Golf club heads with insert and related methods

Some embodiments include a golf club head with an insert. Other embodiments for related golf club heads and methods are also disclosed.

TECHNICAL FIELD

This disclosure relates generally to sports equipment, and relates more particularly to golf club heads and related methods.

BACKGROUND

Golf club heads often include various features that can be designed or configured to improve one or more characteristics of their respective golf club heads. For example, tuning elements may be added to adjust or restrict impact vibrations upon impact with a golf ball, and/or to reinforce some features of the golf club head. The addition of such tuning elements, however, may detrimentally affect some other characteristics of the golf club heads, such as by adding extra mass, by repositioning the center of gravity of the golf club head towards one or more less desirable locations, and/or by decreasing durability of the golf club head. Additionally, manufacturing golf club heads having certain port structures for tuning elements can involve complex processes. Furthermore, tuning elements sometimes can become inadvertently dislodged from port structures in various port structure designs and/or tuning element designs. Accordingly, further developments with respect to positioning of golf club tuning elements can enhance the performance and/or manufacturability of golf clubs.

The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements mechanically and/or otherwise. Two or more mechanical elements may be mechanically coupled together, but not be electrically or otherwise coupled together. Coupling may be for any length of time, e.g., permanent or semi-permanent or only for an instant. “Mechanical coupling” and the like should be broadly understood and include mechanical coupling of all types.

The absence of the word “removably,” “removable,” and the like near the word “coupled,” and the like does not mean that the coupling, etc. in question is or is not removable.

DESCRIPTION OF EXAMPLES OF EMBODIMENTS

Some embodiments include a golf club head. The golf club head includes a strike portion including a strikeface and a backface opposite the strikeface. The backface includes a perimeter portion at a top end of the backface. The golf club head further includes a rear portion coupled to the strike portion at a bottom end of the strike portion. The golf club head additional includes a port structure at least partially defined within the rear portion. The port structure includes a slot extending from a slot opening to a slot base. The bottom end of the strike portion is located closer to the slot base than the slot opening. The slot includes a heel wall and a toe wall. The slot further includes a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The rear wall includes a first rear wall curve along a first direction extending between the slot opening and the slot base. The slot further includes a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The strike face being located closer to the front wall than the rear wall. The front wall includes a first front wall curve along the first direction.

Additional embodiments include a method of providing a golf club head. The method includes providing a strike portion. The strike portion includes a strikeface and a backface opposite the strikeface. The backface includes a perimeter portion at a top end of the backface. The method further includes providing a rear portion coupled to the strike portion at a bottom end of the strike portion. The method additionally includes providing a port structure at least partially defined within the rear portion. The port structure includes a slot extending from a slot opening to a slot base. The method also includes coupling a tuning element to the port structure. The bottom end of the strike portion is located closer to the slot base than the slot opening. The slot includes a heel wall and a toe wall. The slot also includes a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The rear wall includes a first rear wall curve along a first direction extending between the slot opening and the slot base. The slot further includes a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The strike face being located closer to the front wall than the rear wall. The front wall includes a first front wall curve along the first direction.

Further embodiments include a method of forming a golf club head. The method can include providing a first mold piece including a first cavity portion and a tooling piece. The tooling piece can be configured to rotate with respect to the first mold piece about a fixed point on the first mold piece from a mold position to a release position. The method also can include providing a second mold piece including a second cavity portion. The method further can include closing the second mold piece to the first mold piece such that the first and second mold pieces surround the first and second cavity portions, the tooling piece can be in the mold position, and a portion of the tooling piece can be inserted into at least the first cavity portion. The method additionally can include molding an injection mold in the first and second cavity portions. The injection mold can include a golf club head mold including a strike portion, a rear portion, and a port structure at least partially defined within the rear portion. The portion of the tooling piece can be conformal with the port structure. The method further can include opening the second mold piece from the first mold piece such that the tooling piece can be rotated about the fixed point away from the mold position in the port structure to the release position.

Various embodiments include a golf club head. The golf club head includes a strike portion including a strikeface and a backface opposite the strikeface. The backface includes a perimeter portion at a top end of the backface. The golf club head further includes a rear portion coupled to the strike portion at a bottom end of the strike portion. The golf club head additional includes a port structure at least partially defined within the rear portion. The port structure includes a slot extending from a slot opening to a slot base. The bottom end of the strike portion is located closer to the slot base than the slot opening. The slot includes a heel wall and a toe wall. The slot further includes a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The rear wall includes a first rear wall curve along a first direction extending between the slot opening and the slot base. The slot further includes a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The strike face being located closer to the front wall than the rear wall. The front wall includes a first front wall curve along the first direction. A minimum lower thickness of the strikeface measured from the strikeface to the front wall is less than a minimum upper thickness of the strikeface measured from the strikeface to the backface.

Some embodiments include a golf club. The golf club includes a golf club head and a shaft coupled to the golf club head. The golf club head includes a strike portion including a strikeface and a backface opposite the strikeface. The backface includes a perimeter portion at a top end of the backface. The golf club head further includes a rear portion coupled to the strike portion at a bottom end of the strike portion. The golf club head additional includes a port structure at least partially defined within the rear portion. The port structure includes a slot extending from a slot opening to a slot base. The bottom end of the strike portion is located closer to the slot base than the slot opening. The slot includes a heel wall and a toe wall. The slot further includes a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The rear wall includes a first rear wall curve along a first direction extending between the slot opening and the slot base. The slot further includes a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The strike face being located closer to the front wall than the rear wall. The front wall includes a first front wall curve along the first direction. A minimum lower thickness of the strikeface measured from the strikeface to the front wall is less than a minimum upper thickness of the strikeface measured from the strikeface to the backface.

Additional embodiments include a method of providing a golf club head. The method includes providing a strike portion. The strike portion includes a strikeface and a backface opposite the strikeface. The backface includes a perimeter portion at a top end of the backface. The method further includes providing a rear portion coupled to the strike portion at a bottom end of the strike portion. The method additionally includes providing a port structure at least partially defined within the rear portion. The port structure includes a slot extending from a slot opening to a slot base. The method also includes coupling a tuning element to the port structure. The bottom end of the strike portion is located closer to the slot base than the slot opening. The slot includes a heel wall and a toe wall. The slot also includes a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The rear wall includes a first rear wall curve along a first direction extending between the slot opening and the slot base. The slot further includes a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall. The strike face being located closer to the front wall than the rear wall. The front wall includes a first front wall curve along the first direction. A minimum lower thickness of the strikeface measured from the strikeface to the front wall is less than a minimum upper thickness of the strikeface measured from the strikeface to the backface.

Turning to the drawings,FIG. 1illustrates a heel-side, bottom, rear perspective view of a golf club head100with an insert or tuning element150, according to an embodiment.FIG. 2illustrates a bottom, rear view of golf club head100with tuning element150. Golf club head100is merely exemplary and embodiments of the golf club head are not limited to the embodiments presented herein. The golf club head can be employed in many different embodiments or examples not specifically depicted or described herein. In a number of embodiments, golf club head100can be an iron-type club head, a wedge-type club head, or a hybrid-type club head. For example, in some embodiments, golf club head100can have a loft angle of approximately 15 degrees to approximately 70 degrees. Further, in some embodiments, golf club head100can have a loft angle of greater than or equal to approximately 10 degrees, greater than or equal to approximately 15 degrees, greater than or equal to approximately 20 degrees, greater than or equal to approximately 25 degrees, greater than or equal to approximately 30 degrees, greater than or equal to approximately 15 degrees, greater than or equal to approximately 35 degrees, greater than or equal to approximately 40 degrees, greater than or equal to approximately 45 degrees, greater than or equal to approximately 50 degrees, greater than or equal to approximately 55 degrees, greater than or equal to approximately 60 degrees, or greater than or equal to approximately 65 degrees. In a number of embodiments, golf club head100can have a head weight of approximately 200 grams (g) to approximately 325 g. In various embodiments, golf club head100can have a lie angle of approximately 50 degrees to approximately 70 degrees. In many embodiments, golf club head100can include a toe end101and a heel end102. In various embodiments, golf club head100can include a strike portion110, which can include a strikeface111and a backface112. In certain embodiments, strikeface111can be an insert, such as a strikeplate insert (not shown) in strike portion110. In other embodiments, strikeface111can be integral with strike portion110. Backface112can be opposite strikeface111. In various embodiments, backface112can include a perimeter portion113at a top end of backface112. In many embodiments, perimeter portion113can extend around the top end and sides of backface112at or proximate to toe end101and/or heel end102. Perimeter portion113can protrude rearward from backface112.

In various embodiments, golf club head100can include a rear portion120. Rear portion120can be coupled to strike portion110at the bottom end of strike portion110. Rear portion120can include a sole121. In a number of embodiments, at least a portion of sole121can be substantially or approximately horizontal when golf club head100is at the address position, such that cross-sectional lines3-3and5-5can be substantially or approximately vertical when golf club head100is at the address position. In many embodiments, strike portion110can be integral with rear portion120, such that strike portion110and rear portion120can be a single piece of material. In other embodiments, strike portion110can be a separate piece (or more than one separate piece) of material fastened to rear portion120, such as by welding, brazing, adhering, and/or other mechanical or chemical fasteners. In many embodiments, rear portion120and/or strike portion110can include one or more materials, including ferrous materials such as steel, carbon steel, stainless steel, and/or steel alloys, and/or non-ferrous materials such as titanium, tungsten, and/or aluminum. In a number of embodiments, one or more of the materials used in rear portion120and/or strike portion110can have a high shear modulus and/or a high strength-to-weight ratio. In some embodiments, rear portion120and/or strike portion110can have a density of approximately 2.8 g per cubic centimeter (cc) (g/cc) to approximately 18.0 g/cc. For example, rear portion120and/or strike portion110can have a density of approximately 2.8 g/cc, 3.0 g/cc, 3.5 g/cc, 4.0 g/cc, 4.5 g/cc, 5.0 g/cc, 5.5 g/cc, 6.0 g/cc, 6.5 g/cc, 7.0 g/cc, 7.5 g/cc, 8.0 g/cc, 8.5 g/cc, 9.0 g/cc, 9.5 g/cc, 10.0 g/cc, 10.5 g/cc, 11.0 g/cc, 11.5 g/cc, 12.0 g/cc, 12.5 g/cc, 13.0 g/cc, 13.5 g/cc, 14.0 g/cc, 14.5 g/cc, 15.0 g/cc, 15.5 g/cc, 16.0 g/cc, 16.5 g/cc, 17.0 g/cc, 17.5 g/cc, 18.0 g/cc, or any other suitable density value in between those density values, and can range from any one of those density values to any other one of those density values. For example, rear portion120and/or strike portion110for certain hybrid-type golf club heads can have a density of approximately 4.0 g/cc to approximately 8.0 g/cc. As another example, rear portion120and/or strike portion110in certain iron-type golf club heads or certain wedge-type golf club heads can have a density of approximately 7.0 g/cc to approximately 8.0 g/cc. Rear portion120and/or strike portion110in other iron-type, wedge-type, and/or hybrid-type golf club heads can have other suitable densities.

In a number of embodiments, golf club head100can include tuning element150and a port structure for holding and/or securing tuning element150, such as port structure330(as shown inFIGS. 3-5 and 9-11, and described below). Turning ahead in the drawings,FIG. 3illustrates a side cross-sectional view of a golf club head100, where the cross-sectional view is taken along cross-sectional line3-3inFIG. 2, but where golf club head100inFIG. 3is illustrated without tuning element150, according to an embodiment.FIG. 4illustrates a side cross-sectional view of golf club head100, where the cross-sectional view is taken along cross-sectional line3-3inFIG. 2, where golf club head100inFIG. 3is illustrated with radii of curvature and without tuning element150.FIG. 5. illustrates a side cross-sectional view of golf club head100, where the cross-sectional view is taken along cross sectional line5-5inFIG. 2, but where golf club head100inFIG. 5is illustrated without tuning element150. In a number of embodiments, golf club head100can include a port structure330. Port structure330can be at least partially defined within rear portion120. In certain embodiments, port structure330can be at least partially defined within strike port110. In many embodiments, port structure330can be defined within both rear portion120and strike portion110. In certain other embodiments, port structure330can be defined solely within rear portion120.

In various embodiments, port structure330can include a slot331, which can extend from a slot opening332to a slot base333. In many embodiments, slot331can be configured to receive a main portion651(as shown inFIGS. 6-8, described below) of tuning element150(FIGS. 1-2), as described below in further detail. In many embodiments, slot331can include a toe wall334and a heel wall537. Toe wall334can be at the side of golf club head100and/or slot331located closer to toe end101(FIGS. 1-2), and heel wall537can be at the side of golf club head100and/or slot331located closer to heel end102(FIGS. 1-2). Slot331can extend between toe wall334and heel wall537. In many embodiments, toe wall334and/or heel wall537can extend from slot opening332to slot base333. In a number of embodiments, slot331can include a rear wall335and a front wall336. In various embodiments, rear wall335can extend from slot opening332to slot base333, and/or can extend between heel wall537and toe wall334. In some embodiments, front wall336can extend from slot opening332to slot base333, and/or can extend between heel wall537and toe wall334. Slot331can extend between front wall336and rear wall335. In a number of embodiments, strike face111can be located closer to front wall336than rear wall335. In some embodiments, front wall335also can be located closer to strikeface111than rear wall335.

The interfaces between toe wall334, rear wall335, heel wall537, and front wall336can be angled acutely, orthogonally, or obtusely, or can be rounded. For example, in some embodiments, slot331can be tubular, such that the interfaces between toe wall334, rear wall335, heel wall537, and front wall336do not include an angled edge, but even so, slot331can still be considered to have a toe wall, a rear wall, a heel wall, and a front wall. In such embodiments, the toe wall is the portion of the tubular wall that is adjacent to toe end101, and heel wall537is the portion of the tubular wall that is adjacent to heel end102, and so on. In a number of other embodiments, heel wall537can be at an angle of greater than 90 degrees with respect to rear wall335, and/or toe wall334can be at an angle of greater than 90 degrees with respect to rear wall335. In various embodiments, heel wall537can be at an angle of less than 90 degrees with respect to rear wall335, and/or toe wall334can be at an angle of less than 90 degrees with respect to rear wall335. In several embodiments, heel wall537can be orthogonal with respect to rear wall335, and/or toe wall334can be orthogonal with respect to rear wall335. As suggested above, these angles can exist even if the walls do not include angled edges when transitioning to the next or adjacent wall. In a number of embodiments, heel wall537and/or toe wall334can be substantially or approximately straight. In other embodiments, heel wall537and/or toe wall334can be curved.

In many embodiments, port structure330, slot331, and/or one or more elements thereof can have an arcuate shape in one or more directions. For example, rear wall335can be curved and have a rear wall curve in a first direction extending between slot opening332and slot base333, as shown inFIGS. 3-5. As another example, front wall336can be curved and have a front wall curve in the first direction extending between slot opening332and slot base333, as shown inFIGS. 3-5. In several embodiments, the front wall curve and/or rear wall curve in the first direction extending between slot opening332and slot base333can have a circular, elliptical, oval, or other curved shape.

In many embodiments, such as shown inFIG. 4, the rear wall curve extending along the first direction of rear wall335can be a portion of a circle445having a radius447, and/or the front wall curve extending along the first direction of front wall336can be a portion of a circle446having a radius448. A center of circle445can be determined by drawing two lines normal to the curve of rear wall335and finding the intersection of the two lines. The intersection of the two lines normal to rear wall335is the center of circle445. Similarly, a center of circle446can be determined by drawing two lines normal to the curve of front wall336and finding the intersection of the two lines. The intersection of the two lines normal to front wall336is the center of circle446. In geometry, the curvature of a circle is the reciprocal of the radius of the circle. A circle with a small radius has a high curvature (smaller circles bend more sharply than larger circles), and a circle with a large radius has a small curvature. In some embodiments, a curvature of circle445is larger than a curvature of circle446. In other embodiments, the curvature of circle445is smaller than the curvature of circle446. In some embodiments, the curvature of circle445is approximately the same as the curvature of circle446.

In a number of embodiments, circle445and circle446can be substantially or approximately concentric, such that a middle portion of front wall336between heel wall537and toe wall334can be a substantially or approximately constant distance from a middle portion of rear wall335between heel wall537and toe wall334when moving along the first direction. In the same or other embodiments, front wall336can be a substantially or approximately constant distance from rear wall335at any corresponding portion of front wall336and rear wall334when moving along the first direction. For example, in the cross-sectional slice shown inFIG. 4, radius448can be approximately 1.2 inches (3.048 cm), and front wall336can be approximately 0.2 inch (0.508 cm) from rear wall335when moving along the first direction. For manufacturing and/or assembly purposes, the distance between the middle portions of front wall336and rear wall335can be substantially or approximately constant even when the distance decreases slightly (e.g., up to ten percent (10%)) when moving along the first direction from slot opening332towards slot base333. In many embodiments, front wall336can be approximately 0.025 inch (0.0635 cm) to approximately 0.5 inch (0.254 cm) from rear wall335. For example, front wall336can be approximately 0.025 inch (0.0635 cm), 0.05 inch (0.127 cm), 0.075 inch (0.1905 cm), 0.1 inch (0.254 cm), 0.125 inch (0.3175 cm), 0.15 inch (0.381 cm), 0.175 inch (0.4445 cm), 0.2 inch (0.508 cm), 0.225 inch (0.5715 cm), 0.25 inch (0.635 cm), 0.275 inch (0.6985 cm), 0.3 inch (0.762 cm), 0.325 inch (0.8255 cm), 0.35 inch (0.889 cm), 0.375 inch (0.9525 cm), 0.4 inch (1.016 cm), 0.425 inch (1.0795 cm), 0.45 inch (1.143 cm), 0.475 inch (1.2065 cm), or 0.5 inch (1.27 cm) from rear wall335when moving along the first direction, or can be any other suitable distance in between those distance values, and can range from any one of those distance values to any other one of those distance values.

In other embodiments, circle445and circle446can have centers that are not concentric, such that front wall336can be a variable distance from rear wall335when moving along the first direction. In some embodiments, for example, the distance between front wall336and rear wall335can narrow when moving along the first direction extending from slot opening332to slot base333, which can beneficially allow tuning element150(FIGS. 1-2) to be received more easily in port structure330and/or removed more easily from port structure330due at least in part from less friction of tuning element150against rear wall335and front wall336and/or little to no air remaining in an air pocket beneath tuning element150. In some embodiments with the distance between front wall336and rear wall335narrowing when moving along the first direction extending from slot opening332to slot base333, an air pocket is not formed at slot base333. In other embodiments, the distance between front wall336and rear wall335can widen when moving along the first direction extending from slot opening332to slot base333. In a number of embodiments, the distance between the center of circle445and the center of circle446can be approximately 0 inch (0 cm) to approximately 5.0 inch (12.7 cm). For example, the distance between the center of circle445and the center of circle446can be approximately 0 inch (0 cm), 0.005 inch (0.0127 cm), 0.01 inch (0.0254 cm), 0.015 inch (0.0381 cm), 0.02 inch (0.0508 cm), 0.025 inch (0.0635 cm), 0.03 inch (0.0762 cm), 0.04 inch (0.1016 cm), 0.05 inch (0.127 cm), 0.06 inch (0.1524 cm), 0.07 inch (0.1778 cm), 0.08 inch (0.2032 cm), 0.09 inch (0.2286 cm), 0.1 inch (0.254 cm), 0.125 inch (0.3175 cm), 0.15 inch (0.381 cm), 0.175 inch (0.4445 cm), 0.2 inch (0.508 cm), 0.225 inch (0.5715 cm), 0.25 inch (0.635 cm), 0.275 inch (0.6985 cm), 0.3 inch (0.762 cm), 0.35 inch (0.889 cm), 0.4 inch (1.016 cm), 0.45 inch (1.143 cm), 0.5 inch (1.27 cm), 0.6 inch (1.524 cm), 0.7 inch (1.778 cm), 0.8 inch (2.032 cm), 0.9 inch (2.286 cm), 1.0 inch (2.54 cm), 1.25 inches (3.175 cm), 1.5 inches (3.81 cm), 1.75 inches (4.445 cm), 2.0 inches (5.08 cm), 2.25 inches (5.715 cm), 2.5 inches (6.35 cm), 2.75 inches (6.985 cm), 3.0 inches (7.62 cm), 3.25 inches (8.255 cm), 3.5 inches (8.89 cm), 3.75 inches (9.525 cm), 4.0 inches (10.16 cm), 4.25 inches (10.795 cm), 4.5 inches (11.43 cm), 4.75 inches (12.065 cm), 5.0 inches (12.7 cm), or any other suitable distance in between those distance values, and can range from any one of those distance values to any other one of those distance values. When the centers of circles445and446are substantially or approximately concentric, the distances between the centers can be approximately 0 inch (0 cm) to 0.075 inch (0.1905 cm).

In some embodiments, such as shown inFIG. 4, the centers of circle445and circle446can be located closer to rear wall335than front wall336, such that radius447can be smaller than radius448. As shown inFIG. 4, front wall336can be concave in the first direction in slot331(as viewed from the perspective of inside slot331), and/or rear wall335can be convex in the first direction in slot331(as viewed from the same perspective of inside slot331). In other embodiments, front wall336can be convex in slot331, and/or rear wall335can be concave in slot331. In such embodiments, for example, the centers of circle445and circle446can be located closer to front wall336than rear wall335, such that radius448can be smaller than radius447. In some embodiments, a majority of front wall336and/or rear wall335can be substantially curved in the first direction. In several embodiments, the centers of circle445and/or circle446can be located outside of golf club head100. In other embodiments, the centers of circle445and/or circle446can be located inside golf club head100.

In many embodiments, slot331can be oriented such that the bottom end of strike portion110is located closer to slot base333than slot opening332. In some embodiments, slot331also can be oriented such that slot base333is located closer to the bottom end of strike portion110than slot opening332. In some embodiments, at least a portion of rear wall335and/or front wall336can be parallel to strikeface111. In various embodiments, at least a portion of rear wall335and/or front wall336can extend in substantially the same direction as strikeface111. In many embodiments, a distance between strikeface111and front wall336can be greater at slot base333than at slot opening332, such as shown inFIGS. 3-5, which can advantageously provide increased durability of golf club head100on lower portions of strike portion110. In certain embodiments, at least a portion of rear wall335and/or front wall336can be parallel to at least a portion of sole121. In other embodiments, slot331can have other suitable orientations within golf club head100.

In several embodiments, at least a portion of front wall336can be located closer to strikeface111than at least a portion of backface112. In some embodiments, the distance between strikeface111and front wall336at slot opening332can be less than the distance between strikeface111and at least a portion of backface112. For example, the thickness of strike portion110at the top of strike portion110at perimeter portion113can be greater than the distance between strikeface111and front wall336at slot opening332. In many embodiments, backface112can be at least partially concave. For example, as shown inFIGS. 3-5, backface112can curve concavely between perimeter portion113and rear portion120. In some embodiments, the concave curve of backface112can be parallel to, or otherwise similar to, the curves of at least one of rear wall335or front wall336. In many embodiments, the concave curve to backface112can beneficially facilitate simpler manufacturing of golf club head100, such that, even when the thickness of strike portion110at a portion of backface112is greater than the distance between strikeface111and front wall336at slot opening332, port structure330and/or slot331can be cast with a tooling pick piece that can be removed in one motion without interfering with backface112, such as by simply rotating the tooling pick piece about a fixed point. For example, the tooling pick piece can be similar to tooling piece1390, as shown inFIGS. 13-14and described below.

In a number of embodiments, front wall336can be curved and have a front wall curve in a second direction perpendicular to the first direction and extending between heel wall537and toe wall334. In other embodiments, front wall336can be substantially or approximately straight along the second direction. In several embodiments, rear wall335can be curved and have a rear wall curve in the second direction. In other embodiments, rear wall335can be substantially or approximately straight along the second direction. The front wall curve and/or rear wall curve in the second direction extending between heel wall537and toe wall334can at least partially have a circular, elliptical, oval, or other arcuate shape. As an example, as shown inFIGS. 3-5, front wall336can be concave in the second direction in slot331, and rear wall335can be substantially or approximately straight in the second direction in slot331. In some embodiments, front wall336can be a shorter distance from rear wall336at heel wall537and/or at toe wall334than at a midpoint between heel wall537and toe wall334. In some embodiments, a majority of front wall336and/or rear wall335can be substantially curved in the second direction. In various embodiments, a majority of front wall336and/or rear wall335can be substantially or approximately straight in the second direction.

In many embodiments, port structure330can include a cap recess340at slot opening332, which can be configured to receive a cap661(as shown inFIGS. 6-8, described below) of tuning element150(FIGS. 1-2), as described below in further detail. In many embodiments, cap recess340can extend around and beyond front wall336, rear wall335, toe wall334, and/or heel wall537at slot opening332. In some embodiments, cap recess340can extend beyond front wall336to backface112. In a number of embodiments, cap recess340can circumscribe or otherwise extend beyond slot331at slot opening332by approximately 0.02 inch (0.0508 cm) to approximately 0.1 inch (0.254 cm) around the entire perimeter of slot331. For example, cap recess340can extend approximately 0.02 inch (0.0508 cm), 0.03 inch (0.0762 cm), 0.04 inch (0.1016 cm), 0.05 inch (0.127 cm), 0.06 inch (0.1524 cm), 0.07 inch (0.1778 cm), 0.08 inch (0.2032 cm), 0.9 inch (0.2286 cm), or any other suitable distance in between those distance values, and can range from any one of those distance values to any other one of those distance values. In some embodiments, for example, cap recess340can extend beyond slot331at slot opening332approximately 0.03 inch (0.0762 cm) to approximately 0.07 inches (0.1778 cm). For example, at least a portion of cap recess340can extend beyond slot331at slot opening332approximately 0.5 inch (2.54 cm), such as shown inFIGS. 3-5. In some embodiments, cap recess340can extend beyond slot331at slot opening332variable or otherwise different distances on one or more sides of slot opening332. In other embodiments, port structure330does not include cap recess340, such as for a tuning element without a cap.

Turning ahead in the drawings,FIG. 6illustrates a side view of tuning element150, according to an embodiment.FIG. 7illustrates a rear view of tuning element150.FIG. 8illustrates a top view of tuning element150. Tuning element150is merely exemplary and embodiments of the tuning element are not limited to the embodiments presented herein. The tuning element can be employed in many different embodiments or examples not specifically depicted or described herein.

In several embodiments, tuning element150can be located within and/or be substantially conformal with port structure330(FIGS. 3-5). In many embodiments, tuning element150can include a main portion651and a cap661. In other embodiments, tuning element150can include main portion651without cap661, such as when port structure330does not include cap recess340(FIGS. 3-5). In certain embodiments, main portion651and cap661can be made of the same material or materials. In a number of embodiments, main portion651can be integral and/or co-molded with cap661. In other embodiments, main portion651can be a separate piece of material fastened to cap661, such as by welding, brazing, adhering, and/or other mechanical or chemical fasteners. In some embodiments, tuning element150can be injection molded, machined, sintered, or made or placed in port structure330(FIGS. 3-5) by other suitable processes. In various embodiments, tuning element150can be made of the same or different materials than rear portion120(FIGS. 1-5) or strike portion110(FIGS. 1-5). In certain embodiments, tuning element150can be made of one or more elastomers. For example, tuning element150can be made of nonferrous thermoplastic urethane, thermoplastic elastomeric polymer(s), hybrid plastics with a mix of ferrous particles or other alloy ferrous particles mixed into polyurethane or other elastomeric polymers. In other embodiments, tuning element150can be a metal such as aluminum, steel, tungsten, or other suitable metals, such as when tuning element150is sintered or machined.

In many embodiments, main portion651of tuning element150can include a tuning element rear side655, a tuning element front side656, a tuning element heel side757, a tuning element toe side654, and/or a tuning element bottom side653. The interfaces between tuning element rear side655, tuning element heel side757, tuning element front side656, and tuning element toe side654can be angled acutely, orthogonally, or obtusely, or can be rounded. For example, in some embodiments, main portion651can be rounded, such that the interfaces between tuning element rear side655, tuning element heel side757, tuning element front side656, and tuning element toe side654do not include an angled edge. In a number of embodiments, tuning element heel side757can be at an angle of greater than 90 degrees with respect to tuning element rear side655, and/or tuning element toe side654can be at an angle of greater than 90 degrees with respect to tuning element rear side655, as shown inFIG. 7. In various embodiments, tuning element heel side757can be at an angle of less than 90 degrees with respect to tuning element rear side655, and/or tuning element toe side654can be at an angle of less than 90 degrees with respect to tuning element rear side655. In several embodiments, tuning element heel side757can be orthogonal with respect to tuning element rear side655, and/or tuning element toe side654can be orthogonal with respect to tuning element rear side655.

In a number of embodiments, cap661of tuning element150can include a cap rear side665, a cap front side666, a cap heel side767, a cap toe side664, a cap bottom lip663, and/or a cap top side668. The interfaces between cap rear side665, cap heel side767, cap front side666, and cap toe side664can be angled acutely, orthogonally, or obtusely, or can be rounded. For example, in some embodiments, cap661can be rounded, such that the interfaces between cap rear side665, cap heel side767, cap front side666, and cap toe side664do not include an angled edge. In a number of embodiments, cap heel side767can be at an angle of greater than 90 degrees with respect to cap rear side665, and/or cap toe side664can be at an angle of greater than 90 degrees with respect to cap rear side665, as shown inFIGS. 7-8. In various embodiments, cap heel side767can be at an angle of less than 90 degrees with respect to cap rear side665, and/or cap toe side664can be at an angle of less than 90 degrees with respect to cap rear side665. In several embodiments, cap heel side767can be orthogonal with respect to cap rear side665, and/or cap toe side664can be orthogonal with respect to cap rear side665. In many embodiments, cap heel side767can have the same or similar orientation as tuning element heel side757, cap toe side664can have the same or similar orientation as tuning element toe side654, cap rear side665can have the same or similar orientation as tuning element rear side655, and/or cap front side666can have the same or similar orientation as tuning element front side656. In some embodiments, cap661can be optional on tuning element150, and/or cap recess340(FIGS. 3-5) can be optional on port structure330(FIGS. 3-5). For example, tuning element150can, in some embodiments, not include cap661and can sit flush in port structure330(FIGS. 3-5) without port recess340(FIGS. 3-5) at slot opening332(FIGS. 3-5), or tuning element150can protrude slightly from, or be slightly recessed within, slot opening332(FIGS. 3-5).

In many embodiments, tuning element150or one or more elements of tuning element150can have an arcuate shape in one or more directions. For example, tuning element rear side655and/or cap rear side665can be curved in a first direction extending between cap top side668and tuning element bottom side653. As another example, tuning element front side656can be curved in the first direction extending between cap top side668and tuning element bottom side653. In several embodiments, the curves of tuning element rear side655and/or tuning element front side656in the first direction extending between cap top side668and tuning element bottom side653can have a circular, elliptical, oval, or other curved shape, and in many embodiments can be matched or correlated with rear wall335(FIGS. 3-5) and/or front wall336(FIGS. 3-5) of slot331(FIGS. 3-5) in the first direction. For example, tuning element rear side655can have a radius in the first direction that is similar or identical to the radius447(FIG. 4) of circle445(FIG. 4), as described above in connection with rear wall335(FIGS. 3-5). As another example, tuning element front side656can have a radius in the first direction that is similar or identical to radius448(FIG. 4) of circle446(FIG. 4), as described above in connection with front wall336(FIGS. 3-5). In many embodiments, such as shown inFIG. 6, the curves of tuning element rear side655and/or tuning element front side656extending along the first direction can each be a portion of a circle. In certain embodiments, each circle can be concentric. In a number of embodiments, tuning element front side656can be a substantially or approximately constant distance from tuning element rear side655when moving along the first direction. In a number of embodiments, such as shown inFIG. 6, tuning element rear side655can be concave in the first direction and tuning element front side656can be convex in the first direction. In other embodiments, tuning element rear side655can be convex in the first direction and tuning element front side656can be concave in the first direction.

In a number of embodiments, tuning element front side656and/or cap front side666can be curved in a second direction perpendicular to the first direction and extending between tuning element heel side757and tuning element toe side654. In other embodiments, tuning element front side656and/or cap front side666can be substantially or approximately straight along the second direction. In several embodiments, tuning element rear side655and/or cap rear side665can be curved in the second direction. In other embodiments, tuning element rear side655and/or cap rear side665can be substantially or approximately straight along the second direction. In a number of embodiments, the curves of tuning element rear side655and/or tuning element front side656in the second direction extending between extending between tuning element heel side757and tuning element toe side654can at least partially have a circular, elliptical, oval, or other arcuate shape, and in many embodiments can be matched or correlated with rear wall335(FIGS. 3-5) and/or front wall336(FIGS. 3-5) of slot331(FIGS. 3-5) in the second direction.

In the embodiment shown inFIGS. 6-8, tuning element front side656and cap front side666are concave in the second direction, and tuning element rear side655and cap rear side665are substantially or approximately straight in the second direction. In the embodiment presented, tuning element rear side655is concave in the first direction, and tuning element front side656is convex in the first direction. In the embodiment presented, tuning element150has a heel-to-toe length (from cap heel side767to cap toe side664) of approximately 2.5 inches (6.35 cm). In other embodiments, tuning element150can have a heel-to-toe length of approximately 0.5 inch (1.27 cm) to approximately 4.0 inches (10.16 cm). For example, tuning element150can have a heel-to-toe length of approximately 0.5 inch (1.27 cm), 0.75 inch (1.905 cm), 1.0 inch (2.54 cm), 1.25 inches (3.175 cm), 1.5 inches (3.81 cm), 1.75 inches (4.445 cm), 2.0 inches (5.08 cm), 2.25 inches (5.715 cm), 2.5 inches (6.35 cm), 2.75 inches (6.985 cm), 3.0 inches (7.62 cm), 3.25 inches (8.255 cm), 3.5 inches (8.89 cm), 3.75 inches (9.525 cm), 4.0 inches (10.16 cm), or any other suitable length value in between those length values, and can range from any one of those length values to any other one of those length values. For example, tuning element150can have a heel-to-toe length of approximately 1.0 inch (2.54 cm) to approximately 3.0 inches (7.62 cm).

In the embodiment presented, cap661has a front-to-rear thickness (from cap front side666to cap rear side665) of approximately 0.28 inch (0.7112 cm) at a midpoint between cap heel side767and cap toe side664, and main portion651has a front-to-rear thickness of approximately 0.22 inch (0.558 cm) at the midpoint between tuning element heel side757and tuning element toe side654, and main portion651has a front-to-rear thickness of approximately 0.1 inch (0.254 cm) at tuning element heel side757and tuning element toe side654. In various embodiments, tuning element150can have a front-to-rear thickness greater than or equal to approximately 0.025 inch (0.0635), including, for example, at tuning element heel side757, tuning element toe side654, cap heel side767, and/or cap toe side664. In many embodiments, tuning element150can have a front-to-rear thickness of less than or equal to approximately 0.5 inch (1.27 cm), including, for example, at the midpoint between tuning element heel side757and tuning element toe side654. In many embodiments, the front-to-rear thickness of tuning element150at tuning element heel side757, tuning element toe side654, cap heel side767, and/or cap toe side664can be less than the front-to-rear thickness of tuning element150at the midpoint between tuning element heel side757and tuning element toe side654. In other embodiments, the front-to-rear thickness of tuning element150can be uniform between running element heel side757and tuning element toe side654. In yet other embodiments, the front-to-rear thickness of tuning element150at tuning element heel side757, tuning element toe side654, cap heel side767, and/or cap toe side664can be greater than the front-to-rear thickness of tuning element150at the midpoint between tuning element heel side757and tuning element toe side654.

Turning ahead in the drawings,FIG. 9illustrates a side cross-sectional view along line3-3inFIG. 2of golf club head100with tuning element150.FIG. 10illustrates a side, bottom, rear perspective cross-sectional view along line3-3inFIG. 2of golf club head100with tuning element150. As shown inFIGS. 9-10, port structure330can be configured to receive and/or secure tuning element150. Main portion651can fit within and/or be substantially conformal with slot331, and/or cap661can fit within cap recess340. In a number of embodiments, port structure330can be slightly larger than tuning element150to allow tuning element150to be inserted within port structure330. Tuning element150can be adhered or otherwise affixed to port structure330. For example, tuning element150can be secured within port structure using an adhesive, such as an epoxy. In certain embodiments, the epoxy can have a thickness of at least approximately 0.001 inch (0.00254 cm), and port structure330can be at least approximately 0.001 inch (0.00254 cm) larger than tuning element150in one or more directions. For example, port structure can be approximately 0.01 inch (0.0254 cm) larger than tuning element150in each direction. In the embodiment shown inFIGS. 9 and 10, a larger gap can exist between tuning element bottom side653and slot base333than between other parts of tuning element150and port structure330. This gap can be used to hold excess amounts of the adhesive so that the adhesive does not overflow out of slot331or port structure330. In other embodiments, tuning element150(with or without cap661) can be held in port structure330using mechanical mechanisms, such as snaps, ribs, fasteners, or other suitable mechanical mechanisms.

In many embodiments, when tuning element150is seated within port structure330, tuning element toe side654(FIGS. 6-7) can interface with toe wall334(FIGS. 3-4), tuning element heel side757(FIG. 7) can interface with heel wall537(FIG. 5), tuning element rear side655can interface with rear wall335, tuning element front side656can interface with front wall336, and/or tuning element bottom side653can interface with slot base333. In a number of embodiments, when tuning element150is seated within port structure330, cap661can extend beyond slot331and be seated within cap recess340at slot opening332(FIGS. 3-5) extending beyond front wall336, rear wall335, heel wall537(FIG. 5), and/or toe wall334(FIGS. 3-4).

In various embodiments, cap661can fit within cap recess340, and/or cap top side668can be shaped so as to conform to the surrounding shape of rear portion120and/or backface112. For example, cap top side668can include one or more curves or angled surfaces. In some embodiments, an appliqué can be added over cap top side668, rear portion120, backface112and/or the interfaces between cap top side668, rear portion120, and/or backface112, such that rear portion120, cap top side668, backface112, and/or the interfaces thereof can appear seamless, and/or such that the presence of tuning element150within golf club head100can be partially or fully concealed. In some embodiments, the appliqué can cover cap top side668and wrap around the sides of cap661to cover at least a portion of all of cap front side666(FIGS. 6, 8), cap rear side665(FIGS. 6-8), cap toe side664(FIGS. 6-8) and/or cap heel side767(FIGS. 7-8), so that the edges of the appliqué are hidden from view when cap661is located within cap recess340. In some embodiments, cap recess340can be at least approximately 0.01 inch (0.0254 cm) larger than cap661in one or more directions. For example, cap recess340can be approximately 0.03 inch (0.0762 cm) larger than cap661in each direction.

In several embodiments, the shape of port structure330and/or tuning element150can be such that tuning element150can be inserted and/or fit within port structure330in only one orientation, which can advantageously prevent tuning element150from inadvertently being inserted incorrectly during assembly. For example, the arcuate shape of tuning element150, port structure330, and/or one or more elements thereof in one or more directions, and/or the shape of cap661and/or cap recess661can be configured such that tuning element150can fit with port structure330in only one orientation.

In various embodiments, the shape of port structure330and/or tuning element150can be configured so as to increase the surface area of contact between port structure330and tuning element150, which can beneficially increase the bond strength of adhesives securing tuning element150to port structure330and prevent tuning element150from dislodging from port structure330. For example, in certain embodiments, the height of tuning element150can be greater than the front-to-rear thickness of tuning element150, and/or the distance from slot opening332to slot base333can be greater than the distance from front wall336to rear wall335. In the embodiment shown, port structure330has a surface area of approximately 2.4 square inches (in2) (15.48 square cm (cm2). In other embodiments, port structure330can have a surface area of approximately 0.5 in2(3.23 cm2) to approximately 5.5 in2(35.48 cm2). For example, port structure330can have a surface are of approximately 0.5 in2(3.23 cm2), 0.75 in2(4.84 cm2), 1.0 in2(6.45 cm2), 1.25 in2(8.06 cm2), 1.5 in2(9.68 cm2), 1.75 in2(11.29 cm2), 2.0 in2(13.90 cm2), 2.25 in2(14.52 cm2), 2.5 in2(16.13 cm2), 2.75 in2(17.74 cm2), 3.0 in2(19.35 cm2), 3.25 in2(20.97 cm2), 3.5 in2(22.58 cm2), 3.75 in2(24.19 cm2), 4.0 in2(25.81 cm2), 4.25 in2(27.42 cm2), 4.5 in2(29.03 cm2), 4.75 in2(30.65 cm2), 5.0 in2(32.26 cm2), 5.25 in2(33.87 cm2), 5.5 in2(35.48 cm2), or any other suitable surface area value in between those surface area values, and can range from any one of those surface area values to any other one of those surface area values. In many embodiments, the surfaces of tuning element150in contact with port structure330can have a similar or identical surface area as port structure330.

Turning ahead in the drawings,FIG. 11illustrates a side cross-sectional view along line3-3inFIG. 2of golf club head100with tuning element150and showing a force normal line1170upon impact. In many embodiments, the shape, configuration, and/or orientation of tuning element150and/or port structure330in golf club head100can be such that, upon the impact of golf club head100with a golf ball, the forces upon tuning element150, as shown by force normal line1170, can more uniformly distribute and/or balance the forces pushing tuning element150out of port structure330and the forces pushing tuning element150into port structure330, as compared to various other conventional tuning port structures, which can naturally force the tuning element out of the tuning port structure. For example, in some embodiments, a center portion of rear wall335can be orthogonal with normal force line1170and can be convex, such that a bottom portion of rear wall335can direct the impact forces on tuning element150toward slot base333, and a top portion of rear wall335can direct the impact forces on tuning element150toward slot opening332. The configuration of tuning element150and/or port structure330can beneficially prevent tuning element150from becoming inadvertently dislodged from port structure330.

Turning ahead in the drawings,FIG. 12illustrates a flow chart for a method1200, which can be used to provide, form, and/or manufacture a golf club head and/or a golf club in accordance with the present disclosure. Method1200is merely exemplary and is not limited to the embodiments presented herein. Method1200can be employed in many different embodiments or examples not specifically depicted or described herein. In some embodiments, the procedures, the processes, and/or the activities of method1200can be performed in the order presented. In other embodiments, the procedures, the processes, and/or the activities of method1200can be performed in any suitable order. In still other embodiments, one or more of the procedures, the processes, and/or the activities of method1200can be combined or skipped. In some examples, the golf club head can be similar to golf club head100(FIGS. 1-5, 9-11), golf club head1600(FIGS. 16-18 and 20), and/or golf club head1900(FIG. 19).

Referring toFIG. 12, method1200can include block1210for providing a strike portion of a golf club head. In some examples, the strike portion can be similar to strike portion110(FIGS. 1-5, 9-11), strike portion1610(FIGS. 16-18 and 20), and/or strike portion1920(FIG. 19). The strike portion can include a strikeface, which can be similar or identical to strikeface111(FIGS. 1-5, 9-11), strikeface1611(FIGS. 16-18 and 20), and/or strikeface1911(FIG. 19). The strike portion can include a backface, which can be similar or identical to backface112(FIGS. 1-5, 9-11). The backface can be opposite the strikeface. The backface can include a perimeter portion at a top end of the backface. The perimeter portion can be similar or identical to perimeter portion113(FIGS. 1-5, 9-11). The strike portion can be provided via casting, forging, milling, machining, molding, and/or other processes, where the strike portion can be a single piece or can include several pieces coupled together such as via welding, brazing, and/or adhesives.

Method1200also can include block1220for providing a rear portion of the golf club head. In some embodiments, the rear portion can be similar or identical to rear portion120(FIGS. 1-5, 9-11), rear portion1620(FIG. 16), and/or rear portion1920(FIG. 19). The rear portion can be provided via casting, forging, milling, machining, molding, and/or other processes, where the rear portion can be a single piece or can include several pieces coupled together such as via welding, brazing, and/or adhesives. The rear portion can be coupled to the strike portion at a bottom end of the strike portion, such as by welding, brazing, adhering, and/or other mechanical or chemical fasteners. In other embodiments, the rear portion can be integrally formed with the strike portion, such as by being cast as a single piece of material. In these other embodiments, blocks1210and1220can be performed simultaneously with each other. In these other embodiments, the strikeface can be formed simultaneously with the rest of the strike portion, or the strikeface can be formed separately from the rest of the strike portion and the subsequently coupled to the rest of the strike portion.

Method1200also can include block1230for providing a port structure. The port structure can be similar or identical to port structure330(FIGS. 3-5, 9-11), port structure1830(FIGS. 18 and 20). The port structure can be provided via casting, forging, milling, machining, molding, tooling, and/or other processes, where the port structure can be a single piece or can include several pieces coupled together such as via welding, brazing, and/or adhesives. In some examples, the port structure and/or elements thereof can be cast with a tooling pick piece that can be removed in one motion without interfering with the backface by rotating the tooling pick piece about a fixed point, as shown inFIGS. 13-14and described below. In many embodiments, the concave curve to the backface can beneficially facilitate simpler manufacturing of the golf club head, such that, even when the thickness of the strike portion at a portion of the backface is greater than the distance between the strikeface and the front wall at the slot opening, the port structure and/or the slot can be cast with a tooling pick piece that can be removed in one motion without interfering with the backface, such as by simply rotating the tooling pick piece about a fixed point. In some embodiments, the tooling pick piece can be rotated and removed manually after the mold is opened. In other embodiments, the tooling pick piece can be rotated and removed automatically as the mold is opened. The port structure can be at least partially defined within the rear portion and/or the strike portion, and in many embodiments can be integrally formed with the rear portion and/or the strike portion. Accordingly, block1230can be performed simultaneously with block1210and/or1220.

The port structure of block1230can include a slot, which can be similar or identical to slot331(FIGS. 3-5, 9-10) and/or slot1831(FIGS. 18 and 20). The slot can extend from a slot opening, such as slot opening332(FIGS. 3-5, 11) and/or slot opening1832(FIGS. 18 and 20), to a slot base, such as slot base333(FIGS. 3-5, 9-11), and/or slot base1833(FIGS. 18 and 20). The slot base can be located closer to the bottom end of the strike portion than the slot opening, and/or the bottom end of the strike portion can be located closer to the slot base than the slot opening. The slot can include a heel wall, such as heel wall537(FIG. 5), and a toe wall, such as toe wall334(FIGS. 3-4) and/or toe wall1834(FIG. 18). The slot can include a rear wall, such as rear wall335(FIGS. 3-5, 9-11) and/or rear wall1835(FIGS. 18 and 20), which can extend from the slot opening to the slot base, and/or can extend between the heel wall to the toe wall. The rear wall can include a rear wall curve along a first direction extending between the slot opening and the slot base. The slot can include a front wall, such as front wall336(FIGS. 3-5, 9-10) and/or front wall1836(FIGS. 18 and 20), which can extend from the slot opening to the slot base, and/or can extend between the heel wall to the toe wall. The front wall can be located closer to the strikeface than the rear wall, and/or the strikeface can be located closer to the front wall than the rear wall. The front wall can include a front wall curve along a first direction extending between the slot opening and the slot base.

Method1200also can include block1240for coupling a tuning element and/or an insert to the port structure. The tuning element can be similar or identical to tuning element150(FIGS. 1-2, 6-11), insert1650(FIGS. 16-17 and 20), and/or insert1950(FIG. 19). In some examples, one or more elements of the tuning element can be coupled to one or more elements of the port structure, such as described above. For example, the tuning element can be inserted in the port structure by rotating the tuning element about a fixed point. The tuning element can be maintained at the secured position via one or more mechanisms, such as friction forces, adhesives between the tuning element and the port structure, and/or mechanical fasteners attaching the tuning element to the port structure. In the same or other examples, the tuning element can be removable from the secured position in the port structure, and/or can be interchangeable with one or more other tuning elements, such as, for example, tuning elements having different densities.

In some examples, one or more of the different blocks of method1200can be combined into a single block or performed simultaneously, and/or the sequence of such blocks can be changed. For example, as indicated above, blocks1210,1220, and/or1230can be combined or performed simultaneously in some embodiments. In the same or other embodiments, some of the blocks of method1200can be subdivided into several sub-blocks. For example, block1240can be subdivided into a sub-block for molding or otherwise providing the tuning element, a sub-block for coupling an appliqué to the tuning element, a sub-block for inserting the tuning element into the port structure, and/or another sub-block for securing the tuning element into the port structure. There can also be examples where method1200can comprise further or different blocks. As an example, method1200can comprise a block for providing or coupling a golf club shaft to the golf club head. In addition, there can be examples where method1200can comprise only part of the blocks described above. For example, block1240can be optional in some implementations, such as in situations where the tuning element is not needed or desired, or in situations in which the decision of whether to couple a tuning element to the port structure is left up to a player or the end user. Other variations can be implemented for method1200without departing from the scope of the present disclosure.

Turning ahead in the drawings,FIG. 13illustrates a mold1300in a closed configuration.FIG. 14illustrates mold1300in an open configuration. Mold1300is merely exemplary and embodiments of the mold are not limited to the embodiments presented herein. The mold can be employed in many different embodiments or examples not specifically depicted or described herein. In many embodiments, mold1300can include a first mold piece1380and a second mold piece1381. In a number of embodiments, first mold piece can include a first cavity portion1480(FIG. 14), and/or second mold piece1381can include a second cavity portion1481(FIG. 14). In many embodiments, mold1300can be closed to a closed configuration, as shown inFIG. 13, such that first mold piece1381and second mold piece1382surround first cavity portion1480(FIG. 14) and second cavity portion1481(FIG. 14) to allow for injection molding of a golf club head mold1301in first cavity portion1480and second cavity portion1481. In a number of embodiments, mold1300can be opened to an open configuration, as shown inFIG. 14, such that golf club head mold1301(FIG. 13) can be removed from first cavity portion1480and second cavity portion1481.

In several embodiments, golf club head mold1301can be made of wax or another suitable material through injection molding, which can be used for investment casting to form golf club head100(FIGS. 1-5, 9-11), golf club head1600(FIGS. 16-18 and 20), and/or golf club head1900(FIG. 19). In many embodiments, the shape of golf club head mold1301can be similar or identical to the shape of golf club head100(FIGS. 1-5, 9-11), golf club head1600(FIGS. 16-18 and 20), and/or golf club head1900(FIG. 19). For example, golf club head mold1301can include a strike portion1310, a strikeface1311, a backface1312, a perimeter portion1313, a rear portion1320, a sole1321. Strike portion1310can be similar or identical in shape to strike portion110(FIGS. 1-5, 9-11); strikeface1311can be similar or identical in shape to strikeface111(FIGS. 1, 3-5, 9-11); backface1312can be similar or identical in shape to backface112(FIGS. 1-5, 9-11); perimeter portion1313can be similar or identical in shape to perimeter portion113(FIGS. 1-5, 9-11); rear portion1320can be similar or identical to rear portion120(FIGS. 1-5, 9-11); and/or sole1321can be similar or identical to sole121(FIGS. 1-5, 9-10). In many embodiments, golf club head mold1301can include a port structure1336, which can be similar or identical in shape to port structure330(FIGS. 3-5, 9-11).

In some embodiments, first mold piece1380can include a tooling piece1390. In many embodiments, tooling piece1390can include a first arm1391and a second arm1394connected together at a hub1393. In several embodiments, tooling piece1390can be rotationally attached to first mold piece1380at a rotation point1384on hub1393. In some embodiments, tooling piece1390can be rotated between a mold position, as shown inFIG. 13and a release position, as shown inFIG. 14. In many embodiments, tooling piece1390can include a mold portion1395attached to second arm1394. Mold portion1395can include one or more surfaces, which, along with the surfaces of first cavity portion1480(FIG. 14) and second cavity portion1481(FIG. 14), can provide mold surfaces for the injection molding of golf club head mold1301when mold1300is in the closed configuration and tooling piece1390is in the mold position, as shown inFIG. 13. In many embodiments, for example, mold portion1395can include a rear tooling surface1397, a base tooling surface1398, a front tooling surface1396, and/or a backface tooling surface1399. For example, as shown inFIG. 13, rear tooling surface1397, base tooling surface1398, and/or front tooling surface1396can be used to mold port structure1336, and/or backface tooling surface1399can be used to mold backface1312.

In a number of embodiments, second mold piece1381can include a protrusion1383. In some embodiments, first mold piece1380can include a recess1382, which can be configured to receive protrusion1383. In several embodiments, arm1391of tooling piece1390can include a surface1392, which can be configured to engage with protrusion1383to rotate tooling piece1390around rotation point1384. In many embodiments, tooling piece1390can be spring-loaded to be biased to the release position, as shown inFIG. 14. In several embodiments, when second mold piece1381is moved toward first mold piece1380so as to close mold1300, as shown inFIG. 13, protrusion1383can press on surface1392to rotate tooling piece1390clockwise to the mold position, as shown inFIG. 13. In a number of embodiments, mold portion1395of tooling piece1390can be rotated around rotation point1384along a portion of circle1385centered at rotation point1384. For example, rear tooling surface1397can rotate along a portion of circle1385. In several embodiments, mold1300can be opened, which can allow tooling piece1390to automatically rotate back to the release position, as shown inFIG. 14, when tooling piece1390is biased in the release position.

In many embodiments, when tooling piece1390is in the mold position and mold1300is in the closed configuration, as shown inFIG. 13, the surfaces of first cavity portion1480and second cavity portion1481, along with mold portion1395can provide molding surfaces for injection molding of golf club head mold1301. Once golf club head mold1301is formed, tooling piece1390can automatically rotate back to the release position as mold1300is opened, as shown inFIG. 14. When tooling piece1390is rotated back to the release position upon mold1300being opened, as shown inFIG. 14, mold portion1395can be automatically removed from port structure1336of golf club head mold1301, which can beneficially allow golf club head mold1301to be removed from mold1300in a single motion after the injection molding of golf club head mold1301. For example, as mold1300is opened by second mold piece1381being pulled apart from first mold piece1380, or vice versa, the spring-loaded bias of tooling piece1390can result in surface1392following protrusion1383such that tooling piece1390can be rotated counter-clockwise around rotation point1384, and mold portion1395can automatically disengage from port structure1336of golf club head mold1301at the same time that golf club head mold1301is removed from mold1300.

Turning ahead in the drawings,FIG. 15illustrates a flow chart for a method1500of forming a golf club head, according to various embodiments. Method1500is merely exemplary and is not limited to the embodiments presented herein. Method1500can be employed in many different embodiments or examples not specifically depicted or described herein. In some embodiments, the procedures, the processes, and/or the activities of method1500can be performed in the order presented. In other embodiments, the procedures, the processes, and/or the activities of method1500can be performed in any suitable order. In still other embodiments, one or more of the procedures, the processes, and/or the activities of method1500can be combined or skipped. In some examples, the golf club head can be similar to golf club head100(FIGS. 1-5, 9-11), golf club head1600(FIGS. 16-18 and 20), and/or golf club head1900(FIG. 19).

Referring toFIG. 15, in some embodiments, method1500can include a block1510of providing a first mold piece comprising a first cavity portion and a tooling piece. The first mold piece can be similar or identical to first mold piece1380(FIGS. 13-14). The first cavity portion can be similar or identical to first cavity portion1480(FIG. 14). The tooling piece can be similar or identical to tooling piece1390(FIGS. 13-14). In a number of embodiments, the tooling piece can be configured to rotate with respect to the first mold piece about a fixed point on the first mold piece from a mold position to a release position. The fixed point can be similar or identical to rotation point1384(FIGS. 13-14). The mold position can be similar or identical to the position of tooling piece1390shown inFIG. 13. The release position can be similar or identical to the position of tooling piece1390shown inFIG. 14.

In several embodiments, method1500also can include a block1520of providing a second mold piece comprising a second cavity portion. The second mold piece can be similar or identical to second mold piece1381(FIGS. 13-14). The second cavity portion can be similar or identical to second cavity portion1481(FIG. 14).

In a number of embodiments, method1500further can include a block1530of closing the second mold piece to the first mold piece, or vice versa, such that the first and second mold pieces surround the first and second cavity portions, the tooling piece is in the mold position, and a portion of the tooling piece is inserted into at least the first cavity portion. For example, the second mold piece can be closed to the first mold piece as second mold piece1381is closed to first mold piece1380inFIG. 13. The portion of the tooling piece can be similar to mold portion1395(FIGS. 13-14) or portions thereof, such as rear tooling surface1397(FIG. 13), base tooling surface1398(FIG. 13), front tooling surface1396(FIG. 13), and/or backface tooling surface1399(FIG. 13).

In several embodiments, method1500additionally can include a block1540of molding an injection mold in the first and second cavity portions. The injection mold can include a golf club head mold. The golf club head mold can be similar or identical to golf club head mold1301(FIG. 13). In many embodiments, the golf club head mold can include a strike portion, a rear portion, and a port structure at least partially defined within the rear portion. The strike portion can be similar or identical to strike portion1310(FIG. 13). The rear portion can be similar or identical to rear portion1320(FIG. 13). The port structure can be similar or identical to port structure1336. In some embodiments, the portion of the tooling piece can be substantially conformal with the port structure. In many embodiments, the golf club head mold can be molded through injection molding using a wax or another suitable molding material. In many embodiments, the wax can solidify to form the golf club head mold before performing the next block of method1500.

In a number of embodiments, method1500further can include a block1550of opening the second mold piece from the first mold piece, or vice versa, such that the tooling piece is rotated about the fixed point away from the mold position in the port structure to the release position. For example, the second mold piece can be opened from the first mold piece as second mold piece1381is opened from first mold piece1380inFIG. 14. The golf club head mold can be simultaneously removed from the first mold piece, the second mold piece, and the tooling piece, and then used for investment casting, according to conventional investment casting processes. For example, the golf club head mold can be coated with a ceramic casting; the wax of the golf club head mold can be melted out of the ceramic casting; a metal can be poured into the ceramic casting to form the golf club head; and the ceramic casting can be divested from the golf club head.

FIG. 16illustrates a heel-side, bottom, rear perspective view of a golf club head1600similar to golf club head100(FIG. 1) with an insert1650, according to an embodiment.FIG. 17illustrates a bottom, rear view of golf club head1600with insert1650.FIG. 18illustrates a side cross-sectional view of a golf club head1600, where the cross-sectional view is taken along cross-sectional line18-18inFIG. 17, but where golf club head1600inFIG. 18is illustrated without insert1650, according to an embodiment.FIG. 20illustrates a side cross-sectional view along line18-18inFIG. 17of golf club head1600with insert1650.

In many embodiments, insert1650can be similar to tuning element150(FIGS. 1 and 6-8). In some embodiments, insert1650can be a part of the tuning element or custom tuning port (CTP) weight. In many embodiments, insert1650can improve vibration dampening and sound reduction on impact with a golf ball. Golf club head1600is merely exemplary and embodiments of the golf club head are not limited to the embodiments presented herein. The golf club head can be employed in many different embodiments or examples not specifically depicted or described herein. In a number of embodiments, golf club head1600can be an iron-type club head, a wedge-type club head, or a hybrid-type club head. For example, in some embodiments, golf club head1600can have a loft angle of approximately 15 degrees to approximately 70 degrees. In a number of embodiments, golf club head1600can have a head weight of approximately 200 grams (g) to approximately 325 g. In various embodiments, golf club head100can have a lie angle of approximately 50 degrees to approximately 70 degrees. In many embodiments, golf club head1600can include a toe end1601and a heel end1602.

In various embodiments, golf club head1600can include a strike portion1610, which can include a strikeface1611and a backface1612. In certain embodiments, strikeface1611can be an insert, such as a strikeplate insert (not shown) in strike portion1610. In other embodiments, strikeface1611can be integral with strike portion1610. Backface1612can be opposite strikeface1611. In many embodiments, strikeface1611can comprise an upper region1841(FIG. 18) and a lower region1843(FIG. 18). In these embodiments, upper region1841can comprise a region of the strike portion1610above cavity opening1832of port structure1830or between cavity opening1832of port structure1830and top of strike portion1610. Further, in these embodiments, lower region1843can comprise a region of the strike portion1610below cavity opening1832of port structure1830or between cavity opening1832or port structure1830and bottom end of strike portion1610.

In some embodiments, a minimum upper thickness1842(FIG. 18) of upper region1841(FIG. 18) can be measured from strikeface1611to backface1612in a direction substantially perpendicular to strikeface1611. In many embodiments, minimum upper thickness1842(FIG. 18) can be approximately 0.06 inch (0.152 cm) to approximately 0.1 inch (0.254 cm). In many embodiments, minimum upper thickness1842can be less than or equal to approximately 0.10 inch (0.254 cm), less than or equal to approximately 0.09 inch (0.2286 cm), less than or equal to approximately 0.08 inch (0.2032 cm), less than or equal to approximately 0.07 inch (0.1778 cm), or less than or equal to approximately 0.06 inch (0.1524 cm). For example, in some embodiments, minimum upper thickness1842can be approximately 0.06 inch (0.1524 cm), 0.07 inch (0.1778 cm), 0.08 inch (0.2032 cm), 0.09 inch (0.2286 cm), or 0.1 inch (0.254 cm).

In some embodiments, a minimum lower thickness1844(FIG. 18) of lower region1843(FIG. 18) can be measured from strikeface1611to a front wall1836(FIG. 18) of slot1831(FIG. 18) in a direction substantially perpendicular to strikeface1611, and as described further below. In many embodiments, minimum lower thickness1844(FIG. 18) can be less than minimum upper thickness1842(FIG. 18). In some embodiments, minimum lower thickness1843(FIG. 18) of lower region1843(FIG. 18) can be approximately 0.05 inch (0.127 cm) to approximately 0.09 inch (0.2286 cm). In many embodiments, minimum lower thickness1843can be less than or equal to approximately 0.09 inch (0.2286 cm), less than or equal to approximately 0.08 inch (0.2032 cm), less than or equal to approximately 0.07 inch (0.1778 cm), less than or equal to approximately 0.06 inch (0.1524 cm), or less than or equal to approximately 0.05 inch (0.127 cm). For example, in some embodiments, minimum lower thickness1844(FIG. 18) can be approximately 0.05 inch (0.127 cm), 0.06 inch (0.1524 cm), 0.07 inch (0.1778 cm), 0.08 inch (0.2032 cm), or 0.09 inch (0.2286 cm).

In many embodiments, a minimum thickness of the strikeface1611including the upper region1841and lower region1843, measured in a direction substantially perpendicular to strikeface1611, can be less than or equal to approximately 0.10 inch (0.254 cm), less than or equal to approximately 0.09 inch (0.2286 cm), less than or equal to approximately 0.08 inch (0.2032 cm), less than or equal to approximately 0.07 inch (0.1778 cm), less than or equal to approximately 0.06 inch (0.1524 cm), or less than or equal to approximately 0.05 inch (0.127 cm).

Also, in many embodiments, a portion1891of strikeface1611is located between minimum lower thickness1844and minimum upper thickness1842. Portion1891of strikeface1611can have a thickness that is thicker than minimum lower thickness1844and that is also thicker than minimum upper thickness1842. This higher thickness of portion1891can provide additional support for strikeface1611, including both lower region1843of strikeface1611and upper region1741of strikeface1611. In these embodiments, the rate of change in thickness of strikeface1611is not constant from the top rail to sole1621of golf club head1600, and the direction of change in thickness of strikeface1611is not constant from the top rail to sole1621of golf club head1600. Golf club head100(FIGS. 9 & 10) and golf club head1900(FIG. 20) can have a similar, although not necessarily identical, configuration.

In many embodiments, insert1650can provide support to at least a portion strikeface1611(e.g. lower region1843, or upper region1841and lower region1843of strikeface1611). In many embodiments, the area of the strikeface1611supported by insert1650can be positioned below a geometric center of strikeface1611. In other embodiments, the area of the strikeface1611supported by insert1650can extend above the geometric center of the strikeface1611.

Further, in many embodiments, the area of strikeface1611supported by insert1650can be approximately 15-50% of the surface area of the strikeface1611. In some embodiments, the area of strikeface1611supported by insert1650can be greater than 15%, greater than 20%, greater than 25%, or greater than 30% of the surface area of the strikeface1611. For example, in many embodiments, the area of strikeface1611supported by insert1650can be approximately 20-45%, approximately 25-40%, approximately 25-35%, or approximately 25-45% of the surface area of the strikeface1611.

The support provided to strikeface1611by insert1650can allow a thinner strikeface1611where strikeface1611is supported by insert1650. For example, in many embodiments, insert1650supports lower region1843of strikeface1611allowing minimum lower thickness1844to be less than minimum upper thickness1842. Minimum lower thickness1844described herein allows more deflection of strikeface1611during impact than a strikeface having a lower minimum thickness similar to the upper minimum thickness. Increased deflection of strikeface1611can result in increased energy transfer to the ball and increased travel distance for the ball.

Further, thinning of the strikeface1611reduces club head weight, thereby increasing the available discretionary mass to be advantageously positioned elsewhere on the club head. In many embodiments, thinning of the strikeface1611can increase discretionary mass of the club head by greater than 0.5 grams, greater than 2.5 grams, greater than 5.0 grams, greater than 7.5 grams, greater than 10.0 grams, greater than 12.5 grams, greater than 15.0 grams, greater than 17.5 grams, or greater than 20.0 grams. Repositioning mass from near the strikeface of the club head (e.g. on the rear, low toe area) can increase club head moment of inertia to improve consistency in ball direction and distance for off center hits.

In many embodiments, the club head1600has a heel to toe moment of inertia greater than approximately 380 g·in2(2,452 g·cm2), greater than approximately 385 g·in2(2,484 g·cm2), greater than approximately 390 g·in2(2,516 g·cm2), greater than approximately 395 g·in2(2,548 g·cm2), greater than approximately 400 g·in2(2,581 g·cm2), greater than approximately 405 g·in2(2,613 g·cm2), greater than approximately 410 g·in2(2,645 g·cm2), greater than approximately 415 g·in2(2,677 g·cm2), greater than approximately 420 g·in2(2,710 g·cm2), greater than approximately 425 g·in2(2,742 g·cm2), greater than approximately 450 g·in2(2,903 g·cm2), greater than approximately 500 g·in2(3,226 g·cm2), greater than approximately 550 g·in2(3,548 g·cm2), or greater than approximately 600 g·in2(3,871 g·cm2), wherein the heel to toe moment of inertia is measured about an axis extending through the club head center of gravity in a direction from the top to the bottom of the club head. In other embodiments, the heel to toe moment of inertia can be approximately 380-600 g·in2(2,452-3,871 g·cm2), approximately 400-600 g·in2(2,581-3,871 g·cm2), approximately 500-600 g·in2(3,226-3,871 g·cm2), or approximately 550-600 g·in2(3,548-3,871 g·cm2).

Further, in many embodiments, the club head1600has a top to bottom moment of inertia greater than approximately 95 g·in2(613 g·cm2), greater than approximately 96 g·in2(619 g·cm2), greater than approximately 97 g·in2(626 g·cm2), greater than approximately 98 g·in2(632 g·cm2), greater than approximately 99 g·in2(639 g·cm2), greater than approximately 100 g·in2(645 g·cm2), greater than approximately 101 g·in2(652 g·cm2), greater than approximately 102 g·in2(658 g·cm2), greater than approximately 103 g·in2(665 g·cm2), greater than approximately 104 g·in2(671 g·cm2), greater than approximately 105 g·in2(677 g·cm2), greater than approximately 106 g·in2(684 g·cm2), greater than approximately 125 g·in2(806 g·cm2), greater than approximately 150 g·in2(968 g·cm2), greater than approximately 175 g·in2(1,129 g·cm2), or greater than approximately 200 g·in2(1,290 g·cm2), wherein the heel to toe moment of inertia is measured about an axis extending through the club head center of gravity in a direction from the heel to the toe of the club head. In other embodiments, the top to bottom moment of inertia can be approximately 95-200 g·in2(613-1,290 g·cm2), approximately 100-200 g·in2(645-1,290 g·cm2), approximately 125-600 g·in2(806-1,290 g·cm2), or approximately 150-600 g·in2(986-1,290 g·cm2).

For example, in one embodiment, an exemplary club head1600comprises minimum upper thickness1842of approximately 0.080 inches (0.203 cm), minimum lower thickness1844of approximately 0.068 inches (0.172 cm), an area of strikeface1611supported by insert1650of approximately 1.17 in2(7.55 cm2) (or approximately 26.2% of the surface area of the strikeface1611). In this example, the exemplary club head has approximately 9.3 grams of discretionary mass compared to a similar control club head having a thicker face and a reduced contact area of insert with strikeface. Further, in this example, the exemplary club head has a heel to toe moment of approximately 2.8% greater than the control club head. Further still, in this example, the exemplary club head has a top to bottom moment of inertia of approximately 2.3% greater than the control club head. In this example, the control club head comprises a minimum upper thickness of approximately 0.075 inches (0.191 cm), and a minimum lower thickness of approximately 0.137 inches (0.348 cm), and an area of the strikeface supported by the insert of approximately 0.65 in2(4.19 cm2) (or approximately 14.5% of the surface area of the strikeface).

In various embodiments, golf club head1600can include a rear portion1620. Rear portion1620can be coupled to strike portion1610at the bottom end of strike portion1610. Rear portion1620can include a sole1621. In a number of embodiments, at least a portion of sole1621can be substantially or approximately horizontal when golf club head1600is at the address position, such that cross-sectional line18-18(FIG. 17) can be substantially or approximately vertical when golf club head100is at the address position. In many embodiments, strike portion1610can be integral with rear portion1620, such that strike portion1610and rear portion1620can be a single piece of material. In other embodiments, strike portion1610can be a separate piece (or more than one separate piece) of material fastened to rear portion1620, such as by welding, brazing, adhering, and/or other mechanical or chemical fasteners. In many embodiments, rear portion1620and/or strike portion1610can include one or more materials, including ferrous materials such as steel, carbon steel, stainless steel, and/or steel alloys, and/or non-ferrous materials such as titanium, tungsten, and/or aluminum. In a number of embodiments, one or more of the materials used in rear portion1620and/or strike portion1610can have a high shear modulus and/or a high strength-to-weight ratio.

In a number of embodiments, golf club head1600can include insert1650and a port structure for holding and/or securing insert1650, such as port structure1830(as shown inFIG. 18and described below). In many embodiments, insert1650can be located within and substantially conformal with port structure1830. In many embodiments, port structure1830can be similar to port structure330(FIG. 3). In some embodiments, insert1650can provide support and elasticity for strikeface1611. In some embodiments, insert1650can provide support to the geometric center of strikeface1611. In many embodiments, insert1650can reduce stress on strikeface1611. In some embodiments, the support that insert1650provides to strikeface1611can allow for a thinner strikeface and therefore increased bending of strikeface1611during impact with the golf ball, while providing structural support to maintain durability of strikeface1611and preventing failure of strikeface1611. On impact with the golf ball, increased bending of strikeface1611can increase energy transfer to the golf ball. This can increase golf ball speed and distance and result in better distance control.

In some embodiments, insert1650can be made from any material having a shore hardness of approximately 20 A to approximately 80 A. For example, in some embodiments, insert1650can be made from any material having a shore hardness of 20 A-30 A, 30 A-40 A, 40 A-50 A, 50 A-60 A, 60 A-70 A, or 70 A-80 A. In some embodiments, insert1650can comprise an insert having two or more portions, and at least two of the two or more portions can be made of different materials. In embodiments comprising an insert comprising two or more portions, the average shore hardness of insert1650is approximately 20 A to approximately 80 A. For example, in some embodiments, the average shore hardness of insert1650can be approximately 20 A-30 A, 30 A-40 A, 40 A-50 A, 50 A-60 A, 60 A-70 A, or 70 A-80 A.

In some embodiments, a first portion of the two or more portions of the insert can be positioned closer to strikeface1611than a second portion of the two or more portions of the insert. In other embodiments, the first portion of the two or more portions of the insert can be positioned closer to the top of the backface of the golf club head and the second portion of the two or more portions of the insert can be positioned closer to the sole of the golf club head. In many embodiments, the first portion of the two or more portions of the insert can be made of a first material and the second portion of the two or more portions of the insert can be made of a second material. In some embodiments, the first material can have a shore hardness greater than the second material. In other embodiments, the first material can have a shore hardness less than the second material. In some embodiments, the first and/or second material can have a shore hardness less than 20 A or greater than 40 A such that the average shore hardness is approximately 20 A-80 A. In some embodiments, the first and/or second material can have a shore hardness greater than the average shore hardness (e.g., greater than 80 A) and can include voids in the structure of the insert filled with air to lower the equivalent shore hardness within the range of approximately 20 A to approximately 80 A. In some embodiments, the first and/or second material can have a shore hardness less than the average shore hardness (e.g. less than 20 A) and can include additives (e.g. metal powder additives such as tungsten or other heavy metals) in the structure of the insert to increase the equivalent shore hardness within the range of approximately 20 A to approximately 80 A.

In many embodiments, insert1650, or any portion of insert1650, can be made of any elastically flexible material. In certain embodiments, insert1650, or any portion of insert1650, can be made of one or more elastomers. In some embodiments, insert1650, or any portion of insert1650, can be made of nonferrous thermoplastic urethane, thermoplastic elastomeric polymer(s), hybrid plastics with a mix of ferrous particles or other alloy ferrous particles mixed into polyurethane, crystalline polymer, piezoelectric polymer, amorphous polymer, urethane polymer, thermoplastic elastomer, silicones, foam, or other elastomeric polymers or rubber. In other embodiments, insert1650, or any portion of insert1650, can be a metal such as aluminum, steel, tungsten, or other suitable metals, such as when insert1650is sintered or machined. A simulation was performed to determine the stresses on the strike face of a golf club having an insert made of rubber compared to no insert. The results showed a reduction in stresses on the strikeface by approximately 10 kilopounds per square inch (KSI) for the golf club head having the insert made of rubber.

In some embodiments, the first portion of the two or more portions of the insert can have a first thickness and the second portion of the two or more portions of the insert has a second thickness, and the first thickness is less than the second thickness. In many embodiments, the first thickness and the second thickness are each constant along the length of the insert. In other embodiments, the first thickness and/or the second thickness can have varying thicknesses along the length of the insert. In some examples, the first thickness can increase in any capacity including linear, exponential, polynomial, rational, logarithmic, or any combination of the described variations in a direction toward the top end of the backface of the golf club head or toward the sole of the golf club head. In the same or other embodiments, the second thickness can increase in any capacity including linear, exponential, polynomial, rational, logarithmic, or any combination of the described variations in a direction toward the top end of the backface of the golf club head or toward the sole of the golf club head. In some embodiments, as the first thickness increases in a particular direction, the second thickness can decrease in the particular direction. In other embodiments, as the second thickness increases in a particular direction, the first thickness can decrease in the particular direction. In other embodiments, the first thickness can be greater than or equal to the second thickness. In still other embodiments, the second thickness can be greater than the first thickness.

Turning ahead in the drawings and discussingFIGS. 18-19 and 20together, port structure1830can be at least partially defined within rear portion1620. In certain embodiments, port structure1830can be at least partially defined within strike port1610. In many embodiments, port structure1830can be defined within both rear portion1620and strike portion1610. In certain other embodiments, port structure1830can be defined solely within rear portion1620.

In various embodiments, port structure1830can be similar to port structure330(FIG. 3). Port structure1830can include a slot1831, similar to slot331(FIG. 3) which can extend from a slot opening1832to a slot base1833. In many embodiments, slot1831can be configured to receive a main portion2051(FIG. 20) of insert1650(FIGS. 16-17). In many embodiments, slot1831can include a toe wall1834and a heel wall. The heel wall can be similar to heel wall537(FIG. 5). Toe wall1834can be at the side of golf club head1600and/or slot1831located closer to toe end1601(FIGS. 16-17), and the heel wall can be at the side of golf club head1600and/or slot1831located closer to heel end1602(FIGS. 16-17). Slot1831can extend between toe wall1834and the heel wall. In many embodiments, toe wall1834and/or the heel wall can extend from slot opening1832to slot base1833.

In a number of embodiments, slot1831can include a rear wall1835and a front wall1836. In various embodiments, rear wall1835can extend from slot opening1832to slot base1833, and/or can extend between the heel wall and toe wall1834. In some embodiments, front wall1836can extend from slot opening1832to slot base1833, and/or can extend between the heel wall and toe wall1834. Slot1831can extend between front wall1836and rear wall1835. In a number of embodiments, strike face1611can be located closer to front wall1836than rear wall1835. In some embodiments, front wall1835also can be located closer to strikeface1611than rear wall1835.

In many embodiments, port structure1830can be curved similar to port structure330. For example, front wall1836can be curved and have a front wall curvature in the first direction extending between slot opening1832and slot base1833. As another example, rear wall1835can be curved and have a rear wall curvature in the first direction extending between slot opening1832and slot base1833.

As shown inFIG. 20, port structure1830can be configured to receive and/or secure insert1650. Main portion2031of insert1650can fit within and/or be substantially conformal with slot1831, and/or cap2061of insert1650can fit within cap recess1840(FIG. 18). In many embodiments, main portion2031can be similar to main portion651(FIG. 6), and cap2061can be similar to cap661(FIG. 6). In many embodiments, main portion2031of insert1650can include an insert rear side2055, an insert front side2056and/or an insert bottom side2053. In a number of embodiments, cap2061of insert1650can include a cap top side2068. In other embodiments, cap2061can extend from main portion2031of insert1650at an angle relative to slot opening1832such that insert1650supports the geometric center of strikeface1611and/or a portion of upper region1841of strikeface1611.

In a number of embodiments, port structure1830can be slightly larger than insert1650to allow insert1650to be inserted within port structure1830. Insert1650can be adhered or otherwise affixed to port structure1830. For example, insert1650can be secured within port structure using an adhesive, such as an epoxy. In certain embodiments, the epoxy can have a thickness of at least approximately 0.001 inch (0.00254 cm), and port structure1830can be at least approximately 0.001 inch (0.00254 cm) larger than insert1650in one or more directions. For example, port structure can be approximately 0.01 inch (0.0254 cm) larger than insert1650in each direction. In some embodiments, a larger gap can exist between insert bottom side2053and slot base1833than between other parts of insert1650and port structure1830. This gap can be used to hold excess amounts of the adhesive so that the adhesive does not overflow out of slot1831or port structure1830. In other embodiments, insert1650(with or without cap2061) can be held in port structure1830using mechanical mechanisms, such as snaps, ribs, fasteners, or other suitable mechanical mechanisms.

FIG. 19illustrates a bottom, rear view of a golf club head1900with insert1950. Golf club head1900can be similar to golf club head1600(FIGS. 16-18 and 20). In many embodiments, insert1950can be similar to insert1650(FIGS. 16-17 and 20) and/or tuning element150(FIGS. 1 and 6-8). In many embodiments, golf club head1900can include a toe end1901and a heel end1902.

In various embodiments, golf club head1900can include a strike portion1910, which can include a strikeface1911and a backface1912. In certain embodiments, strikeface1911can be an insert, such as a strikeplate insert (not shown) in strike portion1910. In other embodiments, strikeface1911can be integral with strike portion1910. Backface1912can be opposite strikeface1911. In various embodiments, backface1912can include a perimeter portion1913at a top end of backface1912. In many embodiments, perimeter portion1913can extend around the top end and sides of backface1912at or proximate to toe end1901and/or heel end1902. Perimeter portion1913can protrude rearward from backface1912.

In various embodiments, golf club head1900can include a rear portion1920. Rear portion1920can be coupled to strike portion1910at the bottom end of strike portion1910. Rear portion1920can include a sole1921. In many embodiments, strike portion1910can be integral with rear portion1920, such that strike portion1910and rear portion1920can be a single piece of material. In other embodiments, strike portion1910can be a separate piece (or more than one separate piece) of material fastened to rear portion1920, such as by welding, brazing, adhering, and/or other mechanical or chemical fasteners.

In many embodiments, golf club head1900can include a cavity1990. In some embodiments, cavity1990can be located at toe end1901and/or toward sole1921. In many embodiments, a toe weight1995can be inserted in cavity1990. In some embodiments, toe weight1995and cavity1990can be similar to the toe weight and cavity as described in U.S. patent application Ser. No. 14/306,033, filed Jun. 16, 2014, and entitled “Club Head Sets with Varying Characteristics and Related Methods,” which is incorporated herein in its entirety. Toe weight1995can comprise various shapes and dimensional configurations. In some embodiments, toe weight1995can comprise a shape and dimension that is complimentary to cavity1990, as illustrated inFIG. 19. In some embodiments, toe weight1995can comprise a shape and dimension that only partially fills cavity1990. Referring toFIG. 19, in the illustrated embodiment, cavity1990and toe weight1995comprise an enclosed shape or a shape that is confined such that the toe weight1995can only be inserted in a single direction. In many embodiments, the toe weight1995can be coupled to the cavity1990by swaging or centrifugal co-casting when the toe weight comprises a high density tungsten alloy. In other embodiments, the toe weight1995can be coupled to the cavity1990using any other suitable method. For example, the toe weight1995can be coupled to the cavity by welding when the toe weight comprises a lower density tungsten alloy.

In some embodiments, toe weight1995may comprise a metal, and may be a single elemental metal such as iron, tungsten, or any other metal. In some embodiments, toe weight may comprise a metal, and may be a metal alloy, such as a tungsten alloy, a titanium alloy, or any other metal alloy.

In some embodiments, toe weight1995may comprise more than one material. For example, toe weight1995can have a first portion1997comprising a first material and a second portion1999comprising a second material different than the first material. The first material and second material may be single elemental metals (for example iron, tungsten, or any other metal) or metal alloys (for example titanium alloys, tungsten alloys, or any other alloy). In embodiments where the toe weight1995comprises the first portion1997and the second portion1999, the first and second portions may be coupled by sintering, a process of compacting and forming a solid mass of material using heat and/or pressure to achieve atomic diffusion without melting the materials.

In embodiments where the toe weight1995comprises the first material and the second material, the first material may made of a less dense material, and the first portion1997comprising the first material may be positioned on an exterior of the toe weight1995when positioned in cavity1990. Further, the second material may made of a more dense material, and the second portion1999comprising the second material may be positioned on an interior of the toe weight when positioned in cavity1990.

For example, the first material may comprise a tungsten alloy having less than or equal to approximately 70 wt % tungsten, less than or equal to approximately 60 wt % tungsten, less than or equal to approximately 50 wt % tungsten, less than or equal to approximately 40 wt % tungsten, or less than or equal to approximately 30 wt % tungsten. Further, the first material may comprise a tungsten alloy having greater than or equal to approximately 25 wt % nickel, greater than or equal to approximately 35 wt % nickel, greater than or equal to approximately 45 wt % nickel, greater than or equal to approximately 55 wt % nickel, or greater than or equal to approximately 65 wt % nickel. Further still, the first material may comprise a tungsten alloy having a density less than or equal to approximately 14 g/cm3, less than or equal to approximately 13 g/cm3, less than or equal to approximately 12 g/cm3, less than or equal to approximately 11 g/cm3, or less than or equal to approximately 10 g/cm3(e.g. D14, D12, or D10 tungsten). For further example, the second material may comprise a tungsten alloy having greater than or equal to approximately 70 wt % tungsten, greater than or equal to approximately 75 wt % tungsten, greater than or equal to approximately 80 wt % tungsten, greater than or equal to approximately 85 wt % tungsten, or greater than or equal to approximately 90 wt % tungsten. Further, the second material may comprise a tungsten alloy having less than or equal to approximately 25 wt % nickel, less than or equal to approximately 20 wt % nickel, less than or equal to approximately 15 wt % nickel, or less than or equal to approximately 10 wt % nickel. Further still, the second material may comprise a tungsten alloy having a density greater than or equal to approximately 14 g/cm3, greater than or equal to approximately 15 g/cm3, greater than or equal to approximately 16 g/cm3, greater than or equal to approximately 17 g/cm3, greater than or equal to approximately 18 g/cm3, or greater than or equal to approximately 19 g/cm3(e.g. D14, or D17 tungsten) In this example, the first portion1997is able to welded to the club head body around a perimeter1992of cavity1990due to the increased nickel content and/or reduced tungsten content in the first material compared to the second material, while the second material is dense enough to provide increased or maximized weight to the club head by the toe weight1995.

For example, in one embodiment, the first material of the first portion1997of the toe weight1995can comprise a tungsten alloy having approximately 70 wt % tungsten, approximately 25 wt % nickel, and approximately 5 wt % iron, and the second material of the second portion1999of the toe weight1995can comprise a tungsten alloy having approximately 90 wt % tungsten, approximately 7 wt % nickel, and approximately 3 wt % iron.

In many embodiments, the first portion1997of the toe weight1995comprises a thickness of approximately 1.5 mm-3.0 mm. In other embodiments, the first portion1997comprises a thickness of greater than or equal to approximately 1.5 mm, greater than or equal to approximately 1.75 mm, greater than or equal to approximately 2.0 mm, greater than approximately 2.25 mm, or greater than or equal to approximately 2.5 mm. Further, in other embodiments, the first portion1997comprises a thickness of less than or equal to approximately 10 mm, less than or equal to approximately 9 mm, less than or equal to approximately 8 mm, less than or equal to approximately 7 mm, less than or equal to approximately 6 mm, less than or equal to approximately 5 mm, less than or equal to approximately 4 mm, or less than or equal to approximately 3 mm. In these embodiments, the thickness of the first portion1997is large enough to allow welding and post processing (e.g. grinding, sanding, or polishing) of the first portion1997of the toe weight1995, and thin enough to provide maximized weight due to maximized volume of the second portion1999comprising the second material.

In embodiments where the toe weight1995comprises the first and second material, as described above, the toe weight1995can comprise a shape and dimension that is complimentary to cavity1990, as illustrated inFIGS. 25-26. In these embodiments, cavity1990and toe weight1995can be positioned advantageously on the toe end1901of the club head to increase perimeter weighting. The cavity1990and toe weight1995comprising the first and second material can be positioned at or proximate to the toe end1901and along the sole and/or back lower rail of the club head. For example, the cavity1990illustrated inFIGS. 25-26comprises an open shape or a shape does not confine toe weight1995when the toe weight1995is positioned in the cavity1990. Further, the cavity1990illustrated inFIGS. 25-26is larger and is positioned closer to the perimeter of the club head, compared to the cavity1990illustrated inFIG. 19. The cavity1990illustrated inFIGS. 25-26can comprise an open shape, and can be larger and positioned closer to the perimeter of the club head because the toe weight1995having the first portion1997and the second portion1999allows the toe weight1995to be welded into the cavity1990, therefore requiring less enclosure than a toe weight that is swaged into a cavity.

Further, in some embodiments, toe weight1995having first portion1997comprising the first material and second portion1999comprising the second material can be coupled to the club head by welding or centrifugal co-casting, without requiring a cavity1990. In these embodiments, toe weight1995can comprise a greater volume compared to a swaged toe weight positioned in a cavity. Accordingly, toe weight1995comprising the first and second portion1997,1999can have a greater mass compared to a toe weight positioned in a cavity, thereby further increasing or maximizing the moment of inertia of the club head.

In these or other embodiments, the toe weight1995can comprise a volume greater than approximately 0.10 in3(1.64 cm3), greater than approximately 0.12 in3(1.97 cm3), greater than approximately 0.14 in3(2.29 cm3), greater than approximately 0.16 in3(2.62 cm3), greater than approximately 0.18 in3(2.95 cm3), greater than approximately 0.20 in3(3.28 cm3), greater than approximately 0.22 in3(3.61 cm3), greater than approximately 0.24 in3(3.93 cm3), greater than approximately 0.26 in3(4.26 cm3), greater than approximately 0.28 in3(4.59 cm3), or greater than approximately 0.30 in3(4.92 cm3). Further, in these or other embodiments, toe weight1995can comprise a weight greater than approximately 10 grams, greater than approximately 11 grams, greater than approximately 12 grams, greater than approximately 13 grams, greater than approximately 14 grams, greater than approximately 15 grams, greater than approximately 16 grams, greater than approximately 17 grams, greater than approximately 18 grams, greater than approximately 19 grams, greater than approximately 20 grams, greater than approximately 21 grams, greater than approximately 22 grams, greater than approximately 23 grams, greater than approximately 24 grams, or greater than approximately 25 grams.

FIGS. 21-24illustrate another embodiment of a golf club head2100with an insert2150. Golf club head2100can be similar to golf club head100,1600, and/or1900. In many embodiments, insert2150can be similar to insert1650,1950, and/or tuning element150. In many embodiments, golf club head2100can include a slot2131having a front wall2136and a rear wall2135. In many embodiments, insert2150can include a front side2156and a rear side2155.

Referring toFIGS. 21-24, the rear wall2135of the slot2131may include one or more protrusions2172, and the rear side2155of the insert2015may include one or more grooves2174. The one or more grooves2174may correspond to the one or more protrusions2172. In the illustrated embodiment, the rear wall2135of the slot2131includes two protrusions2172that correspond to a groove2174on the rear side2155of the insert2150. In other embodiments, the rear wall2135of the slot2131, and the rear side2155of the insert2150may include any number of protrusions2172such as, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 protrusions and any number of grooves2174, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 grooves. Further, in other embodiments, the rear wall2135of the slot2131may include the one or more grooves2174, and the rear side2155of the insert2150may include the one or more protrusions2172.

In the same or other embodiments, the front wall2136of the slot2131may include one or more protrusions2172and the front side2156of the insert2150may include one or more grooves2174. Further, in the same or other embodiments, the front wall2136of the slot2131may include the one or more grooves2174, and the front side2156of the insert2150may include the one or more protrusions2172. In these embodiments, the front wall2136of the slot2131, and/or the front side2156of the insert2150may include any number of protrusions2172such as, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 protrusions or any number of grooves2174, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 grooves.

The one or more grooves2174and the one or more protrusions2172positioned in the slot2131and on the insert2150, as described above, provide mechanical stability to the insert2150when positioned in the slot2131. Further, the curved shape of the front wall2136and/or rear wall2135of the slot2131provides mechanical stability to the insert2150when positioned in the slot2131. The mechanical stability provided by the grooves2174and protrusions2712can prevent the insert2150from being removed from the slot2131during use. In some embodiments, the insert2150having the grooves2174and protrusions2172may be secured in the slot2131without the use of epoxy. In other embodiments, the insert2150having the grooves2174and protrusions2172may be secured in the slot2131with epoxy, such that the epoxy provides a secondary means of securing the insert within the slot.

Although the golf club heads with port structure, tuning elements, and related methods has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made without departing from the spirit or scope of the present disclosure. For example, to one of ordinary skill in the art, it will be readily apparent that blocks1210and blocks1220of method1200(FIG. 12) can be comprised of many different procedures, processes, and activities and be performed by many different modules, in many different orders, that various elements ofFIGS. 1-20may be modified, and that the foregoing discussion of certain of these embodiments does not necessarily represent a complete description of all possible embodiments.

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

While the above examples may be described in connection with an iron-type club, a wedge-type club, or a hybrid-type club, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of golf clubs such as a driver wood-type golf club, a fairway wood-type golf club, or a putter-type golf club. Alternatively, the apparatus, methods, and articles of manufacture described herein may be applicable other type of sports equipment such as a hockey stick, a tennis racket, a fishing pole, a ski pole, etc.

Additional examples of such changes have been given in the foregoing description. Other permutations of the different embodiments having one or more of the features of the various figures are likewise contemplated. Accordingly, the disclosure of embodiments is intended to be illustrative and is not intended to be limiting. It is intended that the scope of the present disclosure shall be limited only to the extent required by the appended claims.

The golf club heads with port structure, tuning elements, and related methods discussed herein may be implemented in a variety of embodiments, and the foregoing discussion of certain of these embodiments does not necessarily represent a complete description of all possible embodiments. Rather, the detailed description of the drawings, and the drawings themselves, disclose at least one preferred embodiments, and may disclose alternative embodiments.

Clause 1: A golf club head comprising a strike portion comprising a strikeface and a backface opposite the strikeface, the backface comprising a perimeter portion at a top end of the backface, a rear portion coupled to the strike portion at a bottom end of the strike portion, and a port structure at least partially defined within the rear portion, the port structure comprising a slot extending from a slot opening to a slot base, and an insert located within and substantially conformal with the port structure, and a toe weight comprising a material having a density greater than approximately 14 g/cm3, wherein an area of the strikeface supported by the insert comprises approximately 15-50% of the surface area of the strikeface, and a minimum face thickness of the strikeface, measured in a direction substantially parallel to the strikeface, is less than 0.254 cm.

Clause 2: The golf club head of clause 1, wherein the area of the strikeface supported by the insert is approximately 4.84-14.52 cm2.

Clause 3: The golf club head of clause 1, wherein the toe weight comprises a weight greater than approximately 10 grams.

Clause 4: The golf club head of clause 1, wherein the toe weight comprises a weight greater than approximately 20 grams.

Clause 5: The golf club head of clause 1, wherein the toe weight comprises a volume greater than approximately 1.97 cm3.

Clause 6: The golf club head of clause 1, wherein a heel to toe moment of inertia is greater than approximately 2,452 g·cm2and a top to bottom moment of inertia is greater than approximately 619 g·cm2.

Clause 7: The golf club head of clause 1, wherein a minimum lower thickness of the strikeface measured from the strikeface to a front wall of the slot is less than or equal to approximately 0.2286 cm, a minimum upper thickness of the strikeface measured from the strikeface to the backface is less than approximately 0.254 cm, and the minimum lower thickness of the strikeface is less than the minimum upper thickness of the strikeface.

Clause 8: The golf club head of clause 1, wherein the minimum upper thickness of the strikeface is approximately 0.152 cm to approximately 0.254 cm.

Clause 9: The golf club head of clause 1, wherein the minimum lower thickness of the strikeface is approximately 0.127 cm to approximately 0.2286 cm.

Clause 10: The golf club head of clause 1, wherein the toe weight further comprises a first portion comprising a first material and a second portion comprising a second material.

Clause 11: The golf club head of clause 1, wherein the slot further comprises a heel wall, a toe wall, a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall, the rear wall comprises a first rear wall curve along a first direction extending between the slot opening and the slot base wherein the first rear wall curve is convex in the first direction extending between the slot opening and the slot base, and a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall, the strikeface being located closer to the front wall than the rear wall.

Clause 12: The golf club head of clause 2, wherein the first front wall curve comprises a portion of a first circle having a first radius, the first rear wall curve comprises a portion of a second circle having a second radius, and the first circle and the second circle are approximately concentric.

Clause 13: A golf club head comprising a strike portion comprising a strikeface and a backface opposite the strikeface, the backface comprising a perimeter portion at a top end of the backface, a rear portion coupled to the strike portion at a bottom end of the strike portion, and a port structure at least partially defined within the rear portion, the port structure comprising a slot extending from a slot opening to a slot base, and wherein the slot further comprises a heel wall, a toe wall, a rear wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall, the rear wall comprises a first rear wall curve along a first direction extending between the slot opening and the slot base wherein the first rear wall curve is convex in the first direction extending between the slot opening and the slot base, and a front wall extending from the slot opening to the slot base, and extending between the heel wall and the toe wall, the strikeface being located closer to the front wall than the rear wall, and a minimum face thickness of the strikeface, measured in a direction substantially parallel to the strikeface, is less than 0.254 cm.

Clause 14: The golf club head of clause 13, further comprising an insert located within and substantially conformal with the port structure, wherein an area of the strikeface supported by the insert comprises approximately 15-50% of the surface area of the strikeface.

Clause 15: The golf club head of clause 13, further comprising a toe weight comprising a material having a density greater than approximately 14 g/cm3.

Clause 16: The golf club head of clause 13, wherein the area of the strikeface supported by the insert is approximately 4.84-14.52 cm2.

Clause 17: The golf club head of clause 13, wherein the toe weight comprises a weight greater than approximately 10 grams.

Clause 18: The golf club head of clause 13, wherein a heel to toe moment of inertia is greater than approximately 2,452 g·cm2and a top to bottom moment of inertia is greater than approximately 619 g·cm2.

Clause 19: The golf club head of clause 13, wherein the toe weight further comprises a first portion comprising a first material and a second portion comprising a second material.

Clause 20: The golf club head of clause 13, wherein the first front wall curve comprises a portion of a first circle having a first radius, the first rear wall curve comprises a portion of a second circle having a second radius, and the first circle and the second circle are approximately concentric.