Golf Club Head with Impact Response Modulator

This claims the benefit of U.S. Provisional Application No. 63/569,638, filed on Mar. 25, 2024, U.S. Provisional Application No. 63/648,946, filed on May 17, 2024, U.S. Provisional Application No. 63/654,776, filed on May 31, 2024, U.S. Provisional Application No. 63/664,628, filed on Jun. 26, 2024, U.S. Provisional Application No. 63/699,398, filed on Sep. 26, 2024, and U.S. Provisional Application No. 63/769,579, filed on Mar. 10, 2025, the contents of which are fully incorporated herein.

This invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.

The strike face of a golf club head deflects upon impact with a golf ball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. Increased strike face deflection increases energy transfer between the club head and the golf ball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted on the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air and increases carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and/or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. Consequently, there is a need in the art for a golf club head having increased strike face deflection without compromising club head durability.

Described herein are various embodiments of wood-type golf club heads (i.e. drivers, fairway woods, or hybrids) comprising an impact response modulator (hereafter “IRM”) in the sole. The IRM strategically weakens the sole to increase strike face deflection, thereby improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material. The casing includes various stress reducing geometries and/or selected regions of high-strength material to increase strike face deflection while maintaining sufficient club head durability.

In some embodiments, a high-strength material component, such as a faceplate, a cartridge, or an appendage, can form and reinforce one or more portions of the casing, thereby increasing strike face deflection without compromising durability. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Selectively using high-strength material reduces stress in the casing walls. Accordingly, the casing walls can have a reduced thickness and/or be placed closer to the strike face without exceeding the yield strength of the high-strength material, thereby increasing strike face deflection.

In some embodiments, the club head comprises a body and a faceplate coupled together, wherein the faceplate forms at least a portion of the casing. The body comprises a body material that is easily castable to form various complex club head geometries. The faceplate comprises a high-strength faceplate material with a yield strength greater than 175 ksi (i.e., C300 steel, C350 steel, Ti-9s, Ti-9s+, etc.) The faceplate material is more durable than the body material and is suitable to withstand direct impact with a golf ball. In some embodiments, the faceplate comprises a sole return that forms one or more portions of the casing. In some embodiments, the body and the faceplate combine to form the casing, whereby the body and the faceplate each form at least a portion of the casing.

In some embodiments, the club head comprises a separately formed, high-strength material member that forms one or more portions of the casing, referred to herein as a “cartridge,” The cartridge is located on the sole of the club head and integrally forms at least portions of the casing front wall and the casing rear wall. The cartridge can be coupled to both the faceplate and the body, or can be coupled to and entirely surrounded by the body. Similar to the faceplate, the cartridge can comprise a high-strength cartridge material (with a yield strength greater than 225 ksi) that is more durable than the body material.

In other embodiments, the club head can comprise a separately formed high-strength component that forms a portion of the casing front wall, but not a portion of the casing rear wall, referred to herein as an “appendage.” The appendage is located on the sole of the club head and is coupled to both the faceplate and the body. In such embodiments, the body and the appendage combine to form the casing, whereby the body and the appendage each form at least a portion of the casing. Similar to both the faceplate and the cartridge, the appendage can comprise a high-strength appendage material (with a yield strength greater than 225 ksi) that is more durable than the body material.

The IRM selectively uses high-strength material to increase strike face deflection while maintaining durability. For example, one or both of the casing front wall and the casing rear wall can be integrally formed by high-strength material (i.e., the faceplate material, the cartridge material, or the appendage material). In some embodiments, a portion of the front wall front surface, front wall rear surface, front wall base, and/or front wall top surface can be integrally formed by a high-strength component. Similarly, in some embodiments, a portion of the rear wall front surface, rear wall rear surface, rear wall base, and/or rear wall top surface can be integrally formed by a high-strength component. Forming portions of the casing with high-strength material, whether via the faceplate, a cartridge, or an appendage, increases strike face deflection without compromising durability.

The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

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

The strike faceis bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club headdeviates from a bulge curvature and/or roll curvature of the strike face(defined below). The strike face perimeter includes at least a leading edgethat defines a transition from the strike faceto the sole. The strike facedefines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in. The face center (FC) can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA).

The strike facecomprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike facein the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and/or the roll curvature can comprise one or more radii.

The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golf ball.

The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head.

The term “cartridge” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall and at least a portion of the casing rear wall.

The term “appendage” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall but does not form a portion of the casing rear wall.

“Driver golf club heads” as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the volume of the driver can be approximately 400 cc-600 cc, 425 cc-500 cc, approximately 500 cc-600 cc, approximately 500 cc-650 cc, approximately 550 cc-700 cc, approximately 600 cc-650 cc, approximately 600 cc-700 cc, or approximately 600 cc-800 cc.

“Fairway wood golf club heads” as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

Further, “fairway wood golf club heads” as used herein comprises a volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the volume of the fairway wood can be approximately 150 cc-200 cc, approximately 150 cc-250 cc, approximately 150 cc-300 cc, approximately 150 cc-350 cc, approximately 150 cc-400 cc, approximately 300 cc-400 cc, approximately 325 cc-400 cc, approximately 350 cc-400 cc, approximately 250 cc-400 cc, approximately 250-350 cc, or approximately 275-375 cc.

“Hybrid golf club heads” as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

Further, “hybrid golf club heads” as used herein comprise a volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the volume of the hybrid can be approximately 100 cc-150 cc, approximately 75 cc-150 cc, approximately 100 cc-125 cc, or approximately 75 cc-125 cc.

Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Various embodiments of a golf club are illustrated in the figures. A golf club is generally understood to comprise a club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

Referring to, the club headdefines a crown, a soleopposite the crown, a heel, a toe, a front, a rearand a strike face. The club headfurther comprises a hosel, which is configured to receive the shaft. In some embodiments, as illustrated in the embodiment of, the club headcomprises a bodyand a faceplatecoupled together to form an interior cavity. The bodyforms at least a portion of the crown, at least a portion of the sole, at least a portion of the heel, and at least a portion of the toe. The faceplateforms at least a portion of the strike face. Specific configurations of the bodyand the faceplateare described in further detail below.

The features discussed below are demonstrated on club head. While different embodiments may comprise different numbering schemes (i.e., 1xx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club headcomprises a crownand a sole, whereas club headcomprises a crownand a sole). Any one or more of the features below can be used in combination with one another.

The bodycomprises a body material that provides sufficient structural strength and is easy formed into complex geometries. In many embodiments, the body material is a metallic material that is easily castable. In some embodiments, the body material can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the body material can comprise a Ti-8Al-1Mo-1V alloy, or a 17-4 stainless steel. In some embodiments, the body material can be formed from Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6Al-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3A1-2.5V, Ti-6Al-1Zr-1Nb-1Mo (Ti-6-1-1-1), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals. In some embodiments, the bodycomprises a multi-material construction including one or more lightweight materials, such as a lightweight composite material. Generally, the body material can comprise a yield strength between 145 and 165 ksi.

The faceplatecomprises a faceplate material having sufficient strength to withstand repeated impacts with a golf ball. As such, the faceplate material comprises a greater yield strength than the body material and is thus more durable. In some embodiments, the faceplate material can be a high-strength steel alloy, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

In other embodiments, the faceplate material can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6Al-4V (Ti-6-4), Ti-3A1-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3A1 (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9A1-2V (Ti-92), Ti-8Al-1Mo-1V (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-1Cr-1Fe (Ti-55511), Ti-13V-11Cr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si—0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).

The faceplate material comprises a high yield strength. In some embodiments, the faceplate material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club headcomprises a faceplate strength ratio comparing the yield strength of the faceplate material to the yield strength of the body material. In some embodiments, the faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.

The club head bodyand the faceplatecan be formed through one or a combination of manufacturing processes, such as casting, forging, metal injection molding, metal 3D printing, stamping, or any other well-known manufacturing processes. In some embodiments, the club head bodyis cast, whereas the faceplateis forged.

The golf club headcomprises an Impact Response Modulator(hereafter “IRM”) reinforced by high-strength material that increases strike face deflection at impact with a golf ball while maintaining sufficient durability. Referring to, the IRMis disposed in the sole. The IRMstrategically weakens the soleto increase strike face deflection. The IRMcomprises a casingsurrounding an aperturethat is configured to receive an insert. As illustrated in, the IRMextends in a substantially heel-to-toe direction across the soleto increase strike face deflection.

The casingis the structure that surrounds and forms the aperture. One or more portions of the casingcan be formed by a high-strength material component, such as a cartridge or an appendage. As illustrated in, the casingcomprises a front wallproximate the strike face, a rear wallspaced rearward from the front wall, a heel wallproximate the heel, and a toe wallproximate the toe. The front wall, the rear wall, the heel wall, and the toe wallof the casing collectively form and define the aperturetherebetween. The apertureis a through-hole fluidly communicating between the club head exterior and the interior cavity. The front wallcomprises a front wall front surfacedisposed towards the strike face, a front wall rear surfacedisposed towards the aperture, a front wall base, and a front wall top surfaceopposite the front wall base. The rear wallcomprises a rear wall front surfacedisposed towards the aperture, a rear wall rear surfacedisposed towards the rear, a rear wall base, and a rear wall top surfaceopposite the rear wall base.

The casingcan comprise a front wall height FWH, as best illustrated in, measured as the distance between the front wall baseand the front wall top surface, along the front wall rear surface. The front wall height FWH can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the front wall height FWH increases strike face deflection, but potentially decreases durability. Reinforcing the casingwith high-strength material, as described herein, allows the front wall height FWH to be reduced while maintaining durability. The front wall height FWH can be constant along the length of the casing, or the front wall height FWH can vary along the length of the casing. In many embodiments, the front wall height FWH can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall height FWH can be between 0.050 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, between 0.40 and 0.50 inch. In some embodiments, the front wall height FWH can be less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch.

The casing comprises an offset distance OD, as best illustrated in, measured as the distance from the leading edgeto the front wall base, in a strike face-to-rear direction. The casing offset distance OD can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the offset distance OD increases strike face deflection, but potentially decreases durability. Reinforcing the casingwith high-strength material, as described herein, allows the offset distance OD to be reduced while maintaining durability. In many embodiments, the offset distance OD can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the offset distance OD can be between 0.075 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, 0.40 and 0.50 inch, 0.50 and 0.60 inch, 0.60 and 0.70 inch, 0.70 and 0.80 inch, 0.80 and 0.90 inch, or between 0.90 and 1.00 inch. In some embodiments, the offset distance can be less than 1.0 inch, less than 0.90 inch, less than 0.80 inch, less than 0.70 inch, less than 0.60 inch less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. In some embodiments, the casing offset distance OD can be 0.075 inch, 0.080 inch, 0.085 inch, 0.090 inch, 0.095 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, or 1.0 inch.

The front wallcomprises a front wall thickness FWT, as best illustrated in, measured as the distance between front wall front surfaceand the front wall rear surface. As mentioned above, the front wall thickness FWT can be selected to increase strike face deflection without compromising durability. Specifically, the front wall thickness FWT can be increased (i.e., thicker) to decrease performance but increase durability. Decreasing the front wall thickness FWT increases strike face deflection, but potentially decreases durability. Reinforcing the casingwith high-strength material, as described herein, allows the front wall thickness FWT to be reduced while maintaining durability. In many embodiments, the front wall thickness FWT can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall thickness FWT can be between 0.010 and 0.025 inch, 0.025 and 0.050 inch, 0.050 and 0.075 inch, 0.075 and 0.100 inch, 0.100 and 0.125 inch, 0.125 and 0.150 inch, or between 0.150 and 0.175 inch. In some embodiments, the front wall thickness FWT can be less than 0.175 inch, less than 0.150 inch, less than 0.125 inch, less than 0.100 inch, less than 0.075 inch, less than 0.050 inch, less than 0.025 inch, or less than 0.010 inch.

The IRM further comprises an insertdisposed within the apertureand formed of a flexible, polymeric material. The insertcloses off the apertureto prevent migration of debris into the interior chamber and can impact the performance of the IRM and durability of the club head. The insertis configured to engage the casing walls, thereby securing the insertwithin the casing. The material composition, overall construction, inclusion of hybrid materials, and geometry of the insertcan affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insertand the casingcan comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insertwithin the casing, even after repeated, violent impacts.

In some embodiments, the insertis entirely filled with a solid material such that it fills the entire aperturebetween the casing front walland the casing rear wall. In some embodiments, the insertcan be hollowed out or provided with some other suitable geometry that creates a gapor channel within the insert. For example, in some embodiments, the insertcan comprise a front wall, a rear wall, and a base, and takes a general U-shape appearance. The insertmay further comprise a rear extensionto increase bonding surface area.

To better understand the strategic locations at which high-strength material is used, the casingcan be divided up into multiple regions. The casingcan include a casing heel regionproximate the heel wall, a casing toe regionproximate the toe wall, and a casing center regiontherebetween. The casing regions can help describe the location of various casing features and/or describe specific portions of the casingthat are reinforced by a high-strength material component in the various embodiments described below.

In some embodiments, the casing can comprise one or more reliefs that dissipate stress in the casing walls. The reliefs are portions of the casing that extend away from the strike face to dissipate stress. Generally, a significant portion of the casing, particularly at or near the casing center region, extends substantially equidistant to the strike face curvature, as best illustrated in. The relief(s) are angled rearward relative to the strike face. Referring to, the casingcomprises a toe reliefin the casing toe regionand a heel reliefin the casing heel region. The toe reliefand the heel reliefspace the casing toe walland the casing heel wall, respectively, away from the strike face, such that the casing toe walland the casing heel wallare further from the strike facethan the center of the casing. This spacing is necessary because stress concentrations typically occur near the heel walland the toe wall, because the heel walland the toe wallgenerally comprise tight curvatures. The toe reliefand the heel reliefreduce these concentrations by spacing the casing toe walland the casing heel wall, respectively, further from the strike face. The reliefs,allow the casing(and the aperture) to be lengthened without compromising durability, thereby increasing strike face deflection. The illustrated embodiment includes both a toe reliefand a heel relief. In other embodiments, the casingcan comprise only a toe reliefor only a heel relief.

In some embodiments, the casingcan further comprise one or more end reinforcements, as best illustrated in. The end reinforcementscan be thickened portions of the solethat surround one or more of the casing walls. In the illustrated embodiment, casingcomprises a heel end reinforcementsurrounding the heel walland a toe end reinforcementsurrounding the toe wall. The end reinforcements,are concentrations of club head mass with a substantially greater thickness Tthan the surrounding casing walls. As illustrated in, the toe end reinforcementcan comprise an end reinforcement thickness Tmeasured between the casing toe walland an outer surface of the toe end reinforcement, the measurement taken perpendicularly to the casing toe wall. Similarly, the heel end reinforcementcan comprise an end reinforcement thickness Tmeasured between the casing heel walland an outer surface of the heel end reinforcement, the measurement taken perpendicularly to the casing heel wall. In some embodiments, the end reinforcement thickness Tcan be between 0.25 inch and 0.75 inch. In some embodiments, the end reinforcement thickness Tcan be greater than 0.25 inch, greater than 0.30 inch, greater than 0.35 inch, greater than 0.40 inch, greater than 0.45 inch, greater than 0.50 inch, greater than 0.55 inch, greater than 0.60 inch, greater than 0.65 inch, or greater than 0.70 inch. In some embodiments the end reinforcement thickness Tis between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, or between 0.65 and 0.70 inch, between 0.70 and 0.75 inch.

Similar to the reliefs,, the end reinforcements,reduce stress concentrations occurring in the heel walland the toe wall, respectively, thereby increasing casing durability. Although the end reinforcements,are concentrations of club head mass located on the casing walls, they are located towards the heeland the toeand thus do not hinder strike face deflection. In the illustrated embodiment, the end reinforcements,are generally circular in shape. In other embodiments, the end reinforcements,can be any suitable shape for reducing stress near the heel walland the toe wall. The end reinforcements,can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. The illustrated embodiment includes both a heel end reinforcementand a toe end reinforcement. In other embodiments, the casingcan comprise a heel end reinforcement, a toe end reinforcement, or both.

In some embodiments, the casingcan further comprise one or more front wall reinforcements, as best illustrated in. The front wall reinforcementscan be thickened portions of casing front wall. In the illustrated embodiment, the casingcomprises a front reinforcementlocated in the central regionof the casing. The front wall reinforcementsare concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. Similar to the end reinforcements,, the front wall reinforcementsreduce stress concentrations occurring in the front wall, thereby increasing overall casingdurability. In the illustrated embodiment, a single front wall reinforcementis generally located in the central region. In other embodiments, the front wall reinforcementscan be located in the heel region, in the toe region, or in any combination of central, heel, and toe regions,,. The front wall reinforcementscan be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof.

In many embodiments, the casingcomprises a casing recessthat retains the insertand increases strike face deflection. In the illustrated embodiment of, the casing recessis located at the rear wall base. The casing recessincludes a seating surfacethat is inset from an exterior surfaceof the soleby a rising surface. The casing recesscan be in direct communication with the aperture. The casing recessforms a lap joint configured to receive one or more portions of the insert. Although the casing recessof the illustrated embodiment is located only at the rear wall base, in other embodiments, the casing recesscan also be formed at the front wall base. In some embodiments, the casing recessextends around and entirely circumscribes the aperture.

The casing recessremoves mass from the rear wall base, thereby increasing the amount the rear walland the solebend at impact. In some embodiments, the casing recessdefines a recess depth Dmeasured between the exterior surface of the soleand the seating surface. Increasing the recess depth Dwill increase the amount the casingbends at impact, thereby increasing strike face deflection. However, increasing the recess depth Dalso potentially increases stress in the casing. The recess depth Dcan be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the recess depth Dcan be between 0.1 and 0.75 inch. For example, in some embodiments, the recess depth Dcan be between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, between 0.20 and 0.25 inch, between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, between 0.65 and 0.70 inch, or between 0.70 and 0.75 inch.

In alternative embodiments, rather than a lap joint configuration including a rising surface and a seating surface, the casing recesscan comprise a bevel. As best illustrated in, the casing recessdefines a beveled surfacethat gradually slopes between the exterior surfaceof the soleand the rear wall front surfaceand/or the front wall rear surface. Rather than a recess depth, the beveled surfacecan comprise a bevel angle as defined between the exterior surfaceof the soleand the beveled surface. A greater bevel angle as, will increase the amount the casingbends at impact, thereby increasing strike face deflection. However, a greater bevel angle αalso potentially increases stress in the casing. The bevel angle αcan be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the bevel angle αcan be between 5 and 60 degrees. For example, in some embodiments, the bevel angle αcan be between 5 and 10 degrees, between 10 and 16 degrees, between 16 and 21 degrees, between 21 and 27 degrees, between 27 and 32 degrees, between 32 and 38 degrees, between 38 and 43 degrees, between 43 and 49 degrees, between 49 and 54 degrees, or between 54 and 60 degrees.

In some embodiments, the faceplatecomprises one or more return portions that are used in combination with the IRMto increase strike face deflection. The return portions are portions of the faceplatethat wrap over the strike face perimeter and form other forward portions of the club head, such as forward portions of the crown, sole, heel, or toe. The return portions replace these portions of the club head, which typically experience high impact stresses and would otherwise be formed of the body material, with the high-strength faceplate material. This allows these areas of the club headto be thinned without sacrificing durability, thereby increasing strike face deflection.

The one or more return portions can be described in relation to the faceplate perimeter, which is the outermost edge of the faceplatethat couples to the bodyand/or other club head components. Referring to, in some embodiments, the faceplatecomprises a crown returnthat wraps over the transition from the strike faceto the crown, thereby to form a forward portion of the crown. In embodiments comprising a crown return, the faceplate top edgeis located on the crownand not on the strike face. Similarly, in other embodiments such as that illustrated in, the faceplatecan comprise a toe return, wrapping over the transition between the strike faceand the toe, thereby to form a forward portion of the toe. In embodiments comprising a toe return, the faceplate toe edgeis located on the toeand not on the strike face. In other embodiments, the faceplatecomprises a sole return (discussed in further detail below) that wraps over the leading edgeand forms a forward portion of the sole, wherein the faceplate bottom edgeis located on the soleand not on the strike face. In other embodiments, the faceplatecomprises a heel return that wraps over the transition between the strike faceand the heel, thereby to form a forward portion of the heel, wherein the faceplate heel edgeis located on the heeland not on the strike face. The faceplates described herein can comprise a crown return, a heel return, a toe return, or any combination thereof. Specific return combinations and configurations are discussed in detail below.

In some embodiments, the club headcan comprise a “reverse L-cup” faceplate, as best illustrated in. The reverse L-cup faceplatecan comprise a crown returnyet be devoid of a sole return. As such, the reverse L-cup faceplatecomprises a faceplate top edgethat is located on the crown. The faceplate bottom edge that is located on the strike face, above the leading edge. The reverse L-cup faceplatedoes not extend to or wrap over the leading edge, nor does the reverse L-cup faceplateform any portion of the sole. Due to the absence of a sole return, the bodyof the illustrated embodiment forms a forward portion of the soleas well as the entire casing.