Abstract:
The present disclosure concerns embodiments of a badge or insert for a golf club head that can eliminate undesired gaps between the insert and the peripheral sidewall of the cavity that receives the insert. In one embodiment, a golf club head comprises a main body comprising a cavity, which defines a central surface and an inner peripheral surface at least partially surrounding the central surface. An insert comprises a central portion and a deflectable portion coupled to and extending along a peripheral edge section of the central portion. The deflectable portion has a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity. The deflectable portion forms a press-fit engagement with the corresponding section of the inner peripheral surface of the cavity that retains the deflectable portion in a deflected state relative to the central portion.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application is a continuation of U.S. patent application Ser. No. 13/717,518, filed Dec. 17, 2012, which is incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure concerns embodiments of a golf club head, and in particular, embodiments of an improved badge insert for a golf club head. 
       BACKGROUND 
       [0003]    Iron-type golf club heads typically include large cavities in their rear surfaces. Typically, the position and overall size and shape of a cavity are selected to remove mass from that portion of the club head and/or to adjust the center of gravity of the club head. Manufacturers of golf clubs often place a badge or insert in the cavity for decorative purposes and/or for indicating the manufacturer name, logo, trademark, or the like. In addition, a badge or insert may be used to achieve a performance benefit, such as for vibration damping. 
         [0004]    Due to variances in investment casting, the size of the cavity for any particular model can vary between different vendors that perform the casting process and between club heads supplied from the same vendor. As a result, badges are often designed to be undersized relative to the nominal size of the cavity so as not to interfere with the peripheral sidewall of the cavity and sometimes are installed offset toward one side of the cavity. Unfortunately, this leaves unsightly gaps around the periphery of the badge. 
       SUMMARY 
       [0005]    The present disclosure concerns embodiments of a badge or insert that can eliminate undesired gaps between the insert and the peripheral sidewall of the cavity which can otherwise occur due to variances in the exact size of the cavity. The insert typically is installed in the rear surface of an iron-type golf club head. Accordingly, the detailed description that follows describes embodiments of an insert installed in the rear surface of an iron-type club head. However, the insert also can be installed in a cavity formed in another portion of the club head (such as the front, heel, toe, upper, and/or lower portions of the club head) or in another type of club head (such as a driver or wood-type club head, a putter or wedge). 
         [0006]    In one representative embodiment, a golf club head comprises a body comprising a face portion defining a striking face of the club head and a rear portion opposite the face portion. The rear portion includes a cavity, which defines a rear inner surface substantially opposite the striking face and an inner peripheral surface at least partially surrounding the rear inner surface. An insert is disposed in the cavity. The insert comprises a central portion and a peripheral edge portion coupled to the central portion. At least a portion of the peripheral edge portion comprises a deflectable portion having a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity, with the deflectable portion being retained in a deflected state by contact with the corresponding section of the inner peripheral surface of the cavity. 
         [0007]    In another representative embodiment, a golf club head comprises a main body comprising a cavity, which defines a central surface and an inner peripheral surface at least partially surrounding the central surface. An insert is disposed in the cavity. The insert comprises a central portion and a deflectable portion coupled to and extending along a peripheral edge section of the central portion. The deflectable portion has a shape corresponding to and contacting a corresponding section of the inner peripheral surface of the cavity. The deflectable portion forms a press-fit engagement with the corresponding section of the inner peripheral surface of the cavity that retains the deflectable portion in a deflected state relative to the central portion. 
         [0008]    In another representative embodiment, a method of assembling a golf club head comprises providing a golf club head comprising a face portion defining a striking face of the club head and a rear portion opposite the face portion, the rear portion including a cavity, the cavity defining a rear inner surface substantially opposite the striking face and an inner peripheral surface at least partially surrounding the rear inner surface. The method further comprises providing an insert comprising a central portion and a deflectable portion at least partially surrounding the central portion and corresponding to the shape of a corresponding section of the inner peripheral surface of the cavity, the deflectable portion being in a non-deflected state that is larger than the corresponding section of the inner peripheral surface. The insert is then inserted into the cavity such that the deflectable portion contacts the corresponding section of the inner peripheral surface of the cavity and moves to a deflected state relative to the central portion. 
         [0009]    The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of an exemplary embodiment of an iron-type golf club head having an insert installed in the rear portion of the club head. 
           [0011]      FIG. 2  is a cross-sectional view of the club head taken along line  2 - 2  of  FIG. 1 . 
           [0012]      FIG. 3  is a perspective, exploded view of the club head and the insert of  FIG. 1 . 
           [0013]      FIG. 4  is a rear elevation view of the club head of  FIG. 1 , shown with the insert removed for purposes of illustration. 
           [0014]      FIG. 5  is an elevation view of the insert of  FIG. 1 , shown apart from the club head. 
           [0015]      FIG. 6  is a cross-sectional view of a club head having another embodiment of an insert installed in the rear portion of the club head. 
           [0016]      FIG. 7  is an elevation view of the insert of  FIG. 6 , shown apart from the club head. 
           [0017]      FIG. 8  is a cross-sectional view of the insert taken along line  8 - 8  of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Referring first to  FIGS. 1-4 , there is shown an iron-type golf club head  10 , according to one embodiment. The club head  10  comprises a main body  12  having an upper portion  14 , a lower portion  16 , a toe portion  18 , a heel portion  20 , and a hosel  22  extending from the area where the heel portion  20  joins the upper portion  14 . A shaft  24  can be joined to the hosel  22  to form an assembled golf club. The lower end portion of the shaft  24  extends into the hosel  22  and is secured in place relative to the main body  12  using conventional techniques or mechanisms. 
         [0019]    The main body  12  also includes a face portion  26  defining a front striking face  28  for the club head and a rear portion  30  opposite the face portion  26 . The rear portion  30  includes a recessed portion, or cavity,  32 . As best shown in  FIG. 3 , the cavity  32  has a main inner surface  44  and an inner peripheral surface  46  surrounding the main inner surface. Disposed inside the cavity  32  is an insert  34  (also referred to as a “badge,” “badge insert,” or “medallion”). The insert  34  has an exposed outer surface  36  that is visible to a user. Words, logos, designs, graphics, trademarks, and other types of visible indicia may be printed or formed on the outer surface  36  for aesthetic or decorative purposes. In some embodiments, the insert  34  may also comprise materials or be constructed in a manner to provide a performance benefit, such as vibration damping. 
         [0020]    In the illustrated embodiment, as best shown in  FIG. 2 , a lower portion  48  of the cavity  32  is formed between the face portion  26  and a lower rear portion  50  of the club head. Thus, as can be seen, the insert  34  can be sized such that it extends slightly below an upper ledge  52  of the lower rear portion  50 . As shown in  FIG. 2 , there can be a substantial gap between the inner peripheral surface  46  and the insert  34  within the lower cavity portion  48 . The insert  34  need not be sized to cover this gap since it is hidden from view by the lower rear portion  50 . 
         [0021]    Referring to  FIG. 5 , the insert  34  comprises a central portion  38  and an outer peripheral portion  40  coupled to and extending along the peripheral edge of the central portion  38 . At least a portion of the peripheral portion  40  of the insert comprises a deflectable portion  42  that has a shape corresponding to and contacting a corresponding section  56  of the inner peripheral surface  46  of the cavity  32 . In the illustrated embodiment, the deflectable portion  42  comprises the extent of the peripheral portion  40  encircled by dashed line  54  ( FIG. 5 ) and the corresponding section  56  of the inner peripheral surface  46  comprises the extent of the peripheral surface  46  encircled by dashed line  58 . As can be seen, the deflectable portion  42  extends along the peripheral upper edge and the peripheral heel and toe edges of the central portion but not along the peripheral lower edge of the central portion. Thus, in the illustrated embodiment, the lower part of the peripheral portion  40  that extends into the lower cavity portion  48  (and which is mostly hidden from view), need not be part of the deflectable portion because it is spaced from the peripheral inner surface  46  within the lower cavity portion  48  ( FIG. 2 ). 
         [0022]    The deflectable portion  42  is configured to be slightly oversized relative to the corresponding section  56  of the inner peripheral surface  46  but is deflectable relative to the central portion  38  to allow the deflectable portion  42  to conform to the corresponding section  56  as the insert is press-fitted into the cavity. In this manner, the deflectable portion  42  can contact the corresponding section  56  continuously along the entire extent of the deflectable portion  42  so that there are no visible gaps between the deflectable portion and the inner peripheral surface  46  of the cavity. Thus, if the exact size of the cavity for a particular model varies between club heads, such as due to investment casting variances or other manufacturing limitations, the insert  34  can be installed in the cavity without any visible gaps. 
         [0023]    As shown in  FIG. 2 , an inner surface  68  of the insert can be adhesively secured to the inner surface  44  of the cavity, such as with a layer of double-sided tape  60 , to ensure that insert remains in place within the cavity during normal use of the golf club. Alternatively, the insert  34  can be secured to the inner surface  44  of the cavity with epoxy or another suitable adhesive or glue. 
         [0024]    As best shown in  FIG. 2 , the deflectable portion  42  in the illustrated configuration is coupled to the peripheral edge of the central portion  38  by a living hinge  62 . The hinge  62  allows the deflectable portion  42  to conform to the inner peripheral surface  46  when the insert is pressed into the cavity  32 . The hinge  62  can be formed by machining, injection molding, or otherwise forming a thinned region to reduce the cross-sectional thickness of the insert at or near the location at which the peripheral edge of the central portion  38  is coupled to the living hinge  62 , such as a V-shaped gap  64  along the outer peripheral surface of the insert. In particular embodiments, the insert  34  can be a unitary piece of material that is molded, cast, machined or otherwise formed to have a central portion  38  and a raised peripheral portion  40  having a thickness greater than the central portion. The peripheral portion  40  (or at least the portion that will form the deflectable portion  42 ) is formed such that it is slightly larger than the opening defined by the corresponding section  56  of the inner peripheral surface. The gap  64  can then be formed in the outer peripheral surface of the insert to form the deflectable portion  42  and the hinge  62 . The outer peripheral edge  66  of the central portion can be formed, or trimmed (if needed) so that it can fit within the cavity without contacting the inner peripheral surface. In the illustrated embodiment, the gap  64  is not formed in the portion of the insert  34  that extends into the lower cavity portion  48 . Thus, the lower peripheral portion  40  of the insert that extends into the lower cavity portion  48  is simply defined by a raised portion of the insert. However, in other embodiments, the entire extent of the peripheral portion  40  can be a deflectable portion  42  (i.e., the hinge  62  can extend completely around the outer peripheral surface of the insert). 
         [0025]    When the insert  34  is apart from the club head  10 , the deflectable portion  42  is in a non-deflected state having a larger peripheral shape than the opening defined by the corresponding section  56  of the cavity. When the insert  34  is pressed into the cavity, the deflectable portion  42  contacts the corresponding section  56  of the inner peripheral surface  46  and is deflected inwardly slightly relative to the central portion  38  to assume a deflected state while the central portion  38  is not deformed or deflected by the installation process. 
         [0026]    Any of various suitable materials can be used to form the central portion  38  and the peripheral portion  40 . For example, in some embodiments, the central portion  38  may comprise a metal (e.g., aluminum, steel, nickel, cobalt, titanium, or alloys including these materials) and/or one or more of various polymers (e.g., ABS plastic (acrylonitrile—butadiene—styrene), nylon, and/or polycarbonate). In some embodiments, the peripheral portion  40  may comprise a metal (e.g., aluminum, nickel, cobalt, steel, titanium, or alloys including these materials), one or more of various polymers (e.g., ABS plastic, nylon, polycarbonate, or combinations of these materials), and/or an elastomer or a viscoelastic material, such as rubber or any of various synthetic elastomers, such as polyurethane, a thermoplastic or thermoset material polymer, or silicone or combinations of these materials. 
         [0027]    In alternative embodiments, the entire cavity  32  may be visible, or it may be otherwise preferable to provide an insert  34  that is coextensive with the entire cavity  32 . In such cases, the deflectable portion  42  can comprise the entire extent of the peripheral portion  40 , such that the deflectable portion  42  contacts the entire inner peripheral surface  46 , thereby eliminating any gaps between the insert and the inner peripheral surface  46  of the cavity. 
         [0028]      FIGS. 6-8  illustrate an insert  100 , according to another embodiment, installed within the cavity  32  of the club head. The insert  100  comprises a central portion  102  and a deflectable peripheral portion  104  surrounding the outer peripheral edge of the central portion  102 . The central portion  102  comprises an outer, exposed surface  106  on which there can be provided various indicia, logos, designs, and the like. The insert has an inner surface  108  that can be secured to the inner surface  44  of the cavity, such as with a piece of double-sided tape  110  or a suitable adhesive, such as epoxy. 
         [0029]    The central portion  102  comprises a first material (or a first combination of multiple materials) and the peripheral portion  104  comprises a second material that is relatively more pliable and/or deformable than the first material. Like the insert  34  described above, the peripheral portion  104  of insert  100  corresponds to and contacts a corresponding section  56  of the inner peripheral surface  46  of the cavity. When the insert  100  is apart from club head  10 , the peripheral portion  104  is in a non-deformed, non-deflected state that is slightly larger than the opening defined by the corresponding section  56  of the inner peripheral surface  46  of the cavity. When pressed into the cavity, the peripheral portion  104  can conform to the inner peripheral surface  46  and can contact the inner peripheral surface  46  continuously along the entire extent of the corresponding section  56  without any visible gaps between the peripheral portion  104  and the corresponding section  56 . In other words, the peripheral portion  104  that comes in contact with the corresponding section  56  of the inner peripheral surface  46  moves to a deformed or deflected state in continuous contact with that portion of the inner peripheral surface  46  while the central portion  102  is not deflected or deformed by the installation process. 
         [0030]    In particular embodiments, the peripheral portion  104  is formed from an elastomer or a viscoelastic material, such as rubber or any of various synthetic elastomers, such as polyurethane, a thermoplastic or thermoset material polymer, or silicone. The central portion  102  is formed from a material that is firmer than the peripheral portion  104 . Desirably, the material for the central portion  102  is selected such that the central portion  102  does not deflect or deform when the insert  100  is inserted into the cavity  32 . In particular embodiments, for example, the central portion can be formed from any suitable metal (such as aluminum, steel, nickel, cobalt, titanium, or alloys including these materials) or a polymer that is relatively harder than the material used to form the peripheral portion. For example, relatively harder polymers that can be used to form the central portion  102  include ABS plastic, nylon, and/or polycarbonate. 
         [0031]    The peripheral portion  104  can be joined to the central portion  102  using any of various suitable techniques or mechanisms. For example, the peripheral portion  104  can be co-molded with and/or around the central portion  102 . Alternatively, the peripheral portion  104  can be joined to the central portion  102  using an adhesive, welding, or by an interference fit between the two components. 
         [0032]    In the illustrated embodiment, the entire peripheral portion  104  is deflectable, although this not need be the case. Since the lower part of the insert  100  extends into the lower cavity portion  48  and does not contact the adjacent portion of peripheral surface  46  (as shown in  FIG. 6 ), this part of the insert need not include a deflectable peripheral portion. Of course, in embodiments where the entire cavity in the rear of the club head is visible, or where it may be otherwise preferable to provide an insert  100  that is coextensive with the entire cavity  32 , it would be beneficial to provide a deflectable peripheral portion around the entire periphery of the insert. 
         [0033]    The disclosed embodiments can be adapted for inserts that are installed in cavities and/or pockets located in other portions of a club head and for inserts that are installed in club heads other than irons, such as wood-type club heads (e.g., drivers), putters and wedges. In certain embodiments, for example, an insert having a deformable or deflectable peripheral portion as discussed above can be installed in a cavity located at any portion of any type of club head (e.g., a cavity formed in the upper portion, the lower portion, the toe portion, the heel portion, the rear portion, and/or the front portion of a club head). In one specific implementation, an insert having a deformable or deflectable peripheral portion in installed in the front face portion of a club head and forms the striking surface of the club head. 
         [0034]    Furthermore, inserts as disclosed herein can also be adapted to be installed in products other than golf club heads, such as various types of sporting goods, household appliances, machinery, to name just a few. Thus, the embodiments of inserts disclosed herein can be installed in a cavity that is formed in just about any product or device. 
       General Considerations 
       [0035]    For purposes of this description, certain aspects, advantages, and novel features of the embodiments of this disclosure are described herein. The disclosed methods, apparatuses, and systems should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The methods, apparatuses, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed embodiments require that any one or more specific advantages be present or problems be solved. 
         [0036]    Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. As used herein, the terms “a”, “an” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element. 
         [0037]    As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C” or “A, B and C.” 
         [0038]    As used herein, the term “coupled” generally means physically coupled or linked and does not exclude the presence of intermediate elements between the coupled items absent specific contrary language. 
         [0039]    In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.