations is enabled and may be claimed, such as ≥255, ≥265, ≥275, ≥285, ≥295, ≥305, etc., and likewise for the disclosed upper end boundary values, and likewise for any disclosed variable. Further, any discreet value within the disclosed ranges is fully enabled and may be claimed either as a value or as a boundary to a range, which applies to all the disclosure herein. Further, any discreet value within the disclosed ranges is fully enabled and may be claimed either as a value or as a boundary to a range. These principles apply to each variable and/or relationship disclosed, and the contents of each table. Additionally, examples in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.

As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.

The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

	Number	Date	Country
Parent	18323935	May 2023	US
Child	19007332		US

MULTI-PIECE GOLF CLUB HEAD

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