Golf Club Head with Impact Response Modulator

This is a continuation-in-part of U.S. patent application Ser. No. 19/090,340, filed on Mar. 25, 2025, which claims the benefit of U.S. Provisional Application No. 63/569,638, filed on Mar. 25, 2024. This further claims the benefit of 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, and U.S. Provisional Application No. 63/784,868, filed on Apr. 7, 2025, all of which are incorporated in their entirety.

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. Conventional golf club heads fail to increase 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 IRM further balances strike face deflection and club head durability through various stress-reducing casing geometries, dimensions, and/or parameters. Balancing certain casing parameters or localized reinforcements can increase strike face deflection without a corresponding stress increase. For example, balancing the length of the aperture, offset distance of the aperture, relief geometries, and front wall geometries can improve the strike face deflection while maintaining durability.

Any casing geometry described herein can be combined with any suitable high-strength material reinforcement. For example, any IRM geometry or local reinforcement can be combined with any faceplate configuration including a faceplate with a sole return integrally forming the entire IRM or a faceplate a sole return integrally forming only a portion of the IRM. The IRM can comprise any suitable geometry described herein and be integrally formed by the faceplate, the body, a cartridge, an appendage, or any combination thereof. The combination of high-strength material reinforcement and stress-reducing casing geometries further increases strike face deflection without compromising durability.

As such, certain aspects of the present invention, including high-strength material reinforcement and stress-reducing casing geometries, balance strike face deflection and durability. Such aspects increase strike face deflection (and thereby ball flight performance) without a corresponding increase in stress, increase durability without sacrificing performance, or both.

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 an upper edgethat defines a transition between the strike faceand the crownand a leading edgethat defines a transition from the strike faceto the sole. The upper edgedefines a face apex (FA), located at the intersection between the upper edgeand the YZ plane (described below). The leading edgedefines a face nadir (FN) located at the intersection between the leading edgeand the YZ plane. The strike facefurther defines 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 facedefines a strike face height (HSF). Referring to, the strike face height (HSF) is measured within the YZ plane (described in further detail below) and parallel to the loft planebetween the face nadir (FN) and the face apex (FA).

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 golf club headdefines a ground plane (GP) as a reference plane associated with the surface on which a golf ball is placed. The ground plane GP is a horizontal plane tangent to the solein the address position. The ground plane GP is illustrated in.

The golf club headdefines a loft planeas a plane that is tangent to the strike faceat the face center (FC). The loft planeis illustrated in.

The golf club headdefines a loft angleas the angle measured between the loft planeand the XY plane (defined below). The loft angleis illustrated in.

The golf club headdefines a lie angleas the angle between a hosel axis, extending longitudinally through the hosel, and the ground plane GP. The lie angleis measured from a front view of the golf club head, as illustrated in.

The golf club headcan define an address position, wherein the golf club headis oriented such that the golf club headforms its intended loft angleand lie angle. For example, in the address position, the loft planeand the XY plane form the intended loft anglebetween one another. Likewise, in the address position, the hosel axisand the ground plane GP form the intended lie anglebetween one another.

As illustrated in, the golf club headdefines a primary coordinate system centered about the face center (FC). The primary coordinate system comprises an X-axis, a Y-axis, and a Z-axis. The X-axisextends in a heel-to-toe direction, parallel to the ground plane GP. The X-axisis positive towards the heeland negative towards the toe. The Y-axisextends in a crown-to-sole direction and is orthogonal to both the ground plane GP and the X-axis. The Y-axisis positive towards the crownand negative towards the sole. The Z-axisextends in a front-to-rear direction, parallel to the ground plane GP, and is orthogonal to both the X-axisand the Y-axis. The Z-axisis positive towards the strike faceand negative towards the rear.

The primary coordinate system, as described herein, defines an XY plane as a vertical plane extending along the X-axisand the Y-axis. The primary coordinate system defines an XZ plane as a horizontal plane extending along the X-axisand the Z-axis. The primary coordinate system further defines a YZ plane as a vertical plane extending along the Y-axisand the Z-axis. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the primary coordinate system origin located at the face center (FC). In these or other embodiments, the golf club headcan be viewed from a front view when the strike faceis viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the golf club headcan be viewed from a side view when the heelor the toeis viewed from a direction perpendicular to the YZ plane.

The golf club headcomprises a club head center of gravity (hereafter “CG” or “club head CG”), referring to the point at which the mass is centered within the golf club head. The club head CG is illustrated in FIGS. HA and HB.

The “body depth,” or “depth” Dof the club head, as used herein, refers to a front-to-rear dimension measured across the body. Referring to, the body depth Dis measured parallel to the Z-axisfrom the leading edgeto the rearward-most point of the body.

The “body height,” or “height” Hof the club head, as described herein, can refer to a crown-to-sole dimension measured across the body. Referring to, the body height Hcan be measured as a vertical distance (parallel to the Y-axis) between the ground plane GP and the highest point of the crown. In many embodiments, the height Hcan be measured according to a golf governing body such as the United States Golf Association (USGA).

The “body width,” or “width” Wof the club head, as described herein, can refer to a heel-to-toe dimension measured across the body. Referring to, the body width Wcan be measured parallel to the X-axisfrom a body heel apex (BHA) to a body toe apex (BTA). The body toe apex (BTA) is defined as the toeward-most point of the body. The body heel apex (BHA) is heelward-most point of the heelthat is located at a height 0.875 mm from the ground plane GP. In many embodiments, the body width (W) can be measured according to a golf governing body such as the United States Golf Association (USGA). The ranges specified for the body depth (D), body height (H), and body width (W) can be designed in accordance with the USGA regulations.

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” or “driver-type” 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 club head 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 club head 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.

Driver embodiments can comprise a body height Hbetween 2.0 and 3.0 inches. In some driver embodiments, the body height Hcan be between 2.0 and 2.2 inches, between 2.2 and 2.4 inches, between 2.4 and 2.6 inches, between 2.6 and 2.8 inches, or between 2.8 and 3.0 inches. In some driver embodiments, the body height Hcan be greater than 2.0 inches, greater than 2.2 inches, greater than 2.4 inches, greater than 2.6 inches, greater than 2.8 inches, or greater than 3.0 inches.

Driver embodiments can comprise a body width Wbetween 4.4 and 5.0 inches. In some driver embodiments, the body width Wcan be between 4.4 and 4.6 inches, between 4.6 and 4.8 inches, or between 4.8 and 5.0 inches. In some driver embodiments, the body width Wcan be greater than 4.4 inches, greater than 4.6 inches, greater than 4.8 inches, or greater than 5.0 inches.

Driver embodiments can comprise a body depth Dbetween 4.3 and 4.9 inches. In some driver embodiments, the body depth Dcan be between 4.3 and 4.5 inches, between 4.5 and 4.7 inches, or between 4.7 and 4.9 inches. In some driver embodiments, the body depth Dcan be greater than 4.3 inches, greater than 4.5 inches, greater than 4.7 inches, or greater than 4.9 inches.

“Fairway wood” or “fairway wood-type” 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” or “fairway wood-type” golf club heads as used herein comprises a club head 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 club head 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.

Fairway wood embodiments can comprise a body height Hbetween 1.25 and 1.75 inches. In some fairway wood embodiments, the body height Hcan be between 1.25 and 1.40 inches, between 1.40 and 1.55 inches, or between 1.55 and 1.75 inches.

Fairway wood embodiments can comprise a body width Wbetween 3.75 and 4.5 inches. In some fairway wood embodiments, the body width Wcan be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches.

Fairway wood embodiments can comprise a body depth Dbetween 3.0 and 4.0 inches. In some fairway wood embodiments, the body depth Dcan be between 3.0 and 3.3 inches, between 3.3 and 3.6 inches, between 3.6 and 3.8 inches, or between 3.8 and 4.0 inches.

“Hybrid” or “hybrid-type” 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” or “hybrid-type” golf club heads as used herein comprise a club head 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 club head 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.

Hybrid embodiments can comprise a body height Hbetween 1.1 and 1.5 inches. In some hybrid embodiments, the body height Hcan be between 1.1 and 1.25 inches, between 1.25 and 1.4 inches, or between 1.4 and 1.5 inches. In some hybrid embodiments, the body height Hcan be less than 1.5 inches, less than 1.4 inches, less than 1.3 inches, or less than 1.2 inches.

Hybrid embodiments can comprise a body width Wbetween 3.75 and 4.5 inches. In some hybrid embodiments, the body width Wcan be between 3.75 and 4.0 inches, between 4.0 and 4.25 inches, or between 4.25 and 4.5 inches. In some hybrid embodiments, the body width Wcan be less than 4.5 inches, less than 4.25 inches, or less than 4.0 inches.

Hybrid embodiments can comprise a body depth Dbetween 2.25 and 2.75 inches. In some hybrid embodiments, the body depth Dcan be between 2.25 and 2.4 inches, between 2.4 and 2.6 inches, or between 2.6 and 2.75 inches. In some hybrid embodiments, the body depth Dcan be less than 2.75 inches, less than 2.6 inches, less than 2.4 inches, or less than 2.25 inches.

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.