Patent Description:
Typically, a golf club head may be formed primarily from a metal material. In some cases, a golf club head may be formed from a composite material including a polymeric resin and a reinforcing fiber. The reinforcing fiber can be provided in sheets. The sheets can be preimpregnated with a polymeric resin. Sometimes the sheets are first formed into the desired shape and then impregnated with the polymeric resin. These fiber-impregnated sheets can only be formed into simple shapes, such as a crown insert or a sole insert. The sheets cannot easily be formed into unique shapes such as hosel geometries or parts that wrap over the skirt of the club head. There is a need in the art for the ability to manufacture composite (or plastic) components of clubs with intricate geometries. The injection moulding of rear parts of golf club heads is known from <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

Described herein is a golf club head having an injection molded wrap-around component that has high strength and low weight. The golf club head is formed of a metallic front component and a composite rear wrap-around component. In addition to forming the striking face, the main component has an extension that stretches rearwards along the sole. The low-density composite piece can slide or cap over the main component to reduce the weight of upper and rear portions of the club head. The single composite piece forms the majority of the crown and also wraps around a skirt of the club to form portions of the sole. The composite wrap-around component is injection molded from a gate at a rear peripheral edge of the crown. The wrap-around component can comprise thickened regions, which act as flow leaders or highways for distributing the molten composite material to the extremities of the mold during injection molding. The wrap-around component can be formed from a polymeric composite material.

The golf club head can be created by a method that produces a strong and flexible striking face coupled with a lightweight and durable rear crown and toe and heel sole sections. The wrap-around component that forms the rear crown and portions of the sole can be injection molded. The injection molding process, enabled by the geometry of the wrap-around component, creates a component of high strength and low weight. Furthermore, the injection molding process can reduce production times. Forming portions of the crown and sole from a composite material can improve the acoustic response of the golf club head upon impact with a golf ball.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials similar or equivalent to those described herein can be used in practice or testing of the present invention. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

The terms "comprise(s)," "include(s)," "having," "has," "can," "contain(s)," and variants thereof, as used herein are intended to be open-ended transitional phrases, terms or words that do not preclude the possibility of additional acts or structures. The singular forms "a," "and" and "the" include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments "comprising," "consisting of" and "consisting essentially of" the embodiments or elements presented herein, whether explicitly set forth or not.

The modifier "about," "approximately," or "roughly" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes at least the degree of error associated with the measurement of the particular quantity). The modifier "about," "approximately," or "roughly" should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression "from about <NUM> to about <NUM>" also discloses the range "from <NUM> to <NUM>. " The term "about," "approximately," or "roughly" may refer to plus or minus <NUM>% of the indicated number. For example, "about <NUM>%" may indicate a range of <NUM>% to <NUM>%, and "about <NUM>" may mean from <NUM>-<NUM>. Other meanings of "about," "approximately," or "roughly" may be apparent from the context.

"Sole" as used herein may mean the bottom surface or portion of a golf club head when it is set at address. The sole may not be visible from a top or crown view of the golf club head.

"Crown" as used herein may mean the top surface or portion of a golf club head when it is set at address. The crown may not be visible from a bottom or sole view of the golf club head.

"Injection molding" as used herein may mean a process of heating a polymeric material or a composite material, pressing said polymeric or composite material into a mold, cooling the material within the mold to form a solid part, and ejecting the solid part from the mold.

"Mold" as used herein may mean two or more metal pieces that together form a cavity. The cavity may be in the shape of a desired product or component, such as a component of a golf club head. The mold may include a gate or other paths for material to flow through that are not included in the cavity. The mold may include cooling lines that allow coolant to flow through the mold.

"Top mold half' as used herein may mean a first, upper section of a mold. "Bottom mold half" as used herein may mean a second, lower section of a mold. The top mold half is configured to pull, lift, or otherwise move away from the bottom mold half when the part is ejected from the mold.

"Springback" as used herein may mean a warping phenomenon that occurs with some injection molded parts when they are ejected from the mold. If an inner surface of a part has a different surface area than an outer surface of the part, the part can warp when it is ejected from the mold. The compressive stresses on the larger surface (typically the outer surface) can overdo the compressive stresses on the smaller surface (typically the inner surface), causing the part to warp.

"Shrink rate" as used herein may mean the amount which a material shrinks after it is ejected from a mold in an injection molding process. Shrink rate is related to the properties of the material that is used in the injection molding process. Unlike springback, the shrink rate is not dependent on or affected greatly by the part geometry.

"Pathlines" as used herein may mean the simulated or actual direction that a material can flow. Pathlines in simulations can also represent the speed at which the material fills regions of the mold. Pathlines can indicate or represent the direction and/or speed of fill during an injection molding process. A higher density of pathlines within a portion of the mold may represent the portion of the mold that will fill first.

"Gate" as used herein may mean a mouth of a mold used in injection molding. During an injection molding process, the material enters the mold first through the gate. In some embodiments, "gate" may also refer to the injected molded material that was within the gate of the mold before ejection of the part from the mold.

"Flow leaders" as used herein may mean channels, areas of increased thickness, and/or paths for material to flow along or through during an injection molding process. Flow leaders can span from a gate towards other regions of the club head. Flow leaders can be angled towards areas of the mold that would otherwise be challenging for the material to reach.

"Weld line" as used herein may mean a line at which two separate material flows intersect or connect. The weld line may mean a low-strength seam which is formed within a mold during an injection molding process.

"Freeze off thickness" as used herein may mean the minimum thickness at which a material can successfully flow. A mold designed for injection molding must be designed so that all regions of the mold comprise a thickness equal to or greater than the freeze off thickness.

"Cycle time" as used herein may mean the amount of time to injection mold a single part during an injection molding process.

The golf club head <NUM> described herein comprises a main component <NUM> that is generally metal and a wrap-around component <NUM> that is composite. The composite material can be injection molded to form the lightweight wrap-around component <NUM>. The wrap-around component <NUM> can comprise a thin crown section <NUM>, to reduce the weight of the crown <NUM> compared to a conventional metal golf club head. The wrap-around component <NUM> can also comprise heel and toe wings <NUM>, <NUM> that form parts of the sole <NUM>, to reduce the weight of the sole <NUM>, thus directing the center of gravity rearwards. The metallic main component <NUM> comprises a rear extension <NUM> that supports a weight channel or port <NUM> for securing a weight <NUM> at the rear end <NUM> of the club head <NUM>. The combination of the metallic main component <NUM> and the composite wrap-around component <NUM> forms a club head <NUM> with a low and rear located center of gravity, a high moment of inertia, and a reduced spin, launch, and forgiveness benefits over club heads lacking the composite wrap-around component feature. Furthermore, forming the high strength, low weight wrap-around component requires a particular mold design and manufacturing method, as described below.

Referring to <FIG> and <FIG>, the golf club head <NUM> described herein comprises a front end <NUM>, a rear end <NUM>, a crown <NUM>, a sole <NUM>, a skirt <NUM> connecting the crown <NUM> to the sole <NUM>, a toe end <NUM>, and a heel end <NUM>. The golf club head <NUM> comprises the main component <NUM> that forms a strikeface <NUM> at the golf club head front end <NUM>. The main component <NUM> can further form a return <NUM> that extends rearward from the strikeface <NUM>, forming a portion of the sole <NUM> and a portion of the crown <NUM>. The main component <NUM> further comprises a sole extension <NUM>, connected to a sole portion of the return <NUM>. The sole extension <NUM> reaches or extends from the return <NUM> to the rear end <NUM> of the golf club head <NUM>. In some embodiments, the sole extension <NUM> comprises a weight port or weight channel <NUM> for receiving a weight <NUM>. The main component <NUM> can comprise a lip <NUM> that runs along a rear edge <NUM> of the return <NUM> and along edges <NUM>, <NUM> of the sole extension <NUM>.

The golf club head <NUM> further comprises the wrap-around component <NUM> that forms the remainder of the golf club head <NUM> that is not formed by the main component <NUM>. The wrap-around component <NUM> forms portions of both the crown <NUM> and the sole <NUM> of the golf club head <NUM>. The wrap-around component <NUM> can comprise a crown section <NUM>, a toe wing <NUM>, and a heel wing <NUM>. The crown section <NUM> of the wrap-around component forms <NUM> a central and rear portion of the crown <NUM> of the club head <NUM>. The toe wing <NUM> of the wrap-around component <NUM> extends from the crown section <NUM>, around the skirt <NUM>, and into the sole <NUM>. The toe wing <NUM> forms a section of the toe end <NUM> of the club head <NUM>. Similarly, the heel wing <NUM> of the wrap-around component <NUM> extends from the crown section <NUM> opposite the toe wing <NUM>, around the skirt <NUM>, and into the sole <NUM>. The heel wing <NUM> forms a section of the toe end <NUM> of the club head <NUM>. The wrap-around component <NUM> can comprise a lip (not shown) that is configured to engage the main component lip <NUM>. In the assembled club head <NUM>, the overlapping of the lips forms a lap joint structure that allows the wrap-around component <NUM> to bond the main component <NUM>.

Referring to <FIG> and <FIG>, a coordinate system may be defined with an origin <NUM> at the strikeface center of the strikeface <NUM>, the coordinate system having an X-axis <NUM>, a Y-axis <NUM>, and a Z-axis <NUM>. The X-axis <NUM> is a horizontal axis that extends through the striking face center of the strikeface <NUM> in a direction from the heel end <NUM> to the toe end <NUM> of the golf club head <NUM>, and parallel to a ground plane <NUM> when the club head <NUM> is at address. The Y-axis <NUM> is a vertical axis that extends through the striking face center <NUM> of the strikeface <NUM> in a direction from the crown <NUM> to the sole <NUM> of the golf club head <NUM>, and perpendicular to the X-axis <NUM>, and the Z-axis <NUM> extends through the strikeface center <NUM> in a direction from the strikeface to the rear end <NUM> of the golf club head <NUM> and perpendicular to the X-axis and the Y-axis.

The coordinate system defines an XY plane extending through the X-axis <NUM> and the Y-axis <NUM>, an XZ plane extending through the X-axis <NUM> and the Z-axis <NUM>, and a YZ plane extending through the Y-axis <NUM> and the Z-axis <NUM>, wherein the XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the origin <NUM> of the coordinate system at the strikeface center. A loft plane <NUM> is tangent to the strikeface <NUM> at the origin <NUM>. The loft plane <NUM> is angled from the XY plane by a loft angle <NUM>, when viewed perpendicular to the YZ plane.

In some embodiments, particularly when the golf club head <NUM> is a driver, the loft angle <NUM> of the club head <NUM> is less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, or less than approximately <NUM> degrees.

In some embodiments, particularly when the golf club head <NUM> is a fairway wood, the loft angle <NUM> of the club head <NUM> is less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, or less than approximately <NUM> degrees. Further, in many embodiments, the loft angle <NUM> of the club head <NUM> is greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, or greater than approximately <NUM> degrees. For example, in some embodiments, the loft angle of the club head can be between <NUM> degrees and <NUM> degrees, between <NUM> degrees and <NUM> degrees, between <NUM> degrees and <NUM> degrees, or between <NUM> degrees and <NUM> degrees.

In some embodiments, particularly when the golf club head <NUM> is a hybrid, the loft angle <NUM> of the club head <NUM> is less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, less than approximately <NUM> degrees, or less than approximately <NUM> degrees. Further, in many embodiments, the loft angle of the club head is greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, greater than approximately <NUM> degrees, or greater than approximately <NUM> degrees.

Furthermore, referring to <FIG>, a hosel axis <NUM> is inclined from the X-axis <NUM> at a predetermined angle, called the lie angle <NUM>, when viewed from a direction perpendicular to the XY plane. The hosel axis <NUM> can be inclined from the X-axis <NUM> by a lie angle <NUM> of between <NUM> degrees to <NUM> degrees, inclusively.

The length <NUM> of the club head <NUM> can be measured as the furthest extent of the club head <NUM> from the heel end <NUM> to the toe end <NUM>, in a direction parallel to the X-axis <NUM>, when viewed from the front view. In many embodiments, the length <NUM> of the club head <NUM> can be measured according to a golf governing body such as the United States Golf Association (USGA). For example, the length of the club head can be determined in accordance with the USGA's Procedure for Measuring the Club Head Size of Wood Clubs (USGA-TPX3003, Rev. <NUM>, November <NUM>, <NUM>) (available at https://www. org/content/dam/usga/pdf/Equipment/TPX3003-procedure-for-measuring-the-club-head-size-of-wood-clubs. pdf) (the "Procedure for Measuring the Club Head Size of Wood Clubs"). The maximum club head length can range between <NUM> to <NUM> (<NUM> to <NUM> inches).

The height <NUM> of the club head <NUM> can be measured as the furthest extend of the club head <NUM> from the crown <NUM> to the sole <NUM>, in a direction parallel to the Y-axis <NUM>, when viewed from the front view. In many embodiments, the height <NUM> of the club head <NUM> can be measured according to a golf governing body such as the United States Golf Association (USGA). For example, the height of the club head can be determined in accordance with the USGA's Procedure for Measuring the Club Head Size of Wood Clubs (USGA-TPX3003, Rev. <NUM>, November <NUM>, <NUM>) (available at https://www. org/content/dam/usga/pdf/Equipment/TPX3003-procedure-for-measuring-the-club-head-size-of-wood-clubs. pdf) (the "Procedure for Measuring the Club Head Size of Wood Clubs"). The maximum club head height can range between <NUM> to <NUM> (<NUM> to <NUM> inches).

The depth <NUM> of the golf club head <NUM> can be measured as the furthest extent of the club head <NUM> from the front end <NUM> to the rear end <NUM>, in a direction parallel to the Z-axis <NUM>, when viewed from the top view. The club head depth <NUM> can range between <NUM> (<NUM> inches) and <NUM> (<NUM> inches). The volume of the club head <NUM> can be measured by submerging the club head <NUM> into a fluid and measuring the volume of the displaced fluid. In many embodiments, the volume of the club head <NUM> can be measured according to a golf governing body such as the United States Golf Association (USGA). For example, the volume of the club head can be determined in accordance with the USGA's Procedure for Measuring the Club Head Size of Wood Clubs (USGA-TPX3003, Rev. <NUM>, November <NUM>, <NUM>) (available at https://www. org/content/dam/usga/pdf/Equipment/TPX3003-procedure-for-measuring-the-club-head-size-of-wood-clubs. pdf) (the "Procedure for Measuring the Club Head Size of Wood Clubs").

The volume of the club head <NUM> (i.e. the volume contained by the outermost surfaces of the club head) can range between <NUM> cc and 800cc. In some embodiments, particularly when the golf club head is a driver, the volume of the club head is greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, greater than approximately <NUM> cc, or greater than approximately <NUM> cc. In some embodiments, the volume of the club head can be approximately 400cc - 600cc, 425cc - 500cc, approximately 500cc - 600cc, approximately 500cc - 650cc, approximately 550cc - 700cc, approximately 600cc - 650cc, approximately 600cc - 700cc, or approximately 600cc - 800cc.

In some embodiments, particularly when the golf club head is a fairway wood, the volume of the club head <NUM> is less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, or less than approximately <NUM> cc. In some embodiments, the volume of the club head can be approximately 150cc - 200cc, approximately 150cc - 250cc, approximately 150cc - 300cc, approximately 150cc - 350cc, approximately 150cc - 400cc, approximately 300cc - 400cc, approximately 325cc - 400cc, approximately 350cc - 400cc, approximately 250cc - 400cc, approximately <NUM> - <NUM> cc, or approximately <NUM>-<NUM> cc.

In some embodiments, particularly when the golf club head is a hybrid, the volume of the club head <NUM> is less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, less than approximately <NUM> cc, or less than approximately <NUM> cc. In some embodiments, the volume of the club head can be approximately 100cc - 150cc, approximately 75cc - 150cc, approximately 100cc - 125cc, or approximately 75cc - 125cc.

The golf club head <NUM> comprises the main component <NUM> and the wrap-around component <NUM>. The main component <NUM> is metallic and assumes approximately a T-shape when viewed from a crown or sole view. The trunk or base of the T-shape is formed by a sole extension <NUM> which both concentrates weight to the central sole and supports a weight channel or port <NUM> that secures a weight <NUM> at the rear end <NUM> of the golf club head <NUM>. The top of the T-shape comprises the strikeface <NUM> and a face return <NUM> that forms a front end <NUM> of the club head <NUM>. The metallic main component <NUM> makes the club head <NUM> durable to withstand impact and contributes to the desired weighting properties of the club head <NUM>, namely a low and rear located center of gravity and forgiveness.

As illustrated in <FIG>, the main component <NUM> can comprise a strikeface <NUM>, a return <NUM>, and a sole extension <NUM>. The strikeface <NUM> is located at the front end <NUM> of the golf club head <NUM>. The strikeface <NUM> is tangent to the loft plane <NUM>, making it angled from the XY plane when the golf club head <NUM> is at address. The strikeface <NUM> can be formed from a faceplate that is secured into a front cavity (not shown) of a body piece to together form the main component <NUM>. In other embodiments, the main component strikeface <NUM> and return <NUM> are integrally formed as one unit. The main component <NUM> can further comprise an upper hosel aperture <NUM> for receiving a shaft or for receiving a hosel sleeve. In some embodiments, the main component <NUM> can further include a lower hosel aperture or port <NUM> located on the sole portion of the extension <NUM>. In these embodiments, the lower hosel aperture <NUM> can be used for securing a hosel sleeve with a fastener.

The return <NUM> of the main component <NUM> extends rearward from the strikeface <NUM>. The return <NUM> forms a portion of the crown <NUM>, the sole <NUM>, the toe end <NUM>, and the heel end <NUM>. The return <NUM> can comprise a depth <NUM>, measured orthogonal to the XY plane. A ratio of the return depth <NUM> to the club head depth <NUM> can be between <NUM> and <NUM>. In some embodiments the ratio of return depth <NUM> to club head depth <NUM> can be between <NUM> and <NUM>, <NUM> and <NUM>, <NUM> and <NUM>, <NUM> and <NUM>, or <NUM> and <NUM>. In some embodiments, the return <NUM> can have a depth <NUM> that varies depending on where it is measured. For example, the return depth <NUM> can be greater adjacent the toe end <NUM> than it is adjacent the heel end <NUM>. A variable return depth <NUM> can allow one or both of the heel end <NUM> and toe end <NUM> to be weighted more than a center, to increase the forgiveness of the club head <NUM>.

Referring to <FIG>, the return <NUM> can comprise a thickness <NUM> that ranges from <NUM> (<NUM> inch) to <NUM> (<NUM> inch). In other embodiments, the return thickness <NUM> can range from <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), <NUM> (<NUM> inch) to <NUM> (<NUM> inch), or <NUM> (<NUM> inch) to <NUM> (<NUM> inch). For example, the return thickness <NUM> can be <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), or <NUM> (<NUM> inch).

Referring to <FIG>, the sole extension <NUM> stretches from the return <NUM> to the rear end <NUM> of the club head <NUM>. The sole extension <NUM> can further comprise a weight channel <NUM> adjacent the rear end <NUM>. The sole extension <NUM> can comprise a width <NUM>, measured parallel to the X-axis <NUM>, from a first edge <NUM> to a second edge <NUM> of the sole extension <NUM>. In some embodiments, the width <NUM> of the extension <NUM> is uniform, but in other embodiments the width <NUM> of the extension varies depending on where the width <NUM> is measured. The sole extension width <NUM> is less than the length <NUM> of the golf club head <NUM>. (The sole extension width <NUM> and club head length <NUM> are both measured heel-to-toe. ) The sole extension width <NUM> can range from <NUM>% to <NUM>% of the maximum club head width. The sole extension width <NUM> may be <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>% or <NUM>% of the maximum club head length <NUM>. In some embodiments, the sole extension width <NUM> can range from <NUM> (<NUM> inch) to <NUM> (<NUM> inches). A smaller sole extension width <NUM> means less metal material is used to make the sole extension <NUM>, lowering the weight of the main component <NUM>. Giving the main component <NUM> a lower weight allows increases discretionary mass that can be reallocated into desired positions on the club head <NUM> to increase forgiveness and/or position the center of gravity in a low and rearward position. However, a greater sole extension width <NUM> provides more structural support to the rear weight channel or port <NUM>, increasing the durability of the club head <NUM>. Therefore, the width <NUM> of the sole extension can be selected to correspond to the desired weighting arrangement for the club head <NUM>.

Referring to <FIG>, a sole extension axis <NUM> approximates a center of the sole extension <NUM>. The extension axis <NUM> extends between a front midpoint <NUM> and a rear midpoint <NUM> of the sole extension <NUM>. The front midpoint <NUM> is located centrally between a first and second intersection point <NUM>, <NUM>. The first and second intersection points <NUM>, <NUM> are the located where the edges <NUM>, <NUM> of the sole extension <NUM> connect to the return <NUM>. The rear midpoint <NUM> is located centrally along a rear or perimeter edge <NUM> of the sole extension <NUM>.

The sole extension <NUM> can comprise a length (not shown), measured parallel to the Z-axis <NUM>, from the return <NUM> of the main component <NUM> to the rear end <NUM> of the golf club head <NUM>. More specifically, the sole extension length is measured from the front midpoint <NUM> to the rear midpoint <NUM> of the sole extension <NUM>. The sole extension length is less than the length <NUM> of the golf club head <NUM>. The sole extension length can range from <NUM>% to <NUM>% of the maximum club head length <NUM>. In some embodiments, the sole extension length can range from <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, or <NUM>% to <NUM>% of the maximum club head length <NUM>. The sole extension length may be <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>% of the maximum club head length <NUM>.

In some embodiments, the extension axis <NUM> is approximately parallel to the YZ plane. In other embodiments, the sole extension <NUM> can extend from the return <NUM> at an angle <NUM>. The extension axis <NUM> can intersect the YZ plane at a point adjacent the rear end <NUM> of the club head <NUM>. For example, the sole extension <NUM> can attach to the return <NUM> closer to either the heel end <NUM> or the toe end <NUM>, and the sole extension <NUM> can point towards a center of the club head <NUM> as it extends rearward. In yet other embodiments, the extension axis <NUM> can intersect the YZ plane at a point adjacent the return portion <NUM>. For example, the sole extension <NUM> can be pointed away from a center of the golf club head <NUM> as it extends rearward.

The sole extension <NUM> can be positioned so that the extension axis <NUM> intersects the YZ plane at an extension angle <NUM>, as illustrated in <FIG>. The extension angle <NUM> can range from <NUM> degrees to <NUM> degrees. In some embodiments, the extension angle <NUM> can range from <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, or <NUM> to <NUM> degrees. The extension angle <NUM> allows the weight at the rear end <NUM> of the club head <NUM> to be positioned offset towards the heel end <NUM> or the toe end <NUM>. This offset positioning can give the club head <NUM> either a slight draw bias or a slight fade bias to cater to players with certain swing tendencies. In some embodiments, a front end of the sole extension <NUM> is offset to the heel end <NUM> or the toe end <NUM>. In some of these embodiments (not shown), the rear weight channel or port <NUM> remains centered at the rear end <NUM> of the club head <NUM>. In others of these embodiments, a front end and a rear end of the sold extension <NUM> are both offset from the YZ plane in different directions. Offsetting the front end of the sole extension <NUM> moves the center of gravity slightly towards the heel or toe ends <NUM>, <NUM> of the club head <NUM>, but the center of gravity movement is less drastic than when the weight <NUM> is offset.

The golf club head <NUM> further comprises the wrap-around component <NUM> that attaches to the main component <NUM> to form the hollow golf club head <NUM>. The wrap-around component <NUM> is formed from a lightweight composite material to allow more discretionary weight to be redistributed to the perimeter of the club head <NUM>. The injection-molded composite material of the wrap-around component <NUM> exhibits high strength and low weight. Furthermore, the wrap-around component structure includes thickened portions <NUM> that both allow the composite material to flow through the mold evenly during injection molding and provide additional durability to the finished wrap-around component <NUM>.

Referring to <FIG> and <FIG>, the wrap-around component <NUM> comprises a crown section <NUM>, a toe wing <NUM>, and a heel wing <NUM>. The wrap-around component <NUM> comprises an outer surface <NUM> and an inner surface <NUM>. The outer surface <NUM> is smooth. The inner surface <NUM> comprises varying regions of greater thickness that protrude slightly away from the remainder of the inner surface <NUM>, as described below. The wrap-around component <NUM> can comprise one or more thicknesses <NUM> that range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). In some embodiments, the one or more thicknesses <NUM> of the wrap-around component can range between or can range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch). The thinnest regions of the wrap-around component <NUM>, which in some embodiments form a majority of the wrap-around component <NUM>, can have a thickness <NUM> between <NUM> (<NUM> inch) and <NUM> (<NUM> inch).

In some embodiments, the wrap-around component <NUM> can comprise at least one thickness <NUM> as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), as low as <NUM> (<NUM> inch), or as low as <NUM> (<NUM> inch). In some embodiments, at least one thickness <NUM> of the wrap-around component <NUM> is less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), less than <NUM> (<NUM> inch), or less than <NUM> (<NUM> inch).

The crown section <NUM> of the wrap-around component <NUM> forms a majority of the golf club head crown <NUM>. The crown section <NUM> can comprise a gently sloping surface having one or more thicknesses <NUM>. A cross-section of the crown section <NUM>, taken along a plane parallel to the XY plane, can comprise an arcuate or parabolic outline.

In some embodiments, such as generally shown in <FIG>, the crown section <NUM> can comprise a plurality of thickened portions <NUM>. The thickened portions <NUM> can be in the form of channels, ridges, fan-shaped structures, or other regions of greater thickness on the inner surface <NUM> of the crown section <NUM>. The thickened portions <NUM> are elongate regions that extend either roughly front-to-rear or roughly heel-to-toe. In some embodiments, an array of thickened portions <NUM> is fanned out across an inner surface <NUM> (bottom surface) of the crown section <NUM>. The thickened portions <NUM> can comprise a thickness that is greater than the thickness of the remainder of crown section. The thickened portions <NUM> can comprise thicknesses between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). The thickness portions <NUM> can comprise thicknesses of <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), <NUM> (<NUM> inch), or <NUM> (<NUM> inch). Since the thickness of the thickened portions is greater than the thickness of the remainder of the wrap-around component, the thickened portions <NUM> can act as flow leaders or highways for material flow during the injection molding process, as described further below.

The thickened portions <NUM> can each comprise a width <NUM>. The width <NUM> of each thickened portion <NUM> can range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). In some embodiments, the width <NUM> of each thickened portion <NUM> is between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch), <NUM> (<NUM> inch) and <NUM> (<NUM> inch), or between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). As described further below, the thickened portions <NUM> can act as flow leaders, providing a means for composite material to flow within the mold during the injection molding process.

In some embodiments, such as generally shown in <FIG>, the crown section <NUM> can comprise a central thickened portion <NUM> or fan-shaped thickened portion, which has a thickness greater than the remainder of the crown. In one configuration, this central thickened portion <NUM> has total area of from about <NUM><NUM> (<NUM> in<NUM>) to about <NUM><NUM> (<NUM> in<NUM>), measured from a crown view (viewed parallel to the XZ plane). In another configuration, this central thickened portion <NUM> has a total area of from about <NUM><NUM> (<NUM> in<NUM>) to about <NUM><NUM> (<NUM> in<NUM>). In some embodiments, the central thickened portion <NUM> has a slightly trapezoidal shape, whereby at least a section of the central thickened portion <NUM> that is closer to the face and/or front edge <NUM> is wider than a section of the thickened portion <NUM> that is more distant from the face. The central thickened portion <NUM> may be spaced from the front edge <NUM> of the crown section <NUM> by a distance (d) that is greater than about <NUM> (<NUM> inch), or a distance that is between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), or between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), or between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). In some embodiments, the distance (d) is approximately <NUM> (<NUM> inch). As described further below, the central thickened portion <NUM> can act as a flow leader, providing a means for composite material to flow within the mold during the injection molding process.

The toe and heel wings <NUM>, <NUM> of the wrap-around component <NUM> form portions of the sole <NUM>, freeing up more discretionary weight than is possible in golf club heads with only composite crowns. The toe and heel wings <NUM>, <NUM> fill in regions of the sole <NUM> that are not formed by the main component <NUM>, making the sole <NUM> partially composite, so that the sole <NUM> has low weight regions. The toe wing <NUM> and heel wing <NUM> are integral with the crown section <NUM> of the wrap-around component <NUM>. The toe wing <NUM> forms a portion of the toe end <NUM> of the club head <NUM>. The heel wing <NUM> forms a portion of the heel end <NUM> of the club head <NUM>. In the assembled club head <NUM>, the wrap-around component <NUM> can be asymmetrical about the YZ plane. In some embodiments, the toe wing <NUM> is larger than the heel wing <NUM>. The toe and heel wings <NUM>, <NUM> attach to the crown section <NUM> along the skirt <NUM> of the golf club head <NUM>. Instead of forming separate composite sole panels, attaching the toe and heel wings <NUM>, <NUM> along the skirt <NUM> frees up more discretionary weight and simplifies the assembly of the club head <NUM>.

The toe wing <NUM> curves downward and inward from the toe-side skirt or perimeter edge of the crown section <NUM>. The toe wing <NUM> can bend or wrap downward and inward at a gentle rate. The desired final shape of the golf club head <NUM>, particularly the sole <NUM> shape, can determine the rate at which the toe wing <NUM> bends inward. The toe wing <NUM> can be three-sided. The toe wing <NUM> can comprise a crown connection portion or edge <NUM>, a front edge <NUM>, and a side edge <NUM>. The crown connection portion <NUM> is integral with a perimeter of the crown section <NUM> of the wrap-around component <NUM>. The front edge <NUM> connects to the return <NUM> of the main component <NUM> when the club head <NUM> is assembled. The side edge <NUM> connects to the sole extension <NUM> of the main component <NUM> when the club head <NUM> is assembled.

Referring to <FIG>, the toe wing <NUM> attaches to the edge of the crown section <NUM> in an arcuate and/or wrap-around fashion. The wrap-around connection of the toe wing <NUM> to the crown section <NUM>, via the crown connection portion <NUM>, defines a radius of curvature <NUM>. The toe wing connection radius of curvature <NUM> can vary slightly or be constant throughout the transition between the crown section <NUM> and the toe wing <NUM>. The toe wing connection radius of curvature <NUM> can range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), or between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). The crown connection portion <NUM> can have a thickness <NUM> that is greater than the remainder of the toe wing <NUM>. As described below, the crown connection portion <NUM> of the toe wing <NUM> can act as a flow leader, providing a means for composite material to flow within the mold during the injection molding process.

The heel wing <NUM> curves downward and inward from the heel-side skirt or perimeter edge of the crown section <NUM>. Similar to the toe wing <NUM>, the heel wing <NUM> can bend or wrap downward and inward at a gentle rate to form a shape that is desired for the heel-side sole of the golf club head <NUM>. In some embodiments, the heel wing <NUM> bends inward less abruptly than the toe wing <NUM>. The heel wing <NUM> does not extend as far inward as the toe wing <NUM>. The heel wing <NUM> can be three-sided. The heel wing <NUM> can comprise a crown connection portion <NUM>, a front edge <NUM>, and a side edge <NUM>. The crown connection portion <NUM> is integral with a perimeter of the crown section <NUM> of the wrap-around component <NUM>. The front edge <NUM> connects to the return <NUM> of the main component <NUM> when the club head <NUM> is assembled. The side edge <NUM> connects to the sole extension <NUM> of the main component <NUM> when the club head <NUM> is assembled.

Referring to <FIG>, the heel wing <NUM> attaches to the edge of the crown section in an arcuate and/or wrap-around fashion, similar to the toe wing <NUM>. The wrap-around connection of the heel wing <NUM> to the crown section <NUM>, via the heel wing crown connection portion <NUM>, defines a radius of curvature <NUM>. The heel wing connection radius of curvature <NUM> can be similar to the toe wing connection radius of curvature <NUM>. In some embodiments, the heel wing connection radius of curvature <NUM> is smaller than the toe wing radius of curvature <NUM>. As described below, the crown connection portion <NUM> of the heel wing <NUM> can act as a flow leader, providing a means for composite material to flow within the mold during the injection molding process.

In some embodiments, the toe wing <NUM> can be larger than the heel wing <NUM>. The toe wing <NUM> can comprise more material than the heel wing <NUM>. In embodiments where the toe wing <NUM> extends inward more sharply than the heel wing <NUM>, the toe wing connection radius <NUM> can comprise a thickness <NUM> that is greater than the heel wing connection radius thickness <NUM>. The greater thickness in the toe wing connection <NUM> provides strength to support the toe wing <NUM> and, as described below, enables proper material flow during injection molding.

The toe wing <NUM> and heel wing <NUM> can each comprise a thickness <NUM>, <NUM>, respectively, measured orthogonally from an inner surface <NUM> to an outer surface <NUM> of each wing. The thickness <NUM>, <NUM> of each of the wings <NUM>, <NUM> can taper down from adjacent the crown section <NUM> towards the front edges <NUM>, <NUM> and side edges <NUM>, <NUM> of each respective wing <NUM>, <NUM>. For example, the thickness <NUM>, <NUM> of the wings <NUM>, <NUM> adjacent the crown section <NUM> can range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch), whereas the thickness <NUM>, <NUM> of the wings <NUM>, <NUM> at the front edges <NUM>, <NUM> and side edges <NUM>, <NUM> of each wing can range between <NUM> (<NUM> inch) and <NUM> (<NUM> inch). The front and side edges may not require as much strength and durability during impact as the portions of the wings adjacent the crown section <NUM>, including the crown connection portions <NUM>, <NUM>. Therefore, the front edges <NUM>, <NUM> and side edges <NUM>, <NUM> may be thinner to save weight.

The wrap-around component <NUM> can further comprise a thinned region or lip (not shown) that runs around a peripheral edge of the wrap-around component <NUM>. For example, the lip can run along the front edges <NUM>, <NUM> of the wings <NUM>, <NUM>, the side edges <NUM>, <NUM> of the wings, the rear peripheral edge <NUM> of the crown section <NUM>, and a front edge <NUM> of the crown section <NUM>. The lip comprises a thickness less than the thickness of the remainder of the wrap-around component <NUM>. The lip can have a depth that matches a depth of the main component lip, so that the wrap-around component lip is configured to bond with the main component lip.

The wrap-around component <NUM> comprises a less dense material than the material of the main component <NUM>. In some embodiments, the wrap-around component <NUM> can comprise a composite formed from polymer resin and reinforcing fiber. The polymer resin can comprise a thermoplastic. More specifically, the thermoplastic resin can comprise a thermoplastic polyurethane (TPU) or a thermoplastic elastomer (TPE). For example, the resin can comprise polyphenylene sulfide (PPS), polyetheretheretherketone (PEEK), polyimides, polyamides such as PA6 or PA66, polyamide-imides, olyphenylene sulfides (PPS), polycarbonates, engineering polyurethanes, and/or other similar materials. The reinforcing fiber can comprise carbon fibers (or chopped carbon fibers), glass fibers (or chopped glass fibers), graphine fibers (or chopped graphite fibers), or any other suitable filler material. In other embodiments, the composite material may comprise any reinforcing filler that adds strength and/or durability.

The density of the composite material, which forms the wrap-around component <NUM>, can range from about <NUM>/cc to about <NUM>/cc. In some embodiments, the composite material density ranges between about <NUM>/cc and about <NUM>/cc, or between about <NUM>/cc to about <NUM>/cc. The composite material can have a melting temperature of between about <NUM> °F (<NUM>) and <NUM>°F (<NUM>). In some embodiments, the composite material has a melting temperature of between about <NUM> °F (<NUM>) to about <NUM> °F (<NUM>). In some embodiments, the composite material can have a melting temperature of between about <NUM> °F (<NUM>) and about <NUM> °F (<NUM>).

The wrap-around component <NUM> has a high tensile strength of greater than about <NUM> MPa, making the wrap-around component <NUM> durable. The high tensile strength is achieved by forming the wrap-around component <NUM> from the polymer resins and reinforcing fibers described above. The polymer resin should preferably incorporate one or more polymers that have sufficiently high material strengths and/or strength/weight ratio properties to withstand typical use while providing a weight savings benefit to the design. Specifically, it is important for the design and materials to efficiently withstand the stresses imparted during an impact between the strike face and a golf ball, while not contributing substantially to the total weight of the golf club head. In general, the polymers can be characterized by a tensile strength at yield of greater than about <NUM> MPa. When the polymer resin is combined with the reinforcing fiber, the resulting composite material can have a tensile strength at yield of greater than about <NUM> MPa, greater than about <NUM> MPa, greater than about <NUM> MPa, greater than about <NUM> MPa, greater than about <NUM> MPa, or greater than about <NUM> MPa. In some embodiments, suitable composite materials may have a tensile strength at yield of from about <NUM> MPa to about <NUM> MPa.

The composite material of the wrap-around component <NUM> can have a fiber content between about <NUM>% to about <NUM>% by weight. In some embodiments, the composite material has a fiber content between about <NUM>% to about <NUM>% by weight, or between <NUM>% to <NUM>% by weight. In some embodiments, the composite material has a fiber content of between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM> %, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>% by weight. Typically, a higher fiber content produces a composite having a higher strength, and a lower fiber content produces a composite having a lower strength. However, a higher fiber content is not always better than a lower fiber content because the fiber content also affects the moldability of the component. As described below, the fiber content affects the achievable part thickness during injection molding.

In some embodiments, the reinforcing fiber comprises a plurality of distributed discontinuous fibers (i.e. "chopped fibers"). In some embodiments, the reinforcing fiber comprises a plurality of discontinuous "long fibers," having a designed fiber length of from about <NUM> to <NUM>. For example, in some embodiments, the fiber length is about <NUM> (<NUM> inch) prior to the molding process. Other forms of reinforcing fiber, such as discontinuous "short fibers," fail to provide adequate strength properties to the final composite material ("short fibers" typically have a fiber length of from about <NUM> to <NUM>). The reinforcing long fibers are typically given premixed lengths. Due to breakage during the molding process, some fibers may actually be shorter than the described range in the final component. In some configurations, the discontinuous chopped fibers may be characterized by an aspect ratio (e.g., length/diameter of the fiber) of greater than about <NUM>, or more preferably greater than about <NUM>, and less than about <NUM>.

In some embodiments, the composite material comprises a long fiber reinforced TPU. The long fiber TPU can exhibit a high elastic modulus, greater than that of short carbon fiber compounds. The long fiber TPU can withstand high temperatures, making it suitable for use in a golf club head that is used and/or stored in a hot climate. The long fiber TPU further exhibits a high toughness, allowing it to serve well as a replacement for traditionally metal components. In some embodiments, the long fiber TPU comprises a tensile modulus between about <NUM>,<NUM> MPa and about <NUM>,<NUM> MPa or between about <NUM>,<NUM> MPa and about <NUM>,<NUM> MPa. In some embodiments, the long fiber TPU comprises a flexural modulus between about <NUM>,<NUM> MPa and about <NUM>,<NUM> MPa or between about <NUM>,<NUM> MPa and <NUM>,<NUM> MPa. The long fiber TPU material can exhibit a tensile elongation (at break) of between about <NUM>% and about <NUM>%. In some embodiments, the tensile elongation of the composite TPU material can be between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%, between about <NUM>% and about <NUM>%.

Although strength, weight, and moldability are the main considerations for the composite material, a suitable composite material may also exhibit secondary benefits, such as acoustic properties. Some composite materials mimic a metallic sound. For example, PPS and PEEK are two exemplary thermoplastic polymers that meet the strength and weight requirements of the present design, while also emitting a generally metallic acoustic response when impacted. Alternately, some composite materials are desirable because they damp the acoustic response at impact. Furthermore, geometries such as ribs or additional thickened regions can be easily incorporated into the wrap-around component <NUM> to damp the vibrations caused by certain frequencies upon impact. The damping geometries can be located in regions of the part that exhibit or vibrate at frequencies having an amplitude that is undesirably greater than other amplitudes of the acoustic response.

Described herein below is a method of manufacturing a multi-material golf club head, similar to the golf club head described above. Referring to <FIG>, the method comprises providing a main component <NUM>, providing a mold <NUM>, injection molding a wrap-around component <NUM>, plasma treating the wrap-around component <NUM>, joining the wrap-around component onto the main component to form the golf club head <NUM>, and finishing the golf club head <NUM>.

The main component <NUM> can be provided by casting the main component <NUM> from a metal material. The main component <NUM> can be initially cast as a full body. Portions of a crown <NUM> and sole <NUM> of the club head <NUM> can be laser cut out of the full body to leave only the main component <NUM>. This main component <NUM> is finished before the wrap-around component <NUM> is attached to it in the joining step.

A mold <NUM> can be provided in three parts: a top mold half <NUM>, a bottom mold half <NUM>, and a slide <NUM>. The mold parts can together define a cavity <NUM> that corresponds to the desired shape of the wrap-around component <NUM>. In some embodiments, the size of the mold cavity <NUM> is slightly different than the desired shape of the wrap-around component <NUM> to account for material shrink rate and springback. The bottom mold half <NUM> can comprise a center ballast <NUM> that assists in retaining the component in the proper location for ejection from the mold <NUM>. The mold <NUM> can additionally comprise a sprue <NUM>, a gate <NUM>, ejection pins <NUM>, cooling lines, and other necessary components.

Injection molding may be used to produce parts with intricate geometries and high impact strength. Injection molding the wrap-around component <NUM> comprises providing a mold <NUM> designed to account for shrink rate, spring back, and freeze off thickness of the injected material. The mold <NUM> is provided with a gate <NUM> and flow leaders that guide the injected material evenly into the mold. The even spread of the material into and throughout the mold <NUM> reduces weld lines. By reducing the size of the weld lines, the strength of the final part is increased.

Following injection molding, the wrap-around component <NUM> is plasma treated or the surface of the wrap-around component <NUM> is altered. The plasma treating process can increase the roughness and raise the surface energy of an outer surface of the wrap-around component <NUM>. This higher surface energy improves the ability of the wrap-around component <NUM> to join to the main component <NUM> during the last step of the method.

Joining the wrap-around component <NUM> to the main component <NUM> requires applying adhesive to a lip <NUM> of the main component <NUM> and sliding the wrap-around component <NUM> over the main component <NUM>. A lip of the wrap-around component <NUM> can overlap and bond to the lip <NUM> of the main component <NUM>. The bonding step can further comprise allowing the adhesive to dry. In other embodiments, the wrap-around component <NUM> can be mechanically fastened to the main component <NUM>, epoxied to the main component <NUM>, or any other suitable method of permanently affixing the wrap-around component <NUM> to the main component <NUM>.

After the joining step, the full club head <NUM> can be polished and cleaned. The club head <NUM> can be coated, plated, or painted. One or more weights can also be secured to the club head <NUM>. After the club head <NUM> is finished, it is ready to be attached to a shaft and grip to form a fully assembled golf club.

Providing the main component <NUM> can start with casting an unfinished version of the main component <NUM>. The unfinished main component can be cast as a full club body, with a reduced thickness region. The reduced thickness region comprises at least a toe end region and a heel end region. A majority of the reduced thickness region, including the toe and heel end regions, can be located approximately where the wrap-around component <NUM> will later be attached. A peripheral section around an edge of the reduced thickness region will eventually form the lip of the main component. The unfinished main component is cast with the reduced thickness region because the reduced thickness region helps the main component hold its desired shape during the casting process. Casting the main component <NUM> without the reduced thickness region could result in warping of the part or other casting quality issues. Therefore, casting with the reduced thickness region, which is later removed, ensures that the main component <NUM> maintains its desired shape so that wrap-around component <NUM> will fit on it correctly during the bonding step.

After the unfinished main component is removed from the mold in which it was cast, a laser is used to cut out the unwanted portions of the reduced thickness region, leaving only the peripheral section, which forms the lip <NUM> of the main component <NUM>. The heel and toe regions of the reduced thickness region are removed, since these heel and toe regions are intended to be replaced by the wrap-around component <NUM> in the completed club head <NUM>. The lip <NUM> can be ground down or polished, as necessary. In some embodiments, a strikeface <NUM> of the club head <NUM> is integrally cast as part of the main component <NUM>. In other embodiments, the main component <NUM> can be cast without a strikeface (with an opening or void in the front of the main component). In these embodiments, a faceplate is provided separately by either casting or forging the faceplate from a metallic material. The faceplate can be conventionally welded, laser welded, or swedged into the front opening of the main component <NUM>. The main component <NUM> can be finished through sanding, plasma treatment, polishing, or other finishing processes.

Referring to <FIG>, in most embodiments, the mold <NUM> comprises a top mold half <NUM>, a bottom mold half <NUM>, and a slide <NUM>. Referring to <FIG> and <FIG>, the top mold half <NUM> can comprise a sprue <NUM>, a gate <NUM>, and a top reservoir <NUM>. Referring to <FIG> and <FIG>, the bottom mold half <NUM> can comprise a bottom reservoir <NUM> and a center ballast <NUM>. <FIG> illustrates a front view of the top mold half <NUM> and the bottom mold half <NUM> forming the outer surface shape of the wrap-around component <NUM>, before the slide <NUM> is added to the mold assembly. Referring to <FIG>, the slide <NUM> comprises a fork <NUM>, and a lock <NUM>. As shown in <FIG>, when the top mold half <NUM> and bottom mold half <NUM> compress, the slide <NUM> is inserted in between the top and bottom mold halves <NUM>, <NUM>, forming a sealed, mold cavity <NUM> in roughly the shape of the wrap-around component <NUM>. The composite material is then dispensed into the mold cavity <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, the top mold half <NUM> comprises the sprue <NUM>, the mold top reservoir <NUM>, and the gate <NUM>. The sprue <NUM> transfers the molten composite material from the screw tip <NUM> of the injection molding compression screw <NUM> to the gate <NUM> of the mold <NUM>. The gate <NUM> then transfers the material evenly into the top and bottom reservoirs <NUM>, <NUM>, which form the mold cavity <NUM>. The walls of the sprue <NUM>, gate <NUM>, and mold <NUM> can interact with the flowing composite material, causing at least <NUM>% of the fibers to align in the direction of flow.

Referring to <FIG> and <FIG>, the bottom mold half <NUM> comprises the bottom reservoir <NUM> and the center ballast <NUM>. The center ballast <NUM> is integral to the bottom mold half <NUM>. The center ballast <NUM> further comprises at least one ejector pin <NUM>, embedded in the center ballast <NUM>. The center ballast <NUM> functions to create the shape of the wrap around component <NUM>.

Referring to <FIG>, the slide <NUM> comprises the fork <NUM> and the lock <NUM>. The slide <NUM> is placed in between the top mold half <NUM> and bottom mold half <NUM>, and the fork <NUM> surrounds the center ballast <NUM> of the bottom mold half <NUM>. In most embodiments, the fork <NUM> is asymmetrical in shape, and comprises two prongs <NUM>. In other embodiments, the fork <NUM> can comprise a symmetrical shape or <NUM>-<NUM> prongs <NUM>. The fork <NUM> functions to surround the center ballast <NUM> and form the full shape of the wrap-around component <NUM>. The slide lock <NUM> functions to hold the slide <NUM> in between the top mold half <NUM> and bottom mold half <NUM> during injection, forming a sealed and secure cavity <NUM>. Without the lock <NUM>, the mold <NUM> would be subject to molten composite material leaking from the mold <NUM>, causing improperly formed components.

The location of the gate <NUM> affects the flow direction of the molten composite material through the mold <NUM>. The flow direction of the composite material determines the fiber alignment within the finished wrap-around component <NUM>. The fiber alignment determines the strength of the wrap-around component <NUM>, particularly the directional strength. The injection-molded component <NUM> is strongest in a direction parallel to an average fiber alignment direction. Therefore, the location of the gate <NUM> of the mold <NUM> is critical to the final structural strength and durability of the wrap-around component <NUM>, so as to achieve the alignment of as many fibers as possible in a front-to-rear direction.

In the illustrated embodiment of the mold <NUM>, the gate <NUM> is positioned at what will become the rear end <NUM> of the club head <NUM>. The gate <NUM> connects to a rear peripheral edge <NUM> of the wrap-around component <NUM>. Specifically, the gate <NUM> connects to the crown section <NUM> of the wrap-around component <NUM>. As described further below, locating the gate <NUM> adjacent the rear peripheral edge <NUM> of the crown section <NUM> causes the material to flow generally forward, which initially aligns the fibers in a generally front-to-rear direction. This can increase the strength of the final component, since the composite material strength is affected by the fiber alignment. Furthermore, locating the gate <NUM> centrally, between what becomes the toe end <NUM> and the heel end <NUM>, allows the composite material to flow quickly and evenly throughout the part. In contrast, if for instance the gate <NUM> were connected to the toe wing <NUM> or heel wing <NUM> of the club head <NUM>, the material flow could create unwanted weld lines within the opposite toe or heel wing <NUM>, <NUM>.

Referring to <FIG>, during the injection molding process, the direction of material flow within the mold will affect the fiber alignment. <FIG> show a mold pathline simulation (showing the flow direction of material) at a first, second, third, and fourth stage in time, respectively. By locating the gate <NUM> on a rear extremity <NUM> of the mold <NUM> (corresponding to the rear peripheral edge <NUM> of the wrap-around component <NUM>) the material initially flows forward towards a front extremity <NUM> of the mold <NUM> (opposite of the gate <NUM>, and corresponding to a front edge <NUM> of the wrap-around component <NUM>). This flow aligns the fibers in the central crown section <NUM> (top reservoir <NUM> of top mold half <NUM>) roughly perpendicular to the strikeface <NUM> (roughly parallel to the YZ plane) in the final club head <NUM>.

The strength of the composite material in a given direction is affected by the fiber alignment. The fiber alignment direction can vary in different parts of the wrap-around component <NUM>, causing the directional strength to also vary throughout the wrap-around component <NUM>. However, since a majority of the fibers are aligned in a roughly front-to-rear direction, the wrap-around component <NUM> is strongest in the front-to-rear direction. This fiber alignment and strength is accomplished by positioning the gate <NUM> at the rear extremity <NUM> of the mold <NUM> (corresponding to the rear peripheral edge <NUM> of the wrap-around component <NUM>).

Having the fibers aligned roughly perpendicular to the strikeface <NUM> increases the durability of the club head <NUM> in the front-to-rear direction. The durability of the crown <NUM> in the front-to-rear direction is necessary to prevent failure, because upon impact with a golf ball, the main component sole extension <NUM> will bend upwards and exert stress on the wrap-around component crown section <NUM>. The crown section <NUM> is compressed between the main component sole extension <NUM> and the main component return <NUM>. Therefore, aligning the fibers with the direction of compression stress that is expected at impact with a golf ball lowers the likelihood of failure within the composite wrap-around component <NUM>.

Referring to <FIG>, the material also flows outwards towards areas of the bottom mold half reservoir <NUM> that correspond to the toe wing <NUM> and heel wing <NUM> of the wrap-around component <NUM>. The material flows around the peripheral edge of the crown section <NUM> to form the skirt <NUM>, including the rear peripheral edge <NUM>, and the toe and heel wings <NUM>, <NUM>. The material flow towards mold areas corresponding to the toe and heel wings <NUM>, <NUM> causes the fibers inside regions of the crown section <NUM> of the wrap-around component <NUM> to align in a center rear-to-toe direction or a center rear-to-heel direction. In other words, some populations, groups, or regions of reinforcing fibers in a rearward toe end of the crown <NUM> and a rearward heel end of the crown <NUM> can be aligned between <NUM> to <NUM> degrees from the YZ plane in the finished golf club head <NUM>. Some fiber populations can be aligned between <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, <NUM> to <NUM> degrees, or <NUM> to <NUM> degrees from the YZ plane in the finished golf club head <NUM>.

As illustrated, the fiber populations closer to the heel and toe wings <NUM>, <NUM> can be aligned at a greater angle than the fiber populations closer to the center of the crown section <NUM> (closer to the YZ plane). Additionally, the fiber populations closer to the rear end <NUM> of the club head (closer to the mold gate <NUM>) can be aligned at a greater angle than fiber populations closer to the front end <NUM> of the club head. This change in fiber alignment is caused by the single gate location <NUM> and the rounded shape of the rear end <NUM> of the club head. The material fills outwards from the single gate <NUM> towards the toe and heel ends <NUM>, <NUM> of the mold <NUM>, causing an initially steep angle of the fibers towards the toe and heel ends. However, as the material continues to fill the mold <NUM> (corresponding to regions of the wrap-around component <NUM> closer to the front edge <NUM>), the alignment angle of the fibers with respect to the YZ plane decreases because the rounded shape mold cavity <NUM> (corresponding to the rounded shape of the wrap-around component <NUM>) causes composite material to flow more forward.

In some embodiments, between <NUM>% and <NUM>%, <NUM>% and <NUM>%, or <NUM>% and <NUM>% of the crown section fibers within <NUM> (one inch) of the gate <NUM> are aligned between <NUM> to <NUM> degrees from the YZ plane (more towards the toe end <NUM> or heel end <NUM> than towards the front end <NUM> of the finished club head <NUM>). In some embodiments, between <NUM>% and <NUM>%, <NUM>% and <NUM>%, or <NUM>% and <NUM>% of the crown section fibers beyond <NUM> (one inch) from the gate but within <NUM> (two inches) of the gate <NUM> are aligned between <NUM> to <NUM> degrees from the YZ plane. In some embodiments, less than <NUM>%, less than <NUM>%, less than <NUM>%, or less than <NUM>% of the crown section fibers beyond <NUM> (two inches) from the gate <NUM> are aligned between <NUM> to <NUM> degrees from the YZ plane.

The gate placement corresponding to the rear peripheral edge <NUM> of the wrap-around component <NUM> results in the reinforcing fibers near the front edge <NUM> of the wrap-around component being aligned more closely (or at a lesser angle) to the YZ plane (perpendicular to the strikeface). In the finished golf club head <NUM>, it is desirable that regions closer to the front end <NUM> of the golf club head <NUM> have a higher strength than regions closer to the rear end <NUM>, because the highest impact stresses occur at the strikeface, which is at the front end. Therefore, by placing the gate at a rear extremity <NUM> of the mold <NUM> instead of a front extremity <NUM> of the mold <NUM>, the created wrap-around component <NUM> is most durable in a region of the golf club head <NUM> that will endure higher stresses at impact.

In some embodiments, the gate <NUM> is connected to the part of the mold <NUM> that corresponds to a thickest portion of the component. In other embodiments, the gate <NUM> is connected to a part of the mold <NUM> that corresponds to a thin portion of the component. Typically, an injection molded component is weaker adjacent where the gate <NUM> was connected to the component during manufacturing. For this reason, placing the gate <NUM> at a rear extremity <NUM> of the mold <NUM> instead of a front extremity <NUM> of the mold further increases the durability of the resulting wrap-around component <NUM>. However, the crown section <NUM> to which the gate <NUM> attaches has a thin geometry, making it necessary to have flow leaders to encourage the flow of material throughout the mold <NUM>. As described further below, the thickened portions <NUM> and the crown connection portions <NUM>, <NUM> of the wrap-around component <NUM> can act as flow leaders during the injection molding process.

<FIG> illustrate simulated mold flow diagrams of different embodiments of the wrap-around component <NUM>, such as provided in <FIG>, respectively. As shown, both embodiments provide substantially uniform flow paths from the gate <NUM>. However, the wide gate shown in <FIG> and <FIG> and the central thickened section <NUM> act as an extra wide flow leader that directs the inflowing polymer uniformly from the gate <NUM> toward the front edge <NUM> of the crown section <NUM>. Said another way, the central thickened section <NUM> provides a more oriented polymer flow (and thus fiber alignment) at and near the front edge <NUM>, despite the central thickened section <NUM> not extending all of the way to the front edge <NUM>. In doing so, the material has a more uniform strength across a central region of the crown <NUM>, as opposed to a strength that is varied across the crown <NUM> due to changes in the alignment angle of the fibers.

The mold cavity <NUM> generally corresponds to the shape of the resulting wrap-around component <NUM>. However, to account for springback (warping) of the injection molded part, the mold cavity <NUM> can be shaped slightly differently than the final desired wrap-around component structure <NUM>. As illustrated in <FIG>, the toe wing <NUM>, the heel wing <NUM>, and the crown section <NUM> of the wrap-around component <NUM> together form a clamshell-like shape. The toe wing side edge <NUM>, the heel wing side edge <NUM>, and a rear peripheral edge <NUM> of the crown section <NUM> together border a cutout section, that is configured to receive the main component sole extension <NUM>. The clamshell shape causes the outer surface <NUM> of the wrap-around component <NUM> to have a slightly greater surface area than the inner surface <NUM> of the wrap-around component <NUM>. This disparity in the outer and inner surface areas affects the geometry of the wrap-around component <NUM> after it is molded. The compressive stresses on the outer surface <NUM> outweigh the compressive stresses on the inner surface <NUM>, pulling the toe and heel wings <NUM>, <NUM> slightly outward. This phenomenon is known as springback in the injection molding industry. Due to springback, injection molding can cause warping of the wrap-around component <NUM> into a wider clamshell shape than originally molded. To account for this warping, the mold <NUM> can be shaped with the wings <NUM>, <NUM> slightly offset inwards from the desired final shape. This allows the wings <NUM>, <NUM> to springback or warp outwards to arrive at the desired shape.

The composite material can comprise a shrink rate. The shrink rate is the amount that the part contracts or shrinks after removal from the mold. Since the composite material may shrink after removal from the mold <NUM>, the mold <NUM> must be designed larger than the desired final component shape. Depending on the composite material that is used, the shrink rate can differ.

Injection molding a wrap-around component <NUM> can comprise the following: selecting a composite material, drying the composite material, heating the composite material, compressing the heated material into the mold <NUM>, cooling the mold <NUM> to solidify the composite material into the wrap-around component <NUM>, and ejecting the wrap-around component <NUM> from the mold <NUM>. The success of the injection molding process is dependent on the thickness and shape of the wrap-around component <NUM>, which affects the flow speed.

The ability of the composite material to flow through the mold <NUM> is limited by the polymer type and the resin content. Different polymers can have different freeze off thicknesses. The freeze off thickness is the thickness at which the material can no longer flow smoothly through or into a region of the mold <NUM>. Composites having a lower fiber content can typically be molded into thinner parts. Using a composite with a lower fiber content can allow a part to be molded with a lower thickness than would be possible with a higher fiber content material. Thermoplastic composites comprise different freeze off thicknesses, the minimum thicknesses at which the material will flow within a mold. Using a material that has a freeze off thickness greater than the mold's minimum thickness will result in the material freezing off or incompletely filling the mold. Since fiber content affects both the strength and the manufacturable thickness of the final component, the composite material must be selected to reflect the desired geometry and properties of the final component.

In addition to keeping the thickness <NUM> of the wrap-around component <NUM> greater than the freeze off thickness of the selected composite material, the smooth flow of material through the mold <NUM> can be improved by tapering the thickness in certain regions and/or including structures which act as flow leaders into the design of the wrap-around component <NUM>. As described above, the wrap-around component <NUM> can comprise multiple thicknesses across the crown section <NUM>, the toe wing <NUM>, and the heel wing <NUM>. As also described above, the wrap-around component <NUM> can comprise thickened portions <NUM> in the crown section <NUM> (or a central thickened portion <NUM>) and crown connection portions <NUM>, <NUM> where the toe wing <NUM> and the heel wing <NUM> join to the crown section <NUM>. Because of their thicknesses and orientations, the thickened portions <NUM> (or the central thickened portion <NUM>) and the crown connection portions <NUM>, <NUM> can act as flow leaders. During injection molding, these flow leaders can direct the molten composite material towards the front extremity <NUM> of the mold <NUM> and the toe and heel wing regions. The thickened portions <NUM> (or the central thickened portion <NUM>) direct the material generally towards the front extremity <NUM>. The crown connection portions <NUM>, <NUM> direct the material generally towards the toe and heel wing regions. The flow leaders ensure that the mold fills evenly and completely, without prematurely freezing off.

The crown connection portion <NUM> of the toe wing <NUM> can act as a toe wing flow leader. The crown connection portion <NUM>, which has a thickness <NUM> greater than the remainder of the toe wing <NUM>, can provide a channel or highway for material to flow through during the injection molding process. The crown connection portion <NUM> (or toe wing flow leader) enables the composite material to evenly and properly fill the toe wing <NUM>. The crown connection portion <NUM> of the heel wing <NUM> can act as a heel wing flow leader. The crown connection portion <NUM>, which has a thickness <NUM> greater than the remainder of the heel wing <NUM>, can provide a channel or highway for material to flow through during the injection molding process. The crown connection portion <NUM> (or heel wing flow leader) enables the composite material to evenly fill the heel wing <NUM>. Additionally, within the completed wrap-around component <NUM>, the added thickness in the toe and heel crown connection portions <NUM>, <NUM> can provide strength to support the toe and heel wings <NUM>, <NUM>, respectively.

In addition to flow leaders, thickness tapering in parts of the wrap-around component structure can contribute to the smooth flow of material into the mold cavity <NUM>. A slight taper in the thickness of each wing <NUM>, <NUM> can minimize material and mass, while leaving sufficient thickness for the material to flow within certain regions (such as mold regions corresponding to edges of the wings) during the manufacturing of the wrap-around component <NUM>. The thicker regions encourage the flow of material within the mold <NUM>. The minimum thickness of the toe and heel wings <NUM>, <NUM> is determined by the freeze off thickness of the material.

The three-sided shape of the toe wing <NUM> facilitates the even/uniform flow of material into the tip end of the wing <NUM> during the injection molding process. During the injection molding process, the crown connection portion <NUM> is formed first. The material then flows towards the front edge <NUM> and the side edge <NUM> to form the remainder of the toe wing <NUM>. The shape of the toe wing <NUM> reduces the size of weld lines in the final wrap-around component <NUM>. Weld lines can form during the injection molding process when material fills different portions of the mold <NUM> at different rates and intersects to form a line or region of discontinuous flow. A weld line is generally located within a portion of the mold <NUM> that fills last during the injection molding process.

In some mold designs, injected material reaches two separate regions of the mold faster than an intermediate region. As the material continues to fill the mold, the material within the two separate regions converge within the intermediate region. The angle and speed at which the material converges within the intermediate region can create a weld line. In some embodiments, the material on one side of the weld line can have an average fiber orientation that differs from the average fiber orientation on the opposite side of the weld line. In some embodiments, the average fiber orientation on the sides of the weld line can differ by between <NUM> degrees and <NUM> degrees. The weld line can be a resin rich region, having up to <NUM>% less fiber content than the surrounding regions. The low fiber content can lead to increased structural failure along weld lines. A weld line can comprise a strength that is up to <NUM>% lower than the rest of the part. Therefore, it is advantageous to limit the number and size of weld lines. The three-sided shape of the toe wing <NUM> minimizes or eliminates the formation of weld lines by providing a geometry that can fill evenly and at a relatively steady rate.

The three-sided shape of the heel wing <NUM> facilitates the flow of material into the tip end of the wing <NUM> during the injection molding process. The flow of material in the heel wing <NUM> can be similar to the flow of material in the toe wing <NUM>, as described above. Similar to the toe wing <NUM>, the three-sided shape of the heel wing <NUM> also reduces or eliminates the weld lines in the final component.

Referring to <FIG>, the mold <NUM> fills at a relatively even rate in the toe end <NUM> and heel ends <NUM> of the mold cavity <NUM>. <FIG> show a mold fill simulation at a first, second, third, and fourth time stamp, respectively. The molten composite material <NUM> flows from the gate <NUM> into the remainder of the mold cavity <NUM>, in a flow direction <NUM> moving away from the gate <NUM>. The even fill rate is achieved in part by the location of the gate <NUM>, the one or more flow leaders in the crown section <NUM>, and the toe and heel wing crown connection portions <NUM>, <NUM>, which act as flow leaders along the skirt <NUM>. The aforementioned three-sided shaping and thickness taper (optional) of the toe and heel wings <NUM>, <NUM> can also contribute to the even fill rate. The gate <NUM> initiates the directional spread of the material when it is injected into the mold cavity <NUM>. The flow leaders, including the crown connection portions <NUM>, <NUM>, facilitate the movement of the composite material across the crown section <NUM> and around into the toe and heel wings <NUM>, <NUM>. The even fill rate reduces weld lines in the completed part, increasing the durability of the wrap-around component <NUM>.

Injection molding the wrap-around component <NUM>, requires first selecting a type of composite material. As described above, the wrap-around component <NUM> can comprise a composite formed from polymer resin and reinforcing fiber. The polymer resin can comprise a thermoplastic. More specifically, the thermoplastic resin can comprise a thermoplastic polyurethane (TPU) or a thermoplastic elastomer (TPE). For example, the resin can comprise polyphenylene sulfide (PPS), polyetheretheretherketone (PEEK), polyimides, polyamides such as PA6 or PA66, polyamide-imides, olyphenylene sulfides (PPS), polycarbonates, engineering polyurethanes, and/or other similar materials. The reinforcing fiber can comprise carbon fibers (or chopped carbon fibers), glass fibers (or chopped glass fibers), graphine fibers (or chopped graphite fibers), or any other suitable filler material. In other embodiments, the composite material may comprise any reinforcing filler that adds strength and/or durability. The composite material can be provided in pellets that comprise both the polymer resin and the reinforcing fiber.

Each of the aforementioned composite materials must be properly dried, prior to the heating of the composite material. Composite materials must be dried prior to injection molding, to remove any and all of the moisture that exists within or on the material (often times composite materials are in pellet forms in large buckets, wherein water or moisture can be trapped between pellets). To properly dry the composite materials, the composite materials are placed in a heated vacuum, with zero humidity, and dried for different amounts of time. This step is necessary, because any moisture that is heated and compressed in the injection molder, can turn into steam and be shot out of the injection molder at high speed, high temperature, and high pressure. Moisture trapped in the composite material must be removed prior to the heating process, to prevent damage to the injection molder or injury to the operator of the machinery.

In Table A below, are <NUM> example polymers that can be used in various embodiments of wrap-around components <NUM> for the golf club head. The drying temperature can range from <NUM> (<NUM>°F) to <NUM> (<NUM>°F). In some embodiments the drying temperature can be <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), <NUM> (<NUM>°F), or <NUM> (<NUM>°F). Furthermore, the drying time can range from <NUM> hours to at least <NUM> hours. In some embodiments, no drying time is necessary. In other embodiments, the drying time required can be at least <NUM> hours, at least <NUM> hours, at least <NUM> hours, at least <NUM> hours, at least <NUM> hours, at least <NUM> hours, or at least <NUM> hours. In some embodiments, the drying time required can range between <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, <NUM>-<NUM> hours, or <NUM>-<NUM> hours. Further still, in some embodiments, the drying time can well exceed the minimum dry time (i.e., drying Nylon <NUM>, which has a minimum drying time of <NUM> hours, for <NUM> hours).

Once the drying process is complete, the chosen composite material can be heated in the injection molder. In reference to <FIG>, in one embodiment, the injection molder comprises a hopper (not shown), a compression screw <NUM>, a screw tip <NUM>, and a mold <NUM>. The composite material (in pellet form) is placed in the hopper, wherein the hopper slowly feeds pellets into the compression screw <NUM>. The compression screw <NUM> gradually rotates moving the pellets from the hopper, towards the screw tip <NUM>. As the pellets are moved from the hopper to the screw tip <NUM>, they are heated at various temperatures, liquifying the pellets. The molten composite material passes into screw tip <NUM> and then dispensed out of the screw tip <NUM> into the mold <NUM>, thus forming the wrap-around component <NUM>.

However, there are a variety of factors that must be accounted for in the injection molder to properly heat the chosen composite material. The chosen composite material must be heated at various temperatures as it moves from the hopper, to the compression screw <NUM>, to screw tip <NUM>, and thus into the mold. Further, the compression screw <NUM> comprises three different zones, including a feed zone <NUM>, a transition zone <NUM>, and a metering zone <NUM>, at which the composite material can be heated at different temperatures. In total there are <NUM> different regions of the injection molder, in which the composite material can be heated at various temperatures, to optimize the flow and material properties of each material.

Referring to Table B, below, are <NUM> example polymers, that can be used in various embodiments of wrap-around components <NUM> for the golf club head, and their respective heating ranges for the five regions of the injection molder.

The temperature at the feed zone <NUM> of the injection molder can range between <NUM>-<NUM> (<NUM>°F-<NUM>°F). In some embodiments, the temperature at the feed zone <NUM> of the injection molder can range between, <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), and <NUM>-<NUM> (<NUM>°F-<NUM>°F). In other embodiments, the temperature at the feed zone of the injection molder can be at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), or at least <NUM> (<NUM>°F). Further still, in some embodiments the temperature at the feed zone <NUM> of the injection molder can range between the provided ranges in Table B above.

The temperature at the transition zone <NUM> of the injection molder can range between <NUM>-<NUM> (<NUM>°F-<NUM>°F). In some embodiments, the temperature at the transition zone <NUM> of the injection molder can range between, <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), and <NUM>-<NUM> (<NUM>°F-<NUM>°F). In other embodiments, the temperature at the transition zone of the injection molder can be at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), or at least <NUM> (<NUM>°F). Further still, in some embodiments the temperature at the transition zone <NUM> of the injection molder can range between the provided ranges in Table B above.

The temperature at the metering zone <NUM> of the injection molder can range between <NUM>-<NUM> (<NUM>°F-<NUM>°F). In some embodiments, the temperature at the metering zone <NUM> of the injection molder can range between, <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), and <NUM>-<NUM> (<NUM>°F-<NUM>°F). In other embodiments, the temperature at the metering zone <NUM> of the injection molder can be at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), or at least <NUM> (<NUM>°F). Further still, in some embodiments the temperature at the metering zone <NUM> of the injection molder can range between the provided ranges in Table B above.

The temperature at the screw tip <NUM> of the injection molder can range between <NUM>-<NUM> (<NUM>°F-<NUM>°F). In some embodiments, the temperature at the screw tip <NUM> of the injection molder can range between, <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), and <NUM>-<NUM> (<NUM>°F-<NUM>°F). In other embodiments, the temperature at the screw tip <NUM> of the injection molder can be at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), or at least <NUM> (<NUM>°F). Further still, in some embodiments the temperature at the screw tip <NUM> of the injection molder can range between the provided ranges in Table B above.

The temperature of the mold <NUM> can range between -<NUM>-<NUM> (<NUM>°F-<NUM>°F). In some embodiments, the temperature at the mold <NUM> of the injection molder can range between, - <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), <NUM>-<NUM> (<NUM>°F-<NUM>°F), or <NUM>-<NUM> (<NUM>°F-<NUM>°F). In other embodiments, the temperature of the mold <NUM> can be at least, -<NUM> (<NUM>°F), at least <NUM> (<NUM>°F), at least <NUM> (<NUM>°F), or at least <NUM> (<NUM>°F). Further still, in some embodiments the temperature of the mold <NUM> can range between the provided ranges in Table B above. The mold <NUM> can be kept at a temperature below the melting point of the composite material so that the molten composite material solidifies in the mold <NUM>. The mold <NUM> can further comprise cooling lines to maintain the mold <NUM> at the desired temperature.

Once the composite material is heated, the screw tip <NUM> injects or dispenses the molten composite into the desired mold <NUM>. When the molten composite is injected into the mold <NUM>, the molten composite material flows around the center ballast <NUM>, and the slide fork <NUM> and down into the bottom reservoir <NUM>, and up into the top reservoir <NUM>. This forms the rounded or clamshell shape of the wrap-around component <NUM> (the composite material "wraps around" or flows around the center ballast <NUM> and fork <NUM>). The crown section <NUM> of the wrap-around component <NUM> is partially formed before the toe and heel wings <NUM>, <NUM> begin to form.

Although the above-described mold <NUM> is designed to form a single wrap-around component <NUM>, the mold <NUM> can also be designed to simultaneously form two, three, four, five, or six wrap-around components. For example, <FIG> illustrate pathlines of material flow within a part that is formed in a mold having two cavities for the simultaneous formation of two wrap-around components. As illustrated, the sprue feeds material from the injection molder compression screw into two gates, one for each wrap-around component being formed.

The pressure and speed at which the composite material is dispensed into the mold <NUM> is equally as important as the temperature and direction of the composite material, in order to achieve a strong wrap-around component <NUM>. The pressure of the injection molder is hydraulically applied from the back of the injection molder into the compression screw <NUM>. The speed of the injection molder is the speed at which the composite material exits the screw tip <NUM>. The pressure and speed help ensure that the composite material flows evenly through the mold, filling the entire mold cavity <NUM>.

In most embodiments, the injection pressure of the composite material through the injection molder can range between <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In some embodiments, the injection pressure of the composite material through the injection molder can range from <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), <NUM>-<NUM> kPa (<NUM>-<NUM> psi), or <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In other embodiments, the injection pressure of the composite material through the injection molder can be at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), at least <NUM> kPa (<NUM> psi), or at least <NUM> kPa (<NUM> psi). Five example polymers, Nylon <NUM>, Nylon <NUM>, PP, TPU, and PES, used in various embodiments of wrap-around components for the golf club head, can require an injection pressure range of <NUM>-<NUM> kPa (<NUM>-<NUM> psi). In most embodiments, the injection speed of the composite material through the injection molder can range between <NUM>/s (<NUM> in/s) and <NUM>/s (<NUM> in/s). In some embodiments, the injection speed of the composite material through the injection molder can range from <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), <NUM>-<NUM>/s (<NUM>-<NUM> in/s), or <NUM>-<NUM>/s (<NUM>-<NUM> in/s). In other embodiments, the injection speed of the composite material through the injection molder can be at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), at least <NUM>/s (<NUM> in/s), or at least <NUM>/s (<NUM> in/s). Five example polymers, Nylon <NUM>, Nylon <NUM>, PP, TPU, and PES, used in various embodiments of wrap-around components for the golf club head, can require an injection speed range of <NUM>-<NUM>/s (<NUM>-<NUM> in/s).

After the composite material is injected into the mold to form the wrap-around component <NUM>, the wrap-around component <NUM> is ejected from the injection molder. In reference to <FIG>, the top mold half <NUM> is removed from the bottom mold half <NUM>, and the slide <NUM> is removed, leaving the wrap-around component <NUM> positioned around the bottom mold half center ballast <NUM>. Without the bottom mold half center ballast <NUM>, the slide <NUM> would not be able to retract without pulling the wrap-around component <NUM> away from the mold cavity <NUM>. The bottom mold half center ballast <NUM> prevents the wrap-around component <NUM> from moving when the slide <NUM> is retracted. The at least one ejector pin <NUM> of the bottom mold half center ballast <NUM> subsequently extends from the center ballast <NUM> pushing the wrap-around component <NUM> out of the mold <NUM>, completing the injection molding process.

In some embodiments of the method, the injection molding step can further comprise cutting off the sprue <NUM> and gate material <NUM> that remains attached to the unfinished wrap-around component after the injection molding process. The area where the gate <NUM> was attached can be sanded, ground, polished, or otherwise finished to give the wrap-around component <NUM> its desired shape. In general, to further conceal any blemishes leftover from injection molding process, the mold <NUM> can be designed with the gate in a location that will be less visible on the final club head <NUM>. For example, in the embodiment described above, locating the gate <NUM> at the rear peripheral edge <NUM> of the crown section <NUM> instead of on a flat surface makes the gate cutoff less visible when the club head <NUM> is in the address position.

The full injection molding step can be completed in an amount of time known as the cycle time. In embodiments where the mold <NUM> comprises more than one cavity <NUM> for forming more than one wrap-around component <NUM> simultaneously, a part production speed is determined by dividing the cycle time by the number of components produced within one cycle. The cycle time can range between <NUM> seconds to <NUM> seconds. In some embodiments, the cycle time ranges between <NUM> seconds and <NUM> seconds, between <NUM> seconds and <NUM> seconds, between <NUM> second and <NUM> seconds, between <NUM> seconds and <NUM> seconds, between <NUM> seconds and <NUM> seconds, or between <NUM> seconds and <NUM> seconds.

Once the wrap-around component <NUM> is formed, through injection molding, the wrap-around component <NUM> is plasma treated, to improve the surface energy of the part. The plasma treatment comprises a reactive treatment of the component, wherein positive and negative ions, electrons, and radicals react and collide (in a vacuum) along the surface of the component, thereby eliminating any foreign objects from the surface and increasing the surface energy of the component (roughening the surface). Increasing the surface energy microscopically changes the surface of the wrap-around component, thus increasing the ability to adhere or bond to other materials (i.e., the main component). This treatment not only cleans the wrap-around component <NUM> but makes it easy to secure to the main component in the following step.

Following the plasma treatment of the wrap-around component <NUM>, the wrap around component <NUM> and main component <NUM> can be joined to form the golf club head <NUM>. Joining the wrap-around component <NUM> to the main component <NUM> requires applying adhesive to the lip <NUM> of the main component <NUM> and sliding the wrap-around component <NUM> over the main component <NUM>. The lip of the wrap-around component <NUM> can overlap and bond to the lip <NUM> of the main component <NUM>. The ability of the wrap-around component <NUM> to be aligned and joined to the main component <NUM> is partially dependent on the type of composite material that is used to form the wrap-around component <NUM>. With certain composite materials, the toe and heel wings <NUM>, <NUM> can be bent or deflected without breaking. In some embodiments, this flexibility allows the wrap-around component <NUM> to be slightly distorted to fit over the lip <NUM> of the main component <NUM>.

The bonding step can further comprise allowing the adhesive to dry. In other embodiments, the wrap-around component <NUM> can be mechanically fastened to the main component <NUM>, epoxied to the main component, or any other suitable method of permanently affixing the wrap-around component <NUM> to the main component <NUM>.

Once the main component <NUM> is joined to the wrap-around component <NUM>, the golf club head <NUM> is finished. This step can comprise polishing, cleaning, coating, and/or painting the club head <NUM>. In some embodiments, this can include adding a removable/detachable weight to the golf club head <NUM> or adding embossed lettering and/or logos to the golf club head <NUM>.

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), golf equipment related to the methods, apparatus, and/or 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 methods, apparatus, and/or articles of manufacture described herein may be advertised, offered for sale, and/or sold as conforming or non-conforming golf equipment. The methods, apparatus, and/or articles of manufacture described herein are not limited in this regard.

Although a particular order of actions is described above, these actions may be performed in other temporal sequences. For example, two or more actions described above may be performed sequentially, concurrently, or simultaneously. Alternatively, two or more actions may be performed in reversed order. Further, one or more actions described above may not be performed at all. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

Claim 1:
A method of forming a golf club head (<NUM>), the method comprising:
providing a main component (<NUM>) by:
casting an unfinished version of the main component from a metallic material; wherein the unfinished version of the main component comprises reduced thickness region, and a lip (<NUM>); and
removing a majority of the reduced thickness region to complete the main component;
providing a mold (<NUM>) comprising:
a top mold half (<NUM>), a bottom mold half (<NUM>), and a slide (<NUM>);
wherein the top mold half forms a top reservoir (<NUM>), the top mold half comprises a sprue (<NUM>) and a gate (<NUM>), and the gate connects to the top reservoir;
wherein the bottom mold half comprises a bottom reservoir (<NUM>) and a center ballast (<NUM>);
wherein the slide comprises a fork (<NUM>) and a lock (<NUM>);
injection molding a wrap-around component (<NUM>) by;
drying a composite material;
heating the composite material into a molten state;
closing the mold, including the top mold half, the bottom mold half, the center ballast, and the fork, to create a mold cavity (<NUM>) in the shape of the wrap-around component;
injecting the molten composite material into the mold cavity of the mold;
allowing the composite material to solidify into the wrap-around component; and ejecting the wrap-around component from the mold;
joining the wrap-around component to the main component to form the golf club head;
wherein:
the center ballast retains the wrap-around component in a proper location for ejection from the mold;
the fork surrounds the center ballast and forms the shape of the wrap-around component;
the golf club head comprises: a front end (<NUM>), a rear end (<NUM>), a toe end (<NUM>), a heel end (<NUM>), a crown (<NUM>), a sole (<NUM>), and a skirt (<NUM>) connecting the crown and the sole;
the main component comprises:
a strike face (<NUM>);
a return (<NUM>);
a sole extension (<NUM>);
the return extends rearward from the strikeface and forms a portion of the sole and a portion of the crown;
the sole extension extends from the return to the rear end of the club head along the sole; and
the wrap-around component comprises a crown section (<NUM>), a toe wing (<NUM>), and a heel wing (<NUM>).