Golf Club Heads and Methods to Manufacture Golf Club Heads

This application is a continuation of U.S. application Ser. No. 18/791,651, filed Aug. 1, 2024, which is a continuation of application Ser. No. 18/243,763, filed Sep. 8, 2023, now U.S. Pat. No. 12,145,033, which is a continuation of application Ser. No. 18/201,300, filed May 24, 2023, now U.S. Pat. No. 11,786,786, which is a continuation of application Ser. No. 18/099,546, filed Jan. 20, 2023, now U.S. Pat. No. 11,707,653, which claims the benefit of Provisional Application No. 63/334,044, filed Apr. 22, 2022.

U.S. application Ser. No. 18/243,763, filed Sep. 8, 2023, is a continuation-in-part of U.S. application Ser. No. 18/102,291, filed Jan. 27, 2023, now U.S. Pat. No. 11,806,588, which is a continuation of application Ser. No. 17/868,043, filed Jul. 19, 2022, now U.S. Pat. No. 11,590,395, which is a continuation of application Ser. No. 17/505,838, filed Oct. 20, 2021, now U.S. Pat. No. 11,426,640, which is a continuation of application Ser. No. 17/185,544, filed Feb. 25, 2021, now U.S. Pat. No. 11,192,003, which claims the benefit of U.S. Provisional Application No. 62/985,382, filed Mar. 5, 2020.

U.S. application Ser. No. 18/099,546, filed Jan. 20, 2023, is a continuation-in-part of application Ser. No. 18/086,803, filed Dec. 22, 2022, now U.S. Pat. No. 11,745,066, which is a continuation of application Ser. No. 17/868,068, filed Jul. 19, 2022, now U.S. Pat. No. 11,565,157, which is a continuation of application Ser. No. 17/528,402, filed Nov. 17, 2021, now U.S. Pat. No. 11,426,641, which is a continuation of application Ser. No. 16/566,597, filed Sep. 10, 2019, now U.S. Pat. No. 11,207,575.

U.S. application Ser. No. 18/099,546, filed Jan. 20, 2023, is a continuation-in-part of application Ser. No. 17/682,476, filed Feb. 28, 2022, now U.S. Pat. No. 12,194,349, which is a continuation of U.S. application Ser. No. 17/099,362, filed Nov. 16, 2020, now U.S. Pat. No. 11,291,890, which is a continuation of application Ser. No. 16/820,136, filed Mar. 16, 2020, now U.S. Pat. No. 10,874,919, which is a continuation of application Ser. No. 16/590,105, filed Oct. 1, 2019, now U.S. Pat. No. 10,632,349, which claims the benefit of U.S. Provisional Application No. 62/908,467, filed Sep. 30, 2019, U.S. Provisional Application No. 62/903,467, filed Sep. 20, 2019, U.S. Provisional Application No. 62/877,934, filed Jul. 24, 2019, U.S. Provisional Application No. 62/877,915, filed Jul. 24, 2019, and U.S. Provisional Application No. 62/865,532, filed Jun. 24, 2019.

U.S. application Ser. No. 18/099,546, filed Jan. 20, 2023, is a continuation-in-part of U.S. application Ser. No. 17/988,585, filed Nov. 16, 2022, now U.S. Pat. No. 11,779,820, which is a continuation of application Ser. No. 17/841,893, filed Jun. 16, 2022, now U.S. Pat. No. 11,806,590, which is a continuation of application Ser. No. 17/685,546, filed Mar. 3, 2022, now U.S. Pat. No. 11,400,352, which claims the benefit of U.S. Provisional Application No. 63/276,981, filed Nov. 8, 2021.

The disclosures of the above-referenced applications are incorporated by reference herein in their entirety.

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

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

Various materials (e.g., steel-based materials, titanium-based materials, tungsten-based materials, etc.) may be used to manufacture golf club heads. By using multiple materials to manufacture golf club heads, the position of the center of gravity (CG) and/or the moment of inertia (MOI) of the golf club heads may be optimized to produce certain trajectory and spin rate of a golf ball.

For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawing figures may not be depicted to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure.

The following U.S. Patents and Patent Applications, which are collectively referred to herein as “the incorporated by reference patent documents,” are incorporated by reference herein in their entirety: U.S. Pat. Nos. 8,961,336; 9,199,143; 9,421,437; 9,427,634; 9,468,821; 9,533,201; 9,610,481; 9,649,542; 9,675,853; 9,814,952; 9,878,220; 10,029,158; 10,029,159; 10,159,876; 10,232,235; 10,265,590; 10,279,233; 10,286,267; 10,293,229; 10,449,428; 10,478,684; 10,512,829; 10,596,424; 10,596,425; 10,632,349; 10,716,978; 10,729,948; 10,729,949; 10,814,193; 10,821,339; 10,821,340; 10,828,538; 10,864,414; 10,874,919; 10,874,921; and U.S. patent application Ser. No. 15/628,251, filed Jun. 20, 2017; U.S. patent application Ser. No. 15/631,610, filed Jun. 23, 2017; U.S. patent application Ser. No. 15/701,131, filed Sep. 11, 2017; U.S. patent application Ser. No. 15/785,001, filed Oct. 16, 2017; U.S. patent application Ser. No. 15/791,020, filed Oct. 23, 2017; U.S. patent application Ser. No. 15/842,591, filed Dec. 14, 2017; U.S. patent application Ser. No. 15/876,877, filed Jan. 22, 2018; U.S. patent application Ser. No. 15/890,961, filed Feb. 7, 2018; U.S. patent application Ser. No. 15/947,383, filed Apr. 6, 2018; U.S. patent application Ser. No. 15/958,288, filed Apr. 20, 2018; U.S. patent application Ser. No. 16/052,254, filed Aug. 1, 2018; U.S. patent application Ser. No. 16/376,863, filed Apr. 5, 2019; U.S. patent application Ser. No. 16/376,868, filed Apr. 5, 2019; U.S. patent application Ser. No. 16/388,619, filed Apr. 18, 2019; U.S. patent application Ser. No. 16/388,645, filed Apr. 18, 2019; U.S. patent application Ser. No. 16/566,597, filed Sep. 10, 2019; U.S. patent application Ser. No. 16/785,336, filed Feb. 7, 2020; U.S. patent application Ser. No. 16/785,340, filed Feb. 7, 2020; U.S. patent application Ser. No. 16/789,167, filed Feb. 12, 2020; U.S. patent application Ser. No. 16/929,552, filed Jul. 15, 2020; U.S. patent application Ser. No. 16/939,284, filed Jul. 27, 2020; U.S. patent application Ser. No. 16/997,091, filed Aug. 19, 2020; U.S. patent application Ser. No. 17/032,253, filed Sep. 25, 2020; U.S. patent application Ser. No. 17/038,155, filed Sep. 30, 2020; U.S. patent application Ser. No. 17/038,195, filed Sep. 30, 2020; U.S. patent application Ser. No. 17/066,271, filed Oct. 8, 2020; U.S. patent application Ser. No. 17/099,362, filed Nov. 16, 2020.

In general, golf club heads, golf clubs, and methods to manufacture golf club heads and golf clubs are described herein. In the example of, a golf club headmay include a body portionwith a top portionhaving a crown portion, a bottom portion, a toe portion, a heel portion, a front portion, and a rear portion. The crown portionmay be a separate piece that may be attached to the top portionand constructed from a composite material. The bottom portionmay include a skirt portion (not shown) defined as a side portion of the golf club headbetween the top portionand the bottom portionexcluding the front portionand extending across a periphery of the golf club headfrom the toe portion, around the rear portion, and to the heel portion. The front portionmay include a face portionto engage a golf ball (not shown). The golf club headmay have a neutral axis. The neutral axismay be perpendicular to the face portionand may intersect a center of the face portion. The body portionmay also include a hosel portionfor receiving a shaft (not shown). Alternatively, the body portionmay include a bore instead of the hosel portion. The body portionmay be made from any one or a combination of materials described herein or described in any of the incorporated by reference patent documents. A maximum front-to-rear distance of the golf club headmay be greater than a maximum heel-to-toe distance of the golf club head. Althoughmay depict a particular type of golf club head (e.g., driver-type club head), the apparatus methods, and articles of manufacture described herein may be applicable to other types of club heads (e.g., a fairway wood-type club head, a hybrid-type club head, an iron-type club head, a putter-type club head). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The bottom portionmay include a plurality of port regions, which are shown for example as a first port regionwith a first set of ports(generally shown as ports,, and) near the toe portion, a second port regionwith a second set of ports(generally shown as ports,, and) near the front portion, and a third port regionwith a third set of ports(generally shown as ports,, and) near the heel portion. Althoughshow a certain configuration of port regions and ports, the number of port regions, the number and configuration of ports in each region, and the location of the ports may be similar to any of the golf club heads described herein on in any of the incorporated by reference patent documents. The body portionmay also include a plurality of mass portions, shown as a first set of mass portions(generally shown as mass portions,, and), a second set of mass portions(generally shown as mass portions,, and), and a third set of mass portions(generally shown as mass portions,and). Each port may interchangeably receive any of the mass portions. The masses of the first set of mass portion, the second set of mass portionsand/or the third set of mass portionsmay be similar or different. Accordingly, by using mass portions having similar or different masses in each of the ports of the port regions,and/or, the overall mass in each port region and/or the mass distribution in each port region may be adjusted as described herein and in any of the incorporated by reference patent documents to generally optimize and/or adjust the swing weight, center of gravity, moment of inertia, and/or an overall feel of the golf club head for an individual using the golf club head. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Certain regions of the interior of the body portionmay include a polymer material, which may also be referred to herein as the filler material, similar to any of the polymer materials described herein or described in any of the incorporated by reference patent documents. The filler material may dampen vibration, dampen noise, lower the center of gravity and/or provide a better feel and sound for the golf club headwhen striking a golf ball (not shown). The golf club head, may have one or more interior regions and/or cavities that may include a filler material similar to any of the golf club heads described herein or described in any of the incorporated by reference patent documents. In one example, as shown in, the body portionmay include a cavity wall portion. The cavity wall portionmay form a first interior cavity portionand a second interior cavity portionwithin the body portion. The first interior cavity portionand the second interior cavity portionmay be separated by the cavity wall portion. Alternatively, the first interior cavity portionand the second interior cavity portionmay be connected through one or more openings in the cavity wall portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As illustrated in, the cavity wall portionmay include a first wall portionextending from a location at or proximate to the top portiontoward the bottom portion. The first wall portionmay extend toward the bottom portionat a certain angle or orientation relative to the face portion. In one example, the first wall portionmay extend toward the bottom portionand away from the face portion. Accordingly, a first width(W) of the first interior cavity portionmay increase in a direction from the top portionto the bottom portion. In another example, the first wall portionmay extend toward the bottom portionand toward the face portion. Accordingly, the first widthof the first interior cavity portionmay decrease in a direction from the top portionto the bottom portion. In the illustrated example of, the first wall portionof the of the cavity wall portionmay extend from a location at or proximate to the top portiongenerally parallel or substantially parallel with the face portion. Accordingly, the first widthof the first interior cavity portionmay be constant or substantially constant. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first interior cavity portionmay include an enlarged cavity portionbetween the top portionand the bottom portion. As shown in the illustrated example of, the enlarged cavity portionextends partially or fully over the second port region. Accordingly, the enlarged cavity portionmay have a second width(W) of the first interior cavity portionthat may be greater than the first widthof the first interior cavity portion. The second widthmay be about two times greater than the first width. The second widthmay be at least two times greater than the first width. The enlarged cavity portionmay be located at least partially below the neutral axisof the golf club head. The enlarged cavity portionmay be located wholly below a neutral axisof the golf club head. The first widthmay be located above the neutral axis. The second widthmay be located below the neutral axis. The enlarged cavity portionmay be defined by a second wall portionthat may extend from the first wall portiontoward the rear portionand the bottom portion, and traverse back over the second port region. The first interior cavity portionmay include a third wall portionthat extends from the second wall portionto a location at or proximate to the bottom portion. The first interior cavity portionmay have a third width(W) extending from the third wall portionto the back surfaceof the face portion. The third widthmay be located below the enlarged cavity portion. The third widthmay be located below the second width. The third widthmay be less than the second width. The third widthmay be substantially equal to the first width. As shown in the illustrated example of, the third widthmay be located between the second port regionand the face portion. The third widthmay be located proximate to the bottom portion. In another example, the first widthmay be similar to the second widthof the first interior cavity portion(not shown). Accordingly, the first wall portionof the cavity wall portionmay located farther back toward the rear portionthan the location of the first wall portionshown insuch that the portion of the first interior cavity portionabove the second port regionextends over the one or more ports of the second port region. In other examples, the first interior cavity portionmay be configured similar any of the interior cavities described herein and shown in. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, the first interior cavity portionmay be unfilled (i.e., empty space). Alternatively, the first interior cavity portionmay be partially (i.e., less than 100% filled) or entirely filled with a filler material (i.e., a cavity filling portion) to absorb shock, isolate vibration, dampen noised, and/or provide structural support for the face portion. For example, at least 50% of the first interior cavity portionmay be filled with a TPE material to absorb shock, isolate vibration, and/or dampen noise when the golf club headstrikes a golf ball via the face portion. In one example, the first interior cavity portionmay be partially or entirely filled with a filler material through a port (e.g. port) located in the bottom portion. In one example, as shown in, the portmay include an opening that accesses the first interior cavity portion. The opening may provide a fluid pathway for filler material to be introduced to the first interior cavity portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

When the face portionof the golf club headstrikes a golf ball, the face portionand the filler material may deform and/or compress. The kinetic energy of the impact may be transferred to the face portionand/or the filler material. For example, some of the kinetic energy may be transformed into heat by the filler material or work done in deforming and/or compressing the filler material. Further, some of the kinetic energy may be transferred back to the golf ball to launch the golf ball at a certain velocity. A filler material with a relatively higher COR may transfer relatively more kinetic energy to the golf ball and dissipate relatively less kinetic energy. Accordingly, a filler material with a relatively high COR may generate relatively higher golf ball speeds because a relatively greater part of the kinetic energy of the impact may be transferred back to the golf ball to launch the golf ball from the golf club head. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

With the support of the cavity wall portionto form the first interior cavity portionand filling at least a portion of the first interior cavity portionwith a filler material, the face portionmay be relatively thin without degrading the structural integrity, sound, and/or feel of the golf club head. In one example, the face portionmay have a thickness of less than or equal to 0.075 inch (e.g., a distance between a front surfaceand the back surface). In another example, the face portionmay have a thickness of less than or equal to 0.2 inch. In another example, the face portionmay have a thickness of less than or equal to 0.06 inch. In yet another example, the face portionmay have a thickness of less than or equal to 0.05 inch. Further, the face portionmay have a thickness of less than or equal to 0.03 inch. In yet another example, a thickness of the face portionmay be greater than or equal to 0.03 inch and less than or equal to 0.2 inch. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In the illustrated example of, the second interior cavity portionmay be unfilled (i.e., empty space). Alternatively (not shown), the second interior cavity portionmay be partially or entirely filled with a filler material (i.e., a cavity filling portion), which may include one or more similar or different types of materials described herein and may be different or similar to the filler material used to fill the first interior cavity portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

While each of the examples herein may describe a certain type of golf club head, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of golf club heads. Referring to, for example, a golf club headmay include a body portionand a cavity wall portion. Althoughmay depict a particular type of club head (e.g., a fairway wood-type club head), the apparatus, methods, and articles of manufacture described herein may be applicable to other types of club head (e.g., a driver-type club head, a hybrid-type club head, an iron-type club head, a putter-type club head, etc.). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The body portionmay include a toe portion, a heel portion, a front portion, a rear portion, a top portion(e.g., a crown portion), and a bottom portion(e.g., a sole portion). The front portionmay include a face portion(e.g., a strike face). The face portionmay include a front surfaceand a back surface. The front surfacemay include a plurality of grooves, generally shown asin. The cavity wall portionmay form a first interior cavity portionand a second interior cavity portionwithin the body portion. As illustrated in, for example, the cavity wall portionmay extend from the back surfaceof the face portion. The cavity wall portionmay be a single curved wall section. In particular, the cavity wall portionmay have a convex arc profile relative to the back surface(e.g., C shape) to form a dome-like structure with an elliptical base (e.g.,) or a circular base on the back surface. In another example, the cavity wall portionmay form a cone-like structure or a cylinder-like structure with the body portion. Alternatively, the cavity wall portionmay be a concave are profile relative to the back surface. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first interior cavity portionmay be partially or entirely filled with a suitable filler material such as any of the filler materials described herein or described in any of the incorporated by reference patent documents to absorb shock, isolate vibration, dampen noise, and/or provide structural support. The elastic polymer material may be injected into the first interior cavity portionvia an injection molding process via a port on the face portion. With the support of the cavity wall portionto form the first interior cavity portionand filling at least a portion of the first interior cavity portionwith an elastic polymer material, the face portionmay be relatively thin without degrading the structural integrity, sound, and/or feel of the golf club head. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The cavity wall portionmay include multiple sections. Turning to, for example, a golf club headmay include a body portionand a cavity wall portion. The body portionmay include a toe portion, a heel portion, a front portion, a rear portion, a top portion(e.g., a crown portion), and a bottom portion(e.g., a sole portion). The front portionmay include a face portion(e.g., a strike face) with a front surfaceand a back surface. The cavity wall portionmay extend from the back surfaceto form a first interior cavity portionand a second interior cavity portionwithin the body portion. The cavity wall portionmay include two or more wall sections, generally shown as,, andin. Similar to the first interior cavity portion(), the first interior cavity portionmay be partially or entirely filled with a filler material. The filler material may be injected into the first interior cavity portionvia an injection molding process via a port on the face portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As illustrated in, for example, a golf club headmay include a body portionand a cavity wall portion. The body portionmay include a toe portion, a heel portion, a front portion, a rear portion, a top portion(e.g., a crown portion), and a bottom portion(e.g., a sole portion). The front portionmay include a face portion(e.g., a strike face) with a front surfaceand a back surface. The face portionmay be associated with a loft planethat defines the loft angle of the golf club head. The cavity wall portionmay be a single flat wall section. In particular, the cavity wall portionmay extend between the toe portionand the heel portionand between the top portionand the bottom portionto form a first interior cavity portionand a second interior cavity portionwithin the body portion. The cavity wall portionmay be parallel or substantially parallel to the loft plane. Alternatively, as shown in, a cavity wall portionmay be perpendicular or substantially perpendicular to a ground plane. Similar to the first interior cavity portion() and the first interior cavity portion(), the first interior cavity portionmay be partially or entirely filled with an elastic polymer or elastomer material. The elastic polymer material may be injected into the first interior cavity portionvia an injection molding process via a port on the face portionand/or the bottom portionas described herein or described in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Alternatively, the cavity wall portionmay extend between the bottom portionand a top-and-front transition region (i.e., a transition region between the top portionand the front portion) so that the cavity wall portionand the loft planemay not be parallel to each other. In another example, the cavity wall portionmay extend between the top portionand a bottom-and-front transition region (i.e., a transition region between the bottom portionand the front portion) so that the cavity wall portionand the loft planemay be not parallel to each other. Although, may depict the cavity wall portionsandbeing flat or substantially flat, the cavity wall portionsand/ormay be concave or convex relative to the face portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In the example of, a golf club headmay include a body portionhaving a toe portion, a heel portionthat may include a hosel portionconfigured to receive a shaft (an example shaftshown in) with a grip (an example gripshown in) on one end and the golf club headon the opposite end of the shaft to form a golf club (an example golf clubshown in), a front portionwith a perimeter edge portion, a back portion, a top portion, and a sole portion. The toe portion, the heel portion, the front portion, the back portion, the top portion, and/or the sole portionmay partially overlap each other. The golf club headmay be an iron-type golf club head (e.g., a 1-iron, a 2-iron, a 3-iron, a 4-iron, a 5-iron, a 6-iron, a 7-iron, an 8-iron, a 9-iron, etc.), or a wedge-type golf club head (e.g., a pitching wedge, a lob wedge, a sand wedge, an n-degree wedge such as 44 degrees (°), 48°, 52°, 56°, 60°, etc.). Althoughmay depict a particular type of club head, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of club heads (e.g., a driver-type club head, a fairway wood-type club head, a hybrid-type club head, a putter-type club head, etc.). The material of construction of the golf club headand/or any components thereof may be similar to any materials described herein or in any of the incorporated by reference patent documents for constructing golf club heads. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club headmay include a face portion(i.e., the strike face), which may be integrally formed with the body portion(e.g., a single unitary piece). In one example, as shown in, the face portionmay be a separate piece coupled (e.g., adhesively, mechanically, by welding or soldering) to the body portion. The face portionmay include a front surfaceand a back surface. In one example (not shown), the front portionmay include one or a plurality of recessed shoulders configured to receive the face portionfor attachment of the face portionto the body portion. In another example, as shown in, the back surfacemay include a perimeter portionthat may be attached to the perimeter edge portionof the body portionto attach the face portionto the body portion. The perimeter edge portionof the body portionand the perimeter portionof the face portionmay be attached by one or more fasteners, one or move adhesive or bonding agents, and/or welding or soldering. In one example, as shown in, the perimeter portionof the face portionmay be welded to the perimeter edge portionof the body portionat one or more locations. Alternatively, the entire perimeter portionof the face portionmay be welded to the entire perimeter edge portionof the body portion(i.e., a continuous weld). The face portionmay include a ball strike regionto strike a golf ball. In one example, the center of the ball strike regionmay be a geometric centerof the face portion. In another example, the geometric centerof the face portionmay be offset from a center of the ball strike region. In one example, the geometric centerand one or more regions near and/or surrounding the geometric center within the ball strike regionmay provide a generally optimum location (i.e., optimum ball distance, ball speed, ball spin characteristics, etc.) on the face portionfor striking a golf ball. In yet another example, any location at or near the geometric centerand within the ball strike regionmay provide a generally optimum location on the face portionfor striking a golf ball. However, a ball may be struck with any portion of the face portionwithin the ball strike regionor outside the ball strike regionfor any of the golf club heads described herein resulting in certain ball flight characteristics different from an on-center hit that may be preferred by an individual. The configuration of the face portionand the attachment of the face portion(e.g., welding) to the body portionmay be similar in many respects to the golf club heads described in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The golf club headmay be associated with a ground plane, a horizontal midplane, and a top plane. In particular, the ground planemay be a plane that is parallel or substantially parallel to the ground and is tangent to the lowermost edge of the sole portionwhen the golf club headis at an address position (e.g., the golf club headaligned to strike a golf ball). A top planemay be a plane that is tangent to the uppermost edge of the top portionwhen the golf club headis at the address position. The ground and top planesand, respectively, may be parallel or substantially parallel to each other. The horizontal midplanemay be vertically halfway between the ground and top planesand, respectively. Further, the golf club headmay be associated with a loft planedefining a loft angle() of the golf club head. The loft planemay be a tangential plane to the face portion. The loft anglemay be defined by the loft planeand a vertical planenormal to the ground plane.

The body portionmay be a hollow body including an interior cavityhaving inner walls. The interior cavitymay extend between the front portion, the back portion, the top portion, and the sole portion. In the example of, the interior cavityof the body portionmay be enclosed with and partially defined with the face portion. The configuration of the interior cavity(e.g., height, width, volume, shape, etc.), the configuration of the interior cavityrelative to the body portion(e.g., volume of the interior cavityrelative to the volume of body portion), the width and height variation, and access to the interior cavityfrom one or more ports on the body portionmay be similar to the golf club heads described in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Further, the body portionmay include one or more ports, which may be exterior ports and/or interior ports (e.g., located inside the body portion). The inner wallsof the interior cavitymay include one or more ports. In one example, as shown in, the back portionmay include one or more ports along or proximate to a periphery of the body portion. For example, the body portionmay include a first set of ports(e.g., shown as ports,, and), a second set of ports(e.g., shown as ports,, and), and a third set of ports(e.g., shown as portsand). The locations, spacing relative to other ports, and any other configuration of each port of the first set of ports, the second set of ports, and/or the third set of portsmay be similar in many respects to any of the ports described herein or described in any of the incorporated by reference patent documents. Further, any one or more of the ports of the first set of ports, the second set of ports, and/or the third set of portsmay be connected to interior cavitythrough which one or more filler materials may be injected into the interior cavity. In the example of, the portmay be connected to the interior cavityvia an opening. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Each port of the first set of portsmay be separated by a distance less than the port diameter of any of the ports of the first set of ports. Each port of the second set of portsmay be separated by a distance less than the port diameter of any of the ports of the second set of ports. Each port of the third set of ports third set of portsmay be separated by a distance less than the port diameter of any of the ports of the third set of ports. The first set of portsand the second set of portsmay be spaced apart by a distance substantially greater than the port diameter of any of the ports of the first set of portsand the second set of ports. In one example, the second set of portsand the third set of portsmay be spaced apart by a distance less than the port diameter of any of the ports of the second set of portsand the third set of ports. In another example, as shown in, the second set of portsand the third set of portsmay be spaced apart by a distance substantially greater than the port diameter of any of the ports of the second set of portsand the third set of ports. In one example, the portion of the body portionbetween the second set of portsand the third set of portsmay generally correspond or be aligned with the ball strike regionand may be devoid of any ports. In another example (not shown), the second set of portsand the third set of portsmay extend continuously and with generally equal port spacing from the toe portionto the heel portion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Although the figures may depict the ports as separate and individual parts, each set of the first, second, and third sets of ports,, and, respectively, may be a single port. In one example, all of the first set of ports(e.g., shown as,, and) may be combined into a single port (e.g., a first port). In another example, all of the second set of ports(e.g., shown as,, and) may be combined into a single port (e.g., a second port). In yet another example, all of the third set of ports(e.g., shown asand) may be combined into a single port (e.g., a third port). While the figures may depict a particular number of ports, the apparatus, methods, and articles of manufacture described herein may include more or a smaller number of ports.

The body portionmay include one or more mass portions (e.g., weight portion(s)), which may be integral mass portion(s) or separate mass portion(s) that may be coupled to the body portion. In the illustrated example as shown in, the body portionmay include a first set of mass portions(e.g., shown as mass portions,, and), a second set of mass portions(e.g., shown as mass portions,, and), and a third set of mass portions(e.g., shown as mass portionsand). While the above example may describe a particular number or portions of mass portions, a set of mass portions may include a single mass portion or a plurality of mass portions as described in any of the incorporated by reference patent documents. For example, the first set of mass portionsmay be a single mass portion (e.g., mass portions,, andmay be a single mass portion referred to as a first mass portion). In a similar manner, the second set of mass portionsand/or the third set of mass portionsmay be a single mass portion. Further, the first set of mass portions, the second set of mass portions, and/or the third set of mass portionsmay be a portion of the physical structure of the body portion. The mass portions of the first set of mass portions, the second set of mass portions, and/or third set of mass portionsmay be similar to any of the mass portions described herein or in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The body portionmay be made of a first material whereas the mass portions of the first set of mass portions, the second set of mass portions, and/or the third set of mass portionsmay be made of a second material. The mass portions of the first set of mass portions, the second set of mass portions, and/or the mass portions of the third set mass portionsmay be similar or different materials. The materials of the body portionand any of the mass portions of the first set of mass portions, the second set of mass portions, and/or the third set mass portionsmay be similar to the materials of the body portion and any of the mass portions, respectively, described in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The interior cavitymay be partially or entirely filled with one or more filler materials (i.e., a cavity filling material), which may include one or more similar or different types of materials. In one example, as shown in, the interior cavitymay be filled with a first filler materialand a second filler material. The first filler materialmay be coupled or attached to the back surfaceof the face portion. In one example, the first filler materialmay have inherent adhesive or bonding properties to attach to the back surfaceof the face portion. In another example, the first filler materialmay be attached to the back surfaceof the face portionwith one or more bonding agents or adhesives that may be mixed with the first filler material. In another example, the first filler materialmay be attached to the back surfaceof the face portionwith one or more bonding agents or adhesives that may be separate from the first filler material. In another example, the first filler materialmay be maintained in contact with the back surfaceof the face portionwith the second filler materialas described herein. In yet another example, the first filler materialmay be both bonded to the back surfaceof the face portionas described herein and maintained in contact with the back surfaceof the face portionwith the second filler material. The first filler materialand/or the second filler materialmay be similar to the filler materials described in any of the incorporated by reference patent documents. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The first filler materialmay be coupled to at least a portion of the back surfaceof the face portionthat corresponds to the ball strike regionof the face portion. The first filler materialmay be coupled to regions of the back surfaceof the face portionthat are beyond the ball strike region. The first filler materialmay be coupled to one or more portions the back surfaceof the face portionthat is greater than or equal to 10% and less than or equal to 100% of the area back surfaceof the face portionthat is exposed to the interior cavity. The amount of the first filler materialthat may be coupled to the back surfaceof the face portionmay depend upon the loft angle of the golf club head, the overall thickness of the face portion, the thickness profile of the face portion, the shape of the interior cavity, the locations and configurations of any ports of mass portions, the material properties of the first filler material, and/or the material properties of the second filler material. In one example, a relatively large portion of the back surfaceof the face portionmay be coupled to the first filler materialfor a relatively thin face portionso that the first filler materialprovides sufficient structural support for the face portion. In another example, a golf club head with a relatively higher loft angle may limit the portions of the back surfaceof the face portionto which the first filler materialmay be coupled. In yet another example, the acoustic properties of the golf club head may be a factor in determining the amount of filler materialthat may be coupled to the back surfaceof the face portion to provide a pleasing sound and feel to an individual. The amount of the first filler materialcoupled to the back surfaceof the face portionmay (i) provide vibration dampening or sound dampening (e.g., consistent and/or pleasing sound and feel when the golf club headstrikes a golf ball as perceived by an individual using the golf club head), (ii) provide structural support for the face portion, and/or (iii) optimize ball travel distance, ball speed, ball launch angle, ball spin rate, ball peak height, ball landing angle and/or ball dispersion. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

A width(W) of the first filler materialmay vary from the toe portionto the heel portionand/or from the top portionto the sole portion. The widthof the first filler materialmay be constant or substantially constant from the toe portionto the heel portionand/or from the top portionto the sole portion. The widthof the first filler materialmay be constant or substantially constant at one or more locations in the interior cavityand vary at certain other locations in the interior cavity. In one example, as shown in, the widthof the first filler materialmay vary at one or more locations in the interior cavitysimilar or substantially similar to the contour of all or portions of the inner wallsof the interior cavity(i.e., similar, or substantially similar to the shape of the inner wallsof the interior cavity). Accordingly, the amount of the first filler materialin the interior cavityand/or coupled to the face portionmay be maximized while maintaining a certain gap as further described herein between the first filler materialand the inner wallsof the interior cavity. In another example, the first filler materialat and/or around the ball strike regionof the face portionmay have a relatively large widthto (i) provide vibration dampening or sound dampening (e.g., consistent and/or pleasing sound and feel when the golf club headstrikes a golf ball as perceived by an individual using the golf club head), (ii) provide structural support for the face portion, and/or (iii) optimize ball travel distance, ball speed, ball launch angle, ball spin rate, ball peak height, ball landing angle and/or ball dispersion. The widthof the first filler materialmay be determined at the ball strike regionand/or other regions of the interior cavityso that a relatively high or optimum coefficient of restitution (COR) is provided for the golf club head. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In one example, as shown in, a distance between the first filler materialand the inner wallsof the interior cavitymay define a gap. The size of the gapmay be constant or may vary in the interior cavitysimilar or substantially similar to the shape of the first filler material, the shape of the inner wallsof the interior cavity, the locations of one or more ports that may be connected to the interior cavity, the locations of one or more integral and/or removable mass portions, and/or other factors as described herein. At certain locations in the interior cavity, the size of the gapmay be as small as possible yet provide sufficient space to accommodate the second filler materialbetween the first filler materialand the inner wallsof the interior cavity. In one example, the gap may be a result of manufacturing the golf club head with the first filler materialand the second filler material.

In one example, the gapmay be greater than or equal to 0.001 inch (0.003 cm) and less than or equal to 0.2 inch (0.508 cm). In another example, the gapmay be greater than or equal to 0.007 inch (0.18 cm) and less than or equal to 0.1 inch (0.384 cm). In another example, the gapmay be greater than or equal to 0.015 inch (0.038 cm) and less than or equal to 0.05 inch (0.127 cm). In yet another example, the gapmay be greater than or equal to 0.003 inch (0.008 cm) and less than or equal to 0.38 inch (0.635 cm). The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

As described herein, the widthof the first filler materialmay vary similar or substantially similar to the shape of the inner wallsof the interior cavity. Accordingly, in one example, the variation in the width of the gap(Wg) may be expressed by the following equation:

In one example, Rmay be 2 or less as the widthof the first filler materialvaries similar or substantially similar to the shape of the inner wallsof the interior cavity. In another example, Rmay be 3 or less. Accordingly, the maximum width of the gap(Wg) may be no more than three times the minimum width of the gap(Wg). In yet another example, Rmay be 4 or less. Accordingly, the maximum width of the gap(Wg) may be no more than four times the minimum width of the gap(Wg). The variation in the gapmay be small such that the shape of the first filler materialmay vary similar or substantially similar to the contour of the inner wallsof the interior cavity(i.e., the shape of the inner walls of the interior cavity). While the above examples may describe particular ratios of Wgto Wg, the apparatus, methods, and articles of manufacture described herein may include greater ratios of Wgto Wg. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The back surfaceof the face portionmay include a perimeter portion, which may be attached to the perimeter edge portionof the body portionas described herein. Accordingly, the back surfaceof the face portionmay include an inner surface portionexposed to the interior cavity. The inner surface portionmay also define a boundary of the interior cavity(i.e., the front boundary of the interior cavity). In one example (not shown), the first filler materialmay be coupled the entire inner surface portionof the face portion. In another example, as shown in, the first filler materialmay be coupled to a portion of the inner surface portionof the face portion. Accordingly, the first filler materialmay include a frontal areaattached to the inner surface portionof the face portion. In one example, a relationship between the frontal areaof the first filler material(the area of the front surface of the first filler materialattached to the face portion) (FA) and the area of the inner surface portionof the face portion(BA) may be expressed by the following equation:

The loft angle α as used herein may be associated with the type of iron golf club head such as a 5-iron golf club, a 7-iron golf club, or a wedge-type golf club. For example, a 5-iron golf club head may have a loft angle α of 380±2°. In another example, a 7-iron golf club head may have a loft angle α of 440±2°. In yet another example, a wedge-type golf club head may have a loft angle α of 5°±2°. Accordingly, any loft angle expressed herein may vary by ±2° for the same type of iron golf club head. While the above examples may describe particular iron-type golf club heads, the apparatus, methods, and articles of manufacture described herein may include a driver-type golf club head, a fairway-wood-type golf club head, a hybrid-type golf club head, a putter-type golf club head, or other types of golf club heads. Further, although the above examples may describe particular loft angles, the apparatus, methods, and articles of manufacture described herein may include greater or less loft angles. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The upper and lower values of the coefficients Aand Amay define the upper and lower boundaries of the ratio of the frontal areaof the first filler materialto the area of the inner surface portionof the face portion. In one example, according to Equation (2) and assuming a value of −0.0018 for the coefficient A, upper, and lower boundaries of a ratio of the frontal areaof the first filler materialto the area of the inner surface portionof the face portionfor a set of iron-type golf club heads may be determined as shown in Table 1.

The loft angle of a golf club head may determine the structural configuration of the golf club head. Accordingly, golf club heads with different loft angles may have different internal cavity shapes, port locations, mass portion locations, filler material volumes, different CG locations, different size face portions, or different golf club head cross sectional shapes. In one example, a golf club head with a relatively higher loft angle may have a generally smaller cavity width profile than a golf club head with a lower loft angle. Accordingly, the value of FA/BAfor the golf club with the relatively higher loft angle may be generally smaller than the golf club head with the lower loft angle due to the difference in the amount of filler materials that may be provided in the interior cavities of each golf club head as described herein. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

In another example, a relationship between the volume of the first filler materialand the volume of the interior cavity(V) may be expressed by the following equation: