WO2025207682A1

WO2025207682A1 - Golf club head with impact response modulator

Info

Publication number: WO2025207682A1
Application number: PCT/US2025/021408
Authority: WO
Inventors: Matthew T. SCHIER; Eric J. Morales; Cory S. Bacon; Cole D. Brubaker; Taylor T. Morton; Mark C. Bloxham; Jesus D. GAMBOA
Original assignee: Karsten Manufacturing Corp
Current assignee: Karsten Manufacturing Corp
Priority date: 2024-03-25
Filing date: 2025-03-25
Publication date: 2025-10-02
Anticipated expiration: 2026-09-25
Also published as: TW202541884A; US20250295961A1

Abstract

Embodiments of a golf club head comprising an Impact Response Modulator disposed in the sole. The Impact Response Modulator comprises a casing with a plurality of casing walls that form an aperture therebetween. One or more portions a high-strength material component, such as a faceplate, a cartridge, or an appendage can form and reinforce one or more portions of the casing, thereby increasing strike face deflection without compromising durability.

Description

GOLF CLUB HEAD WITH IMPACT RESPONSE MODULATOR

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This claims the benefit of U.S. Provisional Application No. 63/569,638, filed on March 25, 2024, U.S. Provisional Application No. 63/648,946, filed on May 17, 2024, U.S. Provisional Application No. 63/654,776, filed on May 31, 2024, U.S. Provisional Application No. 63/664,628, filed on June 26, 2024, U.S. Provisional Application No. 63/699,398, filed on September 26, 2024, and U.S. Provisional Application No. 63/769,579, filed on March 10, 2025, the contents of which are fully incorporated herein.

FIELD OF INVENTION

[0002] This invention generally relates to golf equipment, and more particularly, to golf club heads having sole openings to increase the flexure of the strike face.

BACKGROUND

[0003] The strike face of a golf club head deflects upon impact with a golfball to impart ball flight characteristics such as ball speed, launch angle, and spin rate. Increased strike face deflection increases energy transfer between the club head and the golfball at impact, thereby increasing ball speed. Strike face deflection also influences the launch angle at impact as well as the amount of backspin imparted on the golf ball, wherein a lower backspin rate leads to a more piercing ball flight that cuts through the air and increases carry distance. Traditionally, certain golf club heads, particularly wood-type golf club heads, include features that increase strike face deflection, such as slits, slots, openings, channels, flexures, or other known features that abruptly change geometry and/or create discontinuities in the club head. Features that increase strike face deflection, however, often increase resulting stresses in the area adjacent said features, thereby reducing club head durability. Consequently, there is a need in the art for a golf club head having increased strike face deflection without compromising club head durability. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIG. l is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0005] FIG. 2 is a bottom, front, toe-side perspective view of the golf club head of FIG. 1.

[0006] FIG. 3 is a detailed, plan view of the golf club head of FIG. 1, in cross-section.

[0007] FIG. 4 is a toe-side, detailed, elevation view of the golf club head of FIG. 1, in crosssection.

[0008] FIG. 5 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0009] FIG. 6 is a detailed, plan view of a golf club head according to the present invention, in cross-section.

[0010] FIG. 7 is a toe-side, detailed, elevation view of the golf club head of FIG. 4, in crosssection.

[0011] FIG. 8 is a toe-side, detailed, elevation view of a golf club head according to the present invention, in cross-section.

[0012] FIG. 9 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0013] FIG. 10 is a top, front, toe-side perspective view of a golf club head according to the present invention.

[0014] FIG. 11 is a toe-side, detailed, elevation view of the golf club head of FIG. 10, in cross-section.

[0015] FIG. 12 is a front, toe-side perspective view of a golf club head according to the present invention. [0016] FIG. 13 is a toe-side, elevation view of a golf club head according to the present invention.

[0017] FIG. 14 is a rear, heel-side perspective view of a golf club head faceplate.

[0018] FIG. 15 is a heel-side, detailed, elevation view of a golf club head comprising the faceplate of FIG. 14, in cross-section.

[0019] FIG. 16 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0020] FIG. 17 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0021] FIG. 18 is a detailed, plan view of the golf club head of FIG. 17, in cross-section.

[0022] FIG. 19 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0023] FIG. 20 is a detailed, plan view of the golf club head of FIG. 19, in cross-section.

[0024] FIG. 21 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0025] FIG. 22 is a detailed, bottom view of the golf club head of FIG. 21.

[0026] FIG. 23 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross section.

[0027] FIG. 24 is a bottom view of a golf club head according to the present invention.

[0028] FIG. 25 is a detailed, toe-side, elevation view of the golf club head of FIG. 24, in cross section.

[0029] FIG. 26 is a bottom, front, toe-side perspective view of a golf club head according to the present invention. [0030] FIG. 27 is a bottom view of a golf club head according to the present invention.

[0031] FIG. 28 is a rear, top, toe-side view of the golf club head of FIG. 27, in cross-section.

[0032] FIG 29 is a detailed, plan view of the golf club head of FIG. 27, in cross-section.

[0033] FIG. 30 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0034] FIG. 31 is a detailed, plan view of the golf club head of FIG. 30, in cross-section.

[0035] FIG. 32 is a detailed, toe-side, elevation view of a golf club head according to the present invention, in cross-section.

[0036] FIG. 33 is a detailed, plan view of the golf club head of FIG. 32, in cross-section.

[0037] FIG. 34 a detailed, heel-side, elevation view of a golf club head according to the present invention, in cross-section.

DETAILED DESCRIPTION

[0038] Described herein are various embodiments of wood-type golf club heads (i.e. drivers, fairway woods, or hybrids) comprising an impact response modulator (hereafter “IRM”) in the sole. The IRM strategically weakens the sole to increase strike face deflection, thereby improving ball flight performance. The IRM comprises a casing that forms one or more walls defining an aperture into the club head. The aperture is an opening through the sole that communicates between the environment surrounding the club head and the interior cavity of the club head. The IRM further comprises an insert disposed within the aperture and formed of a flexible, polymeric material. The casing includes various stress reducing geometries and/or selected regions of high-strength material to increase strike face deflection while maintaining sufficient club head durability.

[0039] In some embodiments, a high-strength material component, such as a faceplate, a cartridge, or an appendage, can form and reinforce one or more portions of the casing, thereby increasing strike face deflection without compromising durability. At impact, stress from the strike face flows into the forward portion of the sole, where the casing resides. Selectively using high-strength material reduces stress in the casing walls. Accordingly, the casing walls can have a reduced thickness and/or be placed closer to the strike face without exceeding the yield strength of the high-strength material, thereby increasing strike face deflection.

[0040] In some embodiments, the club head comprises a body and a faceplate coupled together, wherein the faceplate forms at least a portion of the casing. The body comprises a body material that is easily castable to form various complex club head geometries. The faceplate comprises a high-strength faceplate material with a yield strength greater than 175 ksi (i.e., C300 steel, C35O steel, Ti-9s, Ti-9s+, etc.) The faceplate material is more durable than the body material and is suitable to withstand direct impact with a golfball. In some embodiments, the faceplate comprises a sole return that forms one or more portions of the casing. In some embodiments, the body and the faceplate combine to form the casing, whereby the body and the faceplate each form at least a portion of the casing.

[0041] In some embodiments, the club head comprises a separately formed, high-strength material member that forms one or more portions of the casing, referred to herein as a “cartridge,” The cartridge is located on the sole of the club head and integrally forms at least portions of the casing front wall and the casing rear wall. The cartridge can be coupled to both the faceplate and the body, or can be coupled to and entirely surrounded by the body. Similar to the faceplate, the cartridge can comprise a high-strength cartridge material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0042] In other embodiments, the club head can comprise a separately formed high-strength component that forms a portion of the casing front wall, but not a portion of the casing rear wall, referred to herein as an “appendage.” The appendage is located on the sole of the club head and is coupled to both the faceplate and the body. In such embodiments, the body and the appendage combine to form the casing, whereby the body and the appendage each form at least a portion of the casing. Similar to both the faceplate and the cartridge, the appendage can comprise a high- strength appendage material (with a yield strength greater than 225 ksi) that is more durable than the body material.

[0043] The IRM selectively uses high-strength material to increase strike face delfection while maintaining durability. For example, one or both of the casing front wall and the casing rear wall can be integrally formed by high-strength material (i.e., the faceplate material, the cartridge material, or the appendage material). In some embodiments, a portion of the front wall front surface, front wall rear surface, front wall base, and/or front wall top surface can be integrally formed by a high-strength component. Similarly, in some embodiments, a portion of the rear wall front surface, rear wall rear surface, rear wall base, and/or rear wall top surface can be integrally formed by a high-strength component. Forming portions of the casing with high- strength material, whether via the faceplate, a cartridge, or an appendage, increases strike face deflection without compromising durability.

I. Definitions

[0044] The terms "first," "second," "third," "fourth," and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "include," and "have," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0045] The terms "left," "right," "front," "back," "top," "bottom," "over," "under," and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0046] The term “strike face,” as used herein, refers to a club head front surface that is configured to strike a golf ball. The term “strike face” can be used interchangeably with the term “face.”

[0047] The strike face 102 is bounded by an outer edge referred to as a “strike face perimeter.” The strike face perimeter is defined where the curvature of the golf club head 100 deviates from a bulge curvature and/or roll curvature of the strike face 102 (defined below). The strike face perimeter includes at least a leading edge 103 that defines a transition from the strike face 102 to the sole 112. The strike face 102 defines a face center (FC), which is the geometric centerpoint of the strike face perimeter, illustrated in FIG. 1. The face center (FC) can be located in accordance with the definition of a golf governing body such as the United States Golf Association (USGA).

[0048] The strike face 102 comprises a bulge curvature and a roll curvature. The bulge curvature is the curvature of the strike face 102 in the heel-to-toe direction. The roll curvature is the curvature of the strike face in a crown-to-sole direction. The bulge curvature and the roll curvature each respectively comprise a bulge radius and a roll radius defining the radii of curvature associated with each of the bulge curvature and the roll curvature. The bulge curvature and/or the roll curvature can comprise one or more radii.

[0049] The “Impact Response Modulator” or “IRM” described herein, comprises a casing, an aperture, and an insert. The IRM is a club head feature that increases strike face deflection at impact with a golfball.

[0050] The “casing” refers to a component of the IRM that comprises one or more walls and or structures defining an aperture that communicates between the environment surrounding the club head and the interior cavity of the club head. [0051] The term “cartridge” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall and at least a portion of the casing rear wall.

[0052] The term “appendage” refers to a high-strength material component formed separately from the faceplate and the body that forms at least a portion of the casing front wall but does not form a portion of the casing rear wall.

[0053] “Driver golf club heads” as used herein comprise a loft angle less than approximately 16 degrees, less than approximately 15 degrees, less than approximately 14 degrees, less than approximately 13 degrees, less than approximately 12 degrees, less than approximately 11 degrees, or less than approximately 10 degrees. Further, in many embodiments, “driver golf club heads” as used herein comprises a volume greater than approximately 400 cc, greater than approximately 425 cc, greater than approximately 445 cc, greater than approximately 450 cc, greater than approximately 455 cc, greater than approximately 460 cc, greater than approximately 475 cc, greater than approximately 500 cc, greater than approximately 525 cc, greater than approximately 550 cc, greater than approximately 575 cc, greater than approximately 600 cc, greater than approximately 625 cc, greater than approximately 650 cc, greater than approximately 675 cc, or greater than approximately 700 cc. In some embodiments, the volume of the driver 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.

[0054] “Fairway wood golf club heads” as used herein comprise a loft angle less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in some embodiments, the loft angle of the fairway wood club heads can be greater than approximately 12 degrees, greater than approximately 13 degrees, greater than approximately 14 degrees, greater than approximately 15 degrees, greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, or greater than approximately 20 degrees. For example, in other embodiments, the loft angle of the fairway wood can be between 12 degrees and 35 degrees, between 15 degrees and 35 degrees, between 20 degrees and 35 degrees, or between 12 degrees and 30 degrees.

[0055] Further, “fairway wood golf club heads” as used herein comprises a volume less than approximately 400 cc, less than approximately 375 cc, less than approximately 350 cc, less than approximately 325 cc, less than approximately 300 cc, less than approximately 275 cc, less than approximately 250 cc, less than approximately 225 cc, or less than approximately 200 cc. In some embodiments, the volume of the fairway wood 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 250 - 350 cc, or approximately 275-375 cc.

[0056] “Hybrid golf club heads” as used herein comprise a loft angle less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, or less than approximately 30 degrees. Further, in many embodiments, the loft angle of the hybrid can be greater than approximately 16 degrees, greater than approximately 17 degrees, greater than approximately 18 degrees, greater than approximately 19 degrees, greater than approximately 20 degrees, greater than approximately 21 degrees, greater than approximately 22 degrees, greater than approximately 23 degrees, greater than approximately 24 degrees, or greater than approximately 25 degrees.

[0057] Further, “hybrid golf club heads” as used herein comprise a volume less than approximately 200 cc, less than approximately 175 cc, less than approximately 150 cc, less than approximately 125 cc, less than approximately 100 cc, or less than approximately 75 cc. In some embodiments, the volume of the hybrid can be approximately lOOcc - 150cc, approximately 75cc - 150cc, approximately lOOcc - 125cc, or approximately 75cc - 125cc. [0058] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. Before any embodiments of the disclosure are explained in detail, it should be understood that the disclosure is not limited in its application to the details or embodiment and the arrangement of components as set forth in the following description or as illustrated in the drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

II. General Description of a Golf Club Head

[0059] Various embodiments of a golf club are illustrated in the figures. A golf club is generally understood to comprise a club head, a shaft, and a grip. The club head is configured to receive the shaft, and the grip is secured to the shaft.

[0060] Referring to FIGS. 1 and 2, the club head 100 defines a crown 110, a sole 112 opposite the crown 110, a heel 104, a toe 106, a front 108, a rear 111 and a strike face 102. The club head 100 further comprises a hosel 105, which is configured to receive the shaft. In some embodiments, as illustrated in the embodiment of FIGS. 1 and 2, the club head 100 comprises a body 101 and a faceplate 114 coupled together to form an interior cavity. The body 101 forms at least a portion of the crown 110, at least a portion of the sole 112, at least a portion of the heel 104, and at least a portion of the toe 106. The faceplate 114 forms at least a portion of the strike face 102. Specific configurations of the body 101 and the faceplate 114 are described in further detail below.

[0061] The features discussed below are demonstrated on club head 100. While different embodiments may comprise different numbering schemes (i.e., Ixx, 2xx, 3xx numbering schemes, etc.) similar elements are numbered similarly between embodiments (i.e., club head 100 comprises a crown 110 and a sole 112, whereas club head 200 comprises a crown 210 and a sole 212). Any one or more of the features below can be used in combination with one another. [0062] The body 101 comprises a body material that provides sufficient structural strength and is easy formed into complex geometries. In many embodiments, the body material is a metallic material that is easily castable. In some embodiments, the body material can comprise one or more materials such as steel, stainless steel, tungsten, aluminum, titanium, vanadium, chromium, cobalt, nickel, other metals, or metal alloys. In some embodiments, the body material can comprise a Ti-8Al-lMo-lV alloy, or a 17-4 stainless steel. In some embodiments, the body material can be formed from Ni (Nickel)-Co(Cobalt)-Cr(Chromium)-Steel Alloy, 565 Steel, AISI type 304 or AISI type 630 stainless steel, 17-4 stainless steel, 431 stainless steel, 304 stainless steel, 316 stainless steel, 8620 carbon steel, 1020 carbon steel, 1025 carbon steel, 17-7 PH stainless steel, 303 stainless steel, AUS-8 stainless steel, and gray cast iron or ductile iron titanium alloys such as, but not limited to, Ti-6A1-4V (Ti-6-4), Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2- 0.5Si), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-5Al-2.5Sn, Ti-3A1-2.5V, Ti-6Al-lZr-lNb-lMo (Ti-6-1 - 1 - 1 ), Ti-0.3Mo-0.8Ni, and Ti-6Al-7Nb, an amorphous metal alloy, or other similar metals. In some embodiments, the body 101 comprises a multi-material construction including one or more lightweight materials, such as a lightweight composite material. Generally, the body material can comprise a yield strength between 145 and 165 ksi.

[0063] The faceplate 114 comprises a faceplate material having sufficient strength to withstand repeated impacts with a golfball. As such, the faceplate material comprises a greater yield strength than the body material and is thus more durable. In some embodiments, the faceplate material can be a high-strength steel alloy, for example, but not limited to Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel.

[0064] In other embodiments, the faceplate material can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Til85, Ti 6-6-2, Ti- 7s, Ti-9s, Ti-92, Ti-6A1-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-10V-2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6A1- 6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9s+, Ti-9A1-2V (Ti-92), Ti- 8AI-IM0-IV (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti- 6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-lCr-lFe (Ti-55511), Ti-13V- HCr-3Al, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo- 4Cr (Ti-17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si).

[0065] The faceplate material comprises a high yield strength. In some embodiments, the faceplate material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 100 comprises a faceplate strength ratio comparing the yield strength of the faceplate material to the yield strength of the body material. In some embodiments, the faceplate strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.

[0066] The club head body 101 and the faceplate 114 can be formed through one or a combination of manufacturing processes, such as casting, forging, metal injection molding, metal 3D printing, stamping, or any other well-known manufacturing processes. In some embodiments, the club head body 101 is cast, whereas the faceplate 1 14 is forged.

III. Impact Response Modulator

[0067] The golf club head 100 comprises an Impact Response Modulator 120 (hereafter “IRM”) reinforced by high-strength material that increases strike face deflection at impact with a golfball while maintaining sufficient durability. Referring to FIGS. 2 and 3, the IRM 120 is disposed in the sole 112. The IRM 120 strategically weakens the sole 112 to increase strike face deflection. The IRM 120 comprises a casing 130 surrounding an aperture 140 that is configured to receive an insert 170. As illustrated in FIG. 2, the IRM 120 extends in a substantially heel-to- toe direction across the sole 112 to increase strike face deflection.

[0068] The casing 130 is the structure that surrounds and forms the aperture 140. One or more portions of the casing 130 can be formed by a high-strength material component, such as a cartridge or an appendage. As illustrated in FIGS. 3 and 4, the casing 130 comprises a front wall 132 proximate the strike face 102, a rear wall 142 spaced rearward from the front wall 132, a heel wall 152 proximate the heel 104, and a toe wall 154 proximate the toe 106. The front wall 132, the rear wall 142, the heel wall 152, and the toe wall 154 of the casing collectively form and define the aperture 140 therebetween. The aperture 140 is a through-hole fluidly communicating between the club head exterior and the interior cavity. The front wall 132 comprises a front wall front surface 134 disposed towards the strike face 102, a front wall rear surface 136 disposed towards the aperture 140, a front wall base 133, and a front wall top surface 138 opposite the front wall base 133. The rear wall 142 comprises a rear wall front surface 144 disposed towards the aperture 140, a rear wall rear surface 146 disposed towards the rear 111, a rear wall base 143, and a rear wall top surface 148 opposite the rear wall base 143.

[0069] The casing 130 can comprise a front wall height FWH, as best illustrated in FIG. 34, measured as the distance between the front wall base 133 and the front wall top surface 138, along the front wall rear surface 136. The front wall height FWH can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the front wall height FWH increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall height FWH to be reduced while maintaining durability. The front wall height FWH can be constant along the length of the casing, or the front wall height FWH can vary along the length of the casing. In many embodiments, the front wall height FWH can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall height FWH can be between 0.050 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, between 0.40 and 0.50 inch. In some embodiments, the front wall height FWH can be less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch.

[0070] The casing comprises an offset distance OD, as best illustrated in FIG. 34, measured as the distance from the leading edge 103 to the front wall base 133, in a strike face-to-rear direction. The casing offset distance OD can be selected to increase strike face deflection without compromising durability. Specifically, decreasing the offset distance OD increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the offset distance OD to be reduced while maintaining durability. In many embodiments, the offset distance OD can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the offset distance OD can be between 0.075 and 0.10 inch, 0.10 and 0.20 inch, 0.20 and 0.30 inch, 0.30 and 0.40 inch, 0.40 and 0.50 inch, 0.50 and 0.60 inch, 0.60 and 0.70 inch, 0.70 and 0.80 inch, 0.80 and 0.90 inch, or between 0.90 and 1.00 inch. In some embodiments, the offset distance can be less than 1.0 inch, less than 0.90 inch, less than 0.80 inch, less than 0.70 inch, less than 0.60 inch less than 0.50 inch, less than 0.40 inch, less than 0.30 inch, less than 0.20 inch, or less than 0.10 inch. In some embodiments, the casing offset distance OD can be 0.075 inch, 0.080 inch, 0.085 inch, 0.090 inch, 0.095 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, or 1.0 inch.

[0071] The front wall 132 comprises a front wall thickness FWT, as best illustrated in FIG. 34, measured as the distance between front wall front surface 134 and the front wall rear surface 136. As mentioned above, the front wall thickness FWT can be selected to increase strike face deflection without compromising durability. Specifically, the front wall thickness FWT can be increased (i.e., thicker) to decrease performance but increase durability. Decreasing the front wall thickness FWT increases strike face deflection, but potentially decreases durability. Reinforcing the casing 130 with high-strength material, as described herein, allows the front wall thickness FWT to be reduced while maintaining durability. In many embodiments, the front wall thickness FWT can be measured within a vertical plane extending through the face center (FC) in a front-to-back direction. In some embodiments, the front wall thickness FWT can be between 0.010 and 0.025 inch, 0.025 and 0.050 inch, 0.050 and 0.075 inch, 0.075 and 0.100 inch, 0.100 and 0.125 inch, 0.125 and 0.150 inch, or between 0.150 and 0.175 inch. In some embodiments, the front wall thickness FWT can be less than 0.175 inch, less than 0.150 inch, less than 0.125 inch, less than 0.100 inch, less than 0.075 inch, less than 0.050 inch, less than 0.025 inch, or less than 0.010 inch. [0072] The IRM further comprises an insert 170 disposed within the aperture 140 and formed of a flexible, polymeric material. The insert 170 closes off the aperture 140 to prevent migration of debris into the interior chamber and can impact the performance of the IRM and durability of the club head. The insert 170 is configured to engage the casing walls, thereby securing the insert 170 within the casing 130. The material composition, overall construction, inclusion of hybrid materials, and geometry of the insert 170 can affect the overall performance (bending, retraction rate, reactivity to force) of the IRM. The insert 170 and the casing 130 can comprise complementary geometries that provide durability and mechanically interlock or otherwise fit and secure the insert 170 within the casing 130, even after repeated, violent impacts.

[0073] In some embodiments, the insert 170 is entirely filled with a solid material such that it fills the entire aperture 140 between the casing front wall 132 and the casing rear wall 142. In some embodiments, the insert 170 can be hollowed out or provided with some other suitable geometry that creates a gap 171 or channel within the insert 170. For example, in some embodiments, the insert 170 can comprise a front wall 174, a rear wall 176, and a base 172, and takes a general U-shape appearance. The insert 170 may further comprise a rear extension 178 to increase bonding surface area.

[0074] To better understand the strategic locations at which high-strength material is used, the casing 130 can be divided up into multiple regions. The casing 130 can include a casing heel region 135 proximate the heel wall 152, a casing toe region 137 proximate the toe wall 154, and a casing center region 131 therebetween. The casing regions can help describe the location of various casing features and/or describe specific portions of the casing 130 that are reinforced by a high-strength material component in the various embodiments described below.

[0075] In some embodiments, the casing can comprise one or more reliefs that dissipate stress in the casing walls. The reliefs are portions of the casing that extend away from the strike face to dissipate stress. Generally, a significant portion of the casing 130, particularly at or near the casing center region 131, extends substantially equidistant to the strike face curvature, as best illustrated in FIG. 5. The relief(s) are angled rearward relative to the strike face 102. Referring to FIG. 5, the casing 130 comprises a toe relief 128 in the casing toe region 137 and a heel relief 129 in the casing heel region 135. The toe relief 128 and the heel relief 129 space the casing toe wall 154 and the casing heel wall 152, respectively, away from the strike face 102, such that the casing toe wall 154 and the casing heel wall 152 are further from the strike face 102 than the center of the casing 130. This spacing is necessary because stress concentrations typically occur near the heel wall 152 and the toe wall 154, because the heel wall 152 and the toe wall 154 generally comprise tight curvatures. The toe relief 128 and the heel relief 129 reduce these concentrations by spacing the casing toe wall 154 and the casing heel wall 152, respectively, further from the strike face 102. The reliefs 128, 129 allow the casing 130 (and the aperture 140) to be lengthened without compromising durability, thereby increasing strike face deflection. The illustrated embodiment includes both a toe relief 128 and a heel relief 129. In other embodiments, the casing 130 can comprise only a toe relief 128 or only a heel relief 129.

[0076] In some embodiments, the casing 130 can further comprise one or more end reinforcements 126, as best illustrated in FIG. 5. The end reinforcements 126 can be thickened portions of the sole 120 that surround one or more of the casing walls. In the illustrated embodiment, casing 130 comprises a heel end reinforcement 126a surrounding the heel wall 152 and a toe end reinforcement 126b surrounding the toe wall 154. The end reinforcements 126a, 126b are concentrations of club head mass with a substantially greater thickness TER than the surrounding casing walls. As illustrated in FIG. 5, the toe end reinforcement 126b can comprise an end reinforcement thickness TER measured between the casing toe wall 154 and an outer surface of the toe end reinforcement 126b, the measurement taken perpendicularly to the casing toe wall 154. Similarly, the heel end reinforcement 126a can comprise an end reinforcement thickness TER measured between the casing heel wall 152 and an outer surface of the heel end reinforcement 126a, the measurement taken perpendicularly to the casing heel wall 152. In some embodiments, the end reinforcement thickness TER can be between 0.25 inch and 0.75 inch. In some embodiments, the end reinforcement thickness TER can be greater than 0.25 inch, greater than 0.30 inch, greater than 0.35 inch, greater than 0.40 inch, greater than 0.45 inch, greater than 0.50 inch, greater than 0.55 inch, greater than 0.60 inch, greater than 0.65 inch, or greater than 0.70 inch. In some embodiments the end reinforcement thickness TER is between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, or between 0.65 and 0.70 inch, between 0.70 and 0.75 inch.

[0077] Similar to the reliefs 128, 129, the end reinforcements 126a, 126b reduce stress concentrations occurring in the heel wall 152 and the toe wall 154, respectively, thereby increasing casing durability. Although the end reinforcements 126a, 126b are concentrations of club head mass located on the casing walls, they are located towards the heel 104 and the toe 106 and thus do not hinder strike face deflection. In the illustrated embodiment, the end reinforcements 126a, 126b are generally circular in shape. In other embodiments, the end reinforcements 126a, 126b can be any suitable shape for reducing stress near the heel wall 152 and the toe wall 154. The end reinforcements 126a, 126b can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. The illustrated embodiment includes both a heel end reinforcement 126a and a toe end reinforcement 126b. In other embodiments, the casing 130 can comprise a heel end reinforcement 126a, a toe end reinforcement 126b, or both.

[0078] In some embodiments, the casing 130 can further comprise one or more front wall reinforcements 139, as best illustrated in FIG. 6. The front wall reinforcements 139 can be thickened portions of casing front wall 132. In the illustrated embodiment, the casing 130 comprises a front reinforcement 139 located in the central region 131 of the casing. The front wall reinforcements 139 are concentrations of club head mass with a substantially greater thickness than the surrounding casing walls. Similar to the end reinforcements 126a, 126b, the front wall reinforcements 139 reduce stress concentrations occurring in the front wall 132, thereby increasing overall casing 130 durability. In the illustrated embodiment, a single front wall reinforcement 139 is generally located in the central region 131. In other embodiments, the front wall reinforcements 139 can be located in the heel region 135, in the toe region 137, or in any combination of central, heel, and toe regions 131, 135, 137. The front wall reinforcements 139 can be formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof. [0079] In many embodiments, the casing 130 comprises a casing recess 182 that retains the insert 170 and increases strike face deflection. In the illustrated embodiment of FIG. 7, the casing recess 182 is located at the rear wall base 143. The casing recess 182 includes a seating surface 184 that is inset from an exterior surface 109 of the sole 112 by a rising surface 183. The casing recess 182 can be in direct communication with the aperture 140. The casing recess 182 forms a lap joint configured to receive one or more portions of the insert 170. Although the casing recess 182 of the illustrated embodiment is located only at the rear wall base 143, in other embodiments, the casing recess 182 can also be formed at the front wall base 133. In some embodiments, the casing recess 182 extends around and entirely circumscribes the aperture 140.

[0080] The casing recess 182 removes mass from the rear wall base 143, thereby increasing the amount the rear wall 142 and the sole 112 bend at impact. In some embodiments, the casing recess 182 defines a recess depth DR measured between the exterior surface of the sole 112 and the seating surface 184. Increasing the recess depth DR will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, increasing the recess depth DR also potentially increases stress in the casing 130. The recess depth DR can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the recess depth DR can be between 0.1 and 0.75 inch. For example, in some embodiments, the recess depth DR can be between 0.10 and 0.15 inch, between 0.15 and 0.20 inch, between 0.20 and 0.25 inch, between 0.25 and 0.30 inch, between 0.30 and 0.35 inch, between 0.35 and 0.40 inch, between 0.40 and 0.45 inch, between 0.45 and 0.50 inch, between 0.50 and 0.55 inch, between 0.55 and 0.60 inch, between 0.60 and 0.65 inch, between 0.65 and 0.70 inch, or between 0.70 and 0.75 inch.

[0081 ] In alternative embodiments, rather than a lap j oint configuration including a rising surface and a seating surface, the casing recess 182 can comprise a bevel. As best illustrated in FIG. 8, the casing recess 182 defines a beveled surface 185 that gradually slopes between the exterior surface 109 of the sole 112 and the rear wall front surface 144 and/or the front wall rear surface 136. Rather than a recess depth, the beveled surface 185 can comprise a bevel angle OIB defined between the exterior surface 109 of the sole 112 and the beveled surface 185. A greater bevel angle an, will increase the amount the casing 130 bends at impact, thereby increasing strike face deflection. However, a greater bevel angle om also potentially increases stress in the casing 130. The bevel angle OIB can be selected to increase strike face deflection while maintaining sufficient durability. In some embodiments, the bevel angle an can be between 5 and 60 degrees. For example, in some embodiments, the bevel angle an can be between 5 and 10 degrees, between 10 and 16 degrees, between 16 and 21 degrees, between 21 and 27 degrees, between 27 and 32 degrees, between 32 and 38 degrees, between 38 and 43 degrees, between 43 and 49 degrees, between 49 and 54 degrees, or between 54 and 60 degrees.

[0082] In some embodiments, the faceplate 114 comprises one or more return portions that are used in combination with the IRM 120 to increase strike face deflection. The return portions are portions of the faceplate 114 that wrap over the strike face perimeter and form other forward portions of the club head 100, such as forward portions of the crown 110, sole 112, heel 104, or toe 106. The return portions replace these portions of the club head 100, which typically experience high impact stresses and would otherwise be formed of the body material, with the high-strength faceplate material. This allows these areas of the club head 100 to be thinned without sacrificing durability, thereby increasing strike face deflection.

[0083] The one or more return portions can be described in relation to the faceplate perimeter 155, which is the outermost edge of the faceplate 114 that couples to the body 101 and/or other club head components. Referring to FIG. 10, in some embodiments, the faceplate 114 comprises a crown return 115 that wraps over the transition from the strike face 102 to the crown 110, thereby to form a forward portion of the crown 110. In embodiments comprising a crown return 115, the faceplate top edge 160 is located on the crown 110 and not on the strike face 102. Similarly, in other embodiments such as that illustrated in FIG. 12, the faceplate 114 can comprise a toe return 161, wrapping over the transition between the strike face 102 and the toe 106, thereby to form a forward portion of the toe 106. In embodiments comprising a toe return 161, the faceplate toe edge 159 is located on the toe 106 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a sole return (discussed in further detail below) that wraps over the leading edge 103 and forms a forward portion of the sole 112, wherein the faceplate bottom edge 157 is located on the sole 112 and not on the strike face 102. In other embodiments, the faceplate 114 comprises a heel return that wraps over the transition between the strike face 102 and the heel 104 , thereby to form a forward portion of the heel 104, wherein the faceplate heel edge 158 is located on the heel 104 and not on the strike face 102. The faceplates described herein can comprise a crown return, a heel return, a toe return, or any combination thereof. Specific return combinations and configurations are discussed in detail below.

[0084] In some embodiments, the club head 100 can comprise a “reverse L-cup” faceplate 114, as best illustrated in FIGS. 10 and 11. The reverse L-cup faceplate 114 can comprise a crown return 115 yet be devoid of a sole return. As such, the reverse L-cup faceplate 114 comprises a faceplate top edge 160 that is located on the crown 110. The faceplate bottom edge that is located on the strike face 102, above the leading edge 103. The reverse L-cup faceplate 114 does not extend to or wrap over the leading edge 103, nor does the reverse L-cup faceplate 114 form any portion of the sole 112. Due to the absence of a sole return, the body 101 of the illustrated embodiment forms a forward portion of the sole 112 as well as the entire casing 130.

[0085] The crown return increases durability and performance by reinforcing (via the high- strength faceplate material) the transition between the strike face 102 and the crown 110 and forward portions of the crown 110, which are both areas that experience impact stresses. Further, the reverse L-cup faceplate 114 simplifies manufacture. The lack of a sole return in the reverse L-cup faceplate 114 enables the complex casing geometries to be easily cast out of body material. The IRM 120 and the crown return 115 work in conjunction to increase strike face deflection without sacrificing durability. In particular, the IRM 120 increases sole flexibility, whereas the crown return 115 increases crown flexibility.

[0086] In some embodiments, such as the illustrated embodiment of FIGS. 10 and 11, the reverse L-cup faceplate 114 comprises a crown return 115, but no heel return or toe return. However, in other embodiments, the reverse L-cup faceplate 114 can further comprise a toe return 161, as illustrated in FIG. 12. In such embodiments, the faceplate toe edge 159 is located on the toe 106. The toe return 161 further increases durability by reinforcing the transition between the strike face 102 and the toe 106. The toe return 161 thereby allows portions of the toe 106 to be thinned without exceeding the yield strength of the high-strength faceplate material. The reverse L-cup faceplate 114 with both a crown return 115 and a toe return 161 increases strike face deflection over a reverse L-cup faceplate 114 with only a crown return 115. In some embodiments, referring to FIG. 12, the faceplate toe edge 159 can run substantially parallel to the strike face 102. In other embodiments, the faceplate toe edge 159 can be divided into a toe edge sole segment 159a that extends in a substantially horizontal direction parallel to the sole 112 and a toe edge crown segment 159b that extends in a substantially vertical direction perpendicular to the sole 112. This configuration simplifies manufacture by smoothing the transition between the toe edge sole segment 159a and the faceplate bottom edge 157 and the transition between the toe edge crown segment 159b and the faceplate top edge 160.

[0087] In some embodiments, as shown in FIGS. 14 and 15, the crown return 115 further comprises an indentation 141. The indentation 141 is recessed into an interior surface of the crown return 115. The indentation 141 is a region of reduced thickness relative to the remainder the crown return 115. In the illustrated embodiment, the indentation 141 is isolated within the crown return 115, such that the indentation perimeter 194 is located entirely within the bounds of the crown return 115. The indentation 141 increases strike face deflection without compromising faceplate durability. The indentation 141 can increase ball speed by upwards of 0.5 mph (without compromising durability) over a club head comprising a crown return without an indentation. Specifically, the indentation 141 strategically weakens the forward portion of the crown 110, thereby increasing the amount the crown 110 deflects upward at impact. This increased upward crown deflection in turn increases the amount of strike face deflection. Because the indentation 141 is isolated within the crown return 115, this additional deflection can occur without exceeding the yield strength of the high-strength faceplate material.

[0088] The indentation 141 comprises an indentation thickness Ti that is reduced in comparison to the crown return thickness TCR. In some embodiments, the indentation thickness Ti can be between 0.005 and 0.020 inch, whereas the crown return thickness TCR can be between 0.020 and 0.050 inch. In some embodiments, the indentation thickness Ti can be less than 0.020 inch, less than 0.015 inch, or less than 0.010 inch. Further, the crown return 115 can comprise an indentation thickness ratio TI/TCR defined as the indentation thickness Ti divided by the crown return thickness TCR. In some embodiments, the indentation thickness ratio TI/TCR can be less than 0.5, less than 0.4, less than 0.3, less than 0.2, or less than 0.1.

[0089] In the illustrated embodiment, the indentation 141 is located approximately in the center of the crown return 115 and extends in a generally heel -toe direction. In other embodiments, the indentation can be offset towards to the toe 106 or towards the heel 104. In the illustrated embodiment, the indentation 141 has an approximately rectangular shape. In other embodiments, the indentation 141 can have other shapes such as an elongated oval or an arcuate shape.

[0090] The casing embodiments described herein can comprise one or more of the casing features described above. In particular, any casings formed by the body, the faceplate, a cartridge, an appendage, or any combination thereof can include any combination of reliefs, end reinforcements, casing recesses, or returns.

IV. Impact Response Modulator with High-Strength Material Reinforcement

[0091] As described above, a high-strength component forms at least part of the casing. In some embodiments, the faceplate forms part or all of the casing, whereas in other embodiments, a separate, high-strength material component (such as a cartridge or an appendage) forms part or all of the casing. The high-strength material reinforces the casing, increasing strike face deflection without compromising durability. Specifically, design choices that increase strike face deflection, such as decreasing front wall offset, increasing the casing length, or shortening or thinning the front wall, can be implemented without exceeding the high-strength material’s yield strength, thereby maintaining durability.

[0092] The club heads described below include an IRM having high-strength material while improving or simplifying manufacture. In general, high-strength components with complex geometries are difficult to manufacture, particularly by forging. In general, a monolithically forged component can have no more than two “bends” in a given cross-section, wherein a “bend” refers to adjacent surfaces or portions of the component being significantly angled relative to each other. For example, a monolithically forged faceplate can have no more than two bends in a vertical (i.e., crown-to-sole) cross section and no more than two bends in a horizontal (i.e., heel- to-toe) cross section. Components with more than two bends in given cross section may not provide sufficient clearance for a forging tool to be removed post-manufactured.

[0093] As described above, in some embodiments, the faceplate can comprise a crown return, a heel return, or a toe return to reinforce portions of the crown, heel, or toe, respectively, to improve strike face deflection. However, due to the manufacturing constraints discussed above, it can be difficult or impossible to monolithically forge a faceplate with a crown return, heel return, or toe return if the faceplate also forms a sole return and one or more casing geometries. Such an embodiment would exceed the maximum number of two bends in a single cross-section. Some embodiments of the IRM described herein comprise faceplates and/or other high-strength material components having complex geometries that are capable of being manufactured by forging or other processes by selectively placing high-strength material and strategically combining monolithic faceplate geometries (i.e., crown returns, sole returns, toe returns, heel returns, and casing geometries).

A. Body and Faceplate Forming the Casing

[0094] In some embodiments, the faceplate and the body combine to form the casing. The embodiments described below with reference to FIGS. 16-23 include a faceplate that combines with the body to form the casing and reinforce the casing with high-strength faceplate material (having a yield strength above 175 ksi). The faceplate reduces stress in the casing walls, allowing the casing walls to have reduced thickness, reduced length, or being located closer to the strike face, thereby increasing strike face deflection without compromising durability. The embodiments described below increase strike face deflection while maintaining sufficient club head durability and overall manufacturability. The faceplates have relatively simple designs (including two or less bends in a given cross-section) that are suitable for monolithic forging while still reinforcing areas of the casing. Any other complex casing geometries can be cast out of the body material.

[0095] In some embodiments, the club head 700 can comprise an “L-cup” faceplate 714 that reinforces the casing 730. As best illustrated in FIG. 16, the faceplate 714 comprises a sole return 716 that extends rearward from the strike face 702 and forms a forward portion of the sole 712. The sole return 716 is coupled to the body 701 at a sole return rear edge 757. The sole return 716 terminates at the front wall base 733, such that the sole return rear edge 757 is forward of the casing front wall 732. The L-cup faceplate 714, therefore, does not form any portion of the casing front wall 732 or the casing rear wall 742, nor does it form any portion of the aperture 740. In the illustrated embodiment, both the casing front wall 732 and the casing rear wall 742 are integral with the body 701. The body 701 therefore encapsulates and defines the entire aperture 740.

[0096] In some embodiments, the sole return 716 can extend along the entirety of the casing front wall 732. In other embodiments, the sole return 716 can extend along less than the entirety length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 can run along between 25% and 40%, between 30% and 45%, between 35% and 50%, between 40% and 55%, between 45% and 60%, between 50% and 65%, between 55% and 70%, between 60% and 75%, between 65% and 80%, between 70% and 85%, between 75% and 90%, between 80% and 95%, or between 85% and 100% of the length of the front wall base 733. In some embodiments, the sole return 716 is located only in the casing center region to locally reinforce areas of the casing 730 that typically experience high impact stresses.

[0097] The L-cup faceplate 714 is readily manufacturable and reinforces the casing 730. The sole return 716 reinforces high-stress areas of the sole 712 immediately in front of the casing front wall 732 with high-strength material. The L-cup faceplate 714 is easily forged, because it does not include any of the complicated casing wall geometries. The L-cup faceplate 714 comprises only a single bend in the vertical cross-section, located at the juncture between the strike face 702 and the sole return 716. The casing walls, which are integral with the body 701, can be easily cast out of the body material. At impact, the L-cup faceplate 714, specifically the sole return 716, deflects with the portion of the sole 712 immediately in front of the casing front wall 732, which in turn increases strike face deflection. [0098] In some embodiments, the club head 800 can comprise a “J-cup” faceplate 814 that reinforces the casing front wall 832. As best illustrated in FIG. 17, the J-cup faceplate 814 comprises a sole return 816 that extends rearward from the strike face 802. In comparison to the sole return 716 of the L-cup faceplate 714, which only forms a forward portion of the sole 712, the sole return 816 forms both a forward portion of the sole 812 and the casing front wall 832. The J-cup faceplate 814, forms no portion of the casing rear wall 842. As such, the casing front wall 832 can be integral with the faceplate 814, whereas the casing rear wall 842 can be integral with the body 801. In this configuration, the faceplate 814 and the body 801 combine to form the aperture 840 therebetween.

[0099] In some embodiments, the sole return 816 can form the entire casing front wall 832. In other embodiments, the sole return 816 forms only a portion of the casing front wall 832. As best illustrated in FIGS. 17 and 18, the casing front wall 832 comprises a support segment 868 that is integral with the J-cup faceplate 814 and a core segment 869 that is integral with the body 801. The support segment 868 is the portion of the casing front wall 832 formed by the J-cup faceplate 814, whereas the core segment 869 is the portion of the casing front wall 832 formed by the body 801.

[0100] In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall front surface 834. For example, in some embodiments, the support segment 868 can form between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 834. In some embodiments, the support segment 868 forms between 25 and 100% of a surface area of the front wall rear surface 836. For example, in some embodiments, the support segment 868 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between

50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between

70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between

90% and 95%, or between 95% and 100% of the surface area of the front wall rear surface 836. [0101] In some embodiments, such as the illustrated embodiment of FIGS. 17 and 18, support segment 868 is located primarily in the casing center region 831, and the core segment 869 is located primarily in the casing heel region 835 and the casing toe region 837. In the present configuration, the sole return 816 locally reinforces the casing center region 831, where high impact stresses typically occur. In other embodiments, the support segment 868 and the core segment 869 can have alternate configurations. For example, the support segment 868 can be located primarily in the casing center region 831, the casing heel region 835, the casing toe region 837, or any combination thereof.

[0102] In embodiments where the sole return 816 forms only a portion of the casing front wall 832, the sole return 816 can span a lesser distance in a heel-to-toe direction than the aperture 840. As illustrated in FIGS. 17 and 18, the sole return 816 comprises a sole return width WSR measured in a heel-to-toe direction from the sole return heel edge 858 to the sole return toe edge 859. In some embodiments, the sole return width WSR is less than the aperture length LA.

[0103] The J-cup faceplate 814 is readily manufacturable and reinforces the casing 830. The sole return 816 reinforces high-stress areas of the casing front wall 832 with high-strength material. In some embodiments, the J-cup faceplate 814 can be monolithically forged, because it does not include any overly complicated geometries. Referring to FIG. 17, the J-cup faceplate 814 comprises only two bends in the vertical cross-section. The J-cup faceplate 814 comprises a first bend at the juncture between the strike face 802 and the sole return 816 and a second bend at the juncture between the sole 812 and the casing front wall 832. In the illustrated embodiment, the J-cup faceplate 814 is devoid of a crown return. The introduction of a crown return to the J- cup faceplate 814 would add a third bend at the juncture between the strike face 802 and the crown 810, making the J-cup faceplate geometry too complicated for monolithic forging. At impact, the J-cup faceplate 814, specifically the sole return 816, deflects with the casing front wall 832, which in turn increases strike face deflection.

[0104] In some embodiments, the club head 900 can comprise a “partial J-cup” faceplate 914 that reinforces the casing front wall 932. As best illustrated in FIG. 19, the partial J-cup faceplate 914 comprises a sole return 916 that extends rearward from the strike face 902. The sole return 916 forms both a forward portion of the sole 912 and a portion of the casing front wall 932. Specifically, the sole return 916 forms the front wall front surface 934 of the casing 930, but not the front wall rear surface 936. In contrast to the J-cup faceplate 814, which forms the entire casing front wall 832, the partial J-cup faceplate 914 forms only a portion of the front wall thickness FWT. The front wall front surface 934 is therefore integral with the partial J-cup faceplate 914. Similar to the J-cup faceplate 814 illustrated in FIG. 17, the partial J-cup faceplate 914 forms no portion of the casing rear wall 942. As such, both the front wall rear surface 936 and the rear wall 942 of the casing 930 can be integral with the body 901. The partial J-cup faceplate 914 therefore forms no portion of the aperture 940 and the aperture 940 is entirely encapsulated within the body 901.

[0105] In some embodiments, the sole return 916 can form the entire front wall front surface 934 of the casing 930. In other embodiments, the sole return 916 forms only a portion of the front wall front surface 934. As best illustrated in FIG. 20, the casing front wall 932 comprises a support segment 968 that is integral with the partial J-cup faceplate 914 and a core segment 969 that is integral with the body 901. The support segment 968 is the portion of the casing front wall 932 formed by the partial J-cup faceplate 914, whereas the core segment 969 is the portion of the casing front wall 932 formed by the body 901.

[0106] In some embodiments, the support segment 968 forms between 25 and 100% of a surface area of the front wall front surface 934. For example, in some embodiments, the support segment 968 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and 100% of the surface area of the front wall front surface 934. In some embodiments, the support segment 968 forms no portion of the front wall rear surface 936. In contrast to the core segment 869 of the J-cup faceplate 814, which only forms portions of the front wall rear surface 836, the core segment 969 of the partial J-cup faceplate 914 forms the entire front wall rear surface 936. [0107] In some embodiments, such as the illustrated embodiment of FIG. 20, the support segment 968 is located primarily in the casing center region 931. In such embodiments, the core segment 969 forms the entire front wall 932 in the casing heel region 935 and the casing toe region 937. In the present configuration, the sole return 916 locally reinforces the casing center region 931, where high impact stresses typically occur. In other embodiments, the support segment 968 and the core segment 969 can have alternate configurations. For example, the support segment 968 can be located primarily in the casing center region 931, the casing heel region 935, the casing toe region 937, or any combination thereof.

[0108] In embodiments where the sole return 916 forms only a portion of the casing front wall 932, the sole return 916 can span a lesser distance in a heel-to-toe direction than the aperture 940. As illustrated in FIG. 20, the sole return width WSR is less than the aperture length LA.

[0109] The partial J-cup faceplate 914 is readily manufacturable and reinforces the casing 930. The sole return 916 reinforces high-stress areas of the casing front wall 932 with high- strength material. In some embodiments, the partial J-cup faceplate 914 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 20, the partial J-cup faceplate 914 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814, the partial J-cup faceplate 914 comprises a first bend at the juncture between the strike face 902 and the sole return 816 and a second bend at the juncture between the sole 912 and the casing front wall 932. In the illustrated embodiment, the partial J-cup faceplate 914 is devoid of a crown return. The introduction of a crown return to the partial J-cup faceplate 914 would add a third bend at the juncture between the strike face 902 and the crown 910, making the partial J-cup faceplate geometry too complicated for monolithic forging. At impact, the partial J-cup faceplate 914, specifically the sole return 916, deflects with the front wall front surface 934, which in turn increases strike face deflection. This contrasts to the J-cup faceplate 814 described above, which deflects with the entire front wall 832.

[0110] In some embodiments, the club head 1100 can comprise an “underlapping J-cup” faceplate 1114 that reinforces the casing front wall 1132. As best illustrated in FIG. 21, the underlapping J-cup faceplate 1114 comprises a sole return 1116 that extends rearward from the strike face 1102. The sole return 1116 forms both a forward portion of the sole 1112 and a portion of the casing front wall 1132. The sole return 1116 comprises a faceplate lap 1118 that extends upwards at the rear end of the sole return 1116 to form the front wall rear surface 1136. The body 1101 comprises a body lap 1119 that overlaps the faceplate lap 1118 and forms the front wall front surface 1134. Together, the faceplate lap 1118 and the body lap 1119 combine to form the casing front wall 1132. The underlapping J-cup faceplate 1114 therefore forms only a portion of the front wall thickness. The front wall rear surface 1136 is integral with the underlapping J-cup faceplate 1114, whereas the front wall front surface 1134 is integral with the body 1101. As such, the underlapping J-cup faceplate 1114 contrasts with the partial J-cup faceplate 914, which forms the front wall front surface 934 but not the front wall rear surface 936. Similar to the J-cup faceplate 814 illustrated in FIG. 17, the casing rear wall 1142 is integral with the body 1101, and the faceplate 1114 forms no portion of the casing rear wall 1142. As such, both the front wall front surface 1134 and the rear wall 1142 of the casing 1130 can be integral with the body 1101. In this configuration, the faceplate 1114 and the body 1101 combine to form the aperture 1140 therebetween.

[0111] In some embodiments, the sole return 1116 can form the entire front wall rear surface 1136 of the casing 1130. In other embodiments, the sole return 1116 forms only a portion of the front wall rear surface 1136. For example, in some embodiments, as illustrated in FIG. 21, the body lap 1119 includes a cap 1117 that covers the top end of the faceplate lap 1118. The cap 1117 thereby forms the entire front wall top surface 1138 and an upper end of the front wall rear surface 1136. Further, in some embodiments, the faceplate lap 1118 does not extend along the entirety of the front wall rear surface 1136. As best illustrated in FIGS. 21 and 22, the casing front wall 1132 comprises a support segment 1168 that is integral with the underlapping J-cup faceplate 1114 and a core segment 1169 that is integral with the body 1101. The support segment 1168 is the portion of the casing front wall 1132 formed by the underlapping J-cup faceplate 1114, whereas the core segment 1169 is the portion of the casing front wall 1132 formed by the body 1101. [0112] In some embodiments, the support segment 1168 forms between 25 and 100% of a surface area of the front wall rear surface 1136. For example, in some embodiments, the support segment 1168 forms between 25% and 30%, between 30% and 35%, between 35% and 40%, between 40% and 45%, between 45% and 50%, between 50% and 55%, between 55% and 60%, between 60% and 65%, between 65% and 70%, between 70% and 75%, between 75% and 80%, between 80% and 85%, between 85% and 90%, between 90% and 95%, or between 95% and

100% of the surface area of the front wall rear surface 1136. In some embodiments, the support segment 1168 forms no portion of the front wall front surface 1134. The core segment 1169 of the underlapping J-cup faceplate 1114 forms the entire front wall front surface 1134. This contrasts with the core segment 969 of the partial J-cup faceplate 914 described above, which forms the entire front wall rear surface 1136.

[0113] In some embodiments, such as the illustrated embodiment of FIGS. 21 and 22, the support segment 1168 is located primarily in the casing center region 1131. In such embodiments, the core segment 1169 forms the entire front wall 1132 in the casing heel region 1135 and the casing toe region 1137. In the present configuration, the sole return 1116 locally reinforces the casing center region 1131, where high impact stresses typically occur. In other embodiments, the support segment 1168 and the core segment 1169 can have alternate configurations. For example, the support segment 1168 can be located primarily in the casing center region 1131, the casing heel region 1135, the casing toe region 1137, or any combination thereof.

[0114] In embodiments where the sole return 1116 forms only a portion of the casing front wall 1132, the sole return 1116 can span a lesser distance in a heel-to-toe direction than the aperture 1140. As illustrated in FIG. 22, the sole return width WSR is less than the aperture length LA.

[0115] The underlapping J-cup faceplate 1114 is readily manufacturable and reinforces the casing 1130. The sole return 1116 reinforces high-stress areas of the casing front wall 1132 with high-strength material. In some embodiments, the underlapping J-cup faceplate 1114 can be monolithically forged, because it does not include any overly complicated geometries. As described above, a monolithically forged faceplate can have no more than two bends in a given cross-section. Referring to FIG. 21, the underlapping J-cup faceplate 1114 comprises only two bends in the vertical cross-section. Similar to the J-cup faceplate 814 and the partial J-cup faceplate 914, the underlapping J-cup faceplate 1114 comprises a first bend at the juncture between the strike face 1102 and the sole return 1116 and a second bend at the juncture between the sole 1112 and the faceplate lap 1118. In the illustrated embodiment, the underlapping J-cup faceplate 1114 is devoid of a crown return. The introduction of a crown return to the underlapping J-cup faceplate 1114 would add a third bend at the juncture between the strike face 1102 and the crown 1110, making the underlapping J-cup faceplate geometry too complicated for monolithic forging. At impact, the underlapping J-cup faceplate 1114, specifically the faceplate lap 1118, deflects with the front wall rear surface 1136, which in turn increases strike face deflection. This contrasts with the partial J-cup faceplate 914, which deflects with the front wall front surface 1134.

[0116] In some embodiments, the faceplate 1214 comprises one or more bridges 1249 that further reinforce the casing 1230 without compromising strike face deflection. As best illustrated in FIG. 23, the faceplate 1214 comprises a sole return 1216 that extends rearward from the strike face 1202. The sole return 1216 forms both a forward portion of the sole 1212 as well as the casing front wall 1232. As such, the casing front wall 1232 is integral with the faceplate 1214. The faceplate 1214 further comprises one or more bridges 1249 that span the aperture 1240 in a face-to-rear direction. The bridges 1249 connect the front wall 1232 and the rear wall 1242 of the casing 1230. In the illustrated embodiment, the bridges 1249 connect the front wall top surface 1238 and the rear wall top surface 1244. In other embodiments, the bridges 1249 can connect other portions of the front wall 1232 and the rear wall 1242. In some embodiments, the bridges can connect the front wall base 1233 to the rear wall base 1243. In other embodiments, the bridges 1249 can connect portions of the front wall 1232 and the rear wall 1242 in between the top surfaces 1238, 1244 and the bases 1233, 1243. The faceplate 1214 can comprise any suitable number of bridges 1249 for reinforcing the casing walls 1232, 1242. In some embodiments, the faceplate can comprise one, two, three, four, five, six, seven, eight, nine, or any suitable number of bridges 1249. In some embodiments, the bridges 1249 are monolithically formed with the faceplate 1214. In other embodiments, the bridges 1249 can be separately formed from the faceplate 1214 and subsequently attached thereto, such as by welding.

[0117] The bridges 1249 can be located at strategic locations to locally reinforce the casing 1230. In some embodiments, the bridges 1249 are located within the casing center region 1231. For center strikes, the highest impact stresses occur within the casing center region 1231. Placing one or more bridges 1249 in the casing center region 1231 reinforces the casing 1230 in these high-stress areas to improve durability without hindering strike face deflection.

[0118] In the illustrated embodiment, the casing front wall 1232 and the bridges 1249 are both integral with the faceplate 1214, and the casing rear wall 1242 is integral with the body 1201. In such embodiments, the bridges 1249 can be welded or otherwise coupled to the body 1201. In such embodiments, the faceplate 1214 and the body 1201 combine to form the aperture 1240. In other embodiments, the casing front wall 1232, the bridges 1249 and the casing rear wall 1242 are all integral with the faceplate 1214. In such embodiments, the faceplate 1214 entirely encapsulates the aperture 1240. At impact, the faceplate 1214 with one or more bridges 1249 bends with the casing 1230. Specifically, the sole return 1216 bends with the casing front wall 1232. As the casing walls bend towards each other, the bridges 1249 are compressed by the casing walls and return a stiffening force back to the casing walls. The stiffening force allows the casing walls to bend further than they otherwise would in the absence of bridges, thereby increasing strike face deflection.

B. Cartridge Forming the Casing

[0119] In some embodiments, the club head 1400 comprises a component separate from the faceplate and body, such as a cartridge 1450, that integrally forms at least a portion of the casing 1430. Referring to FIGS. 24 and 25, the cartridge 1450 is a component distinct from the faceplate 1414 that is attached to the faceplate 1414, the body 1401, or both. Although the cartridge 1450 and the faceplate 1414 are both high-strength material components, they are not the same component. The cartridge 1450 integrally forms at least a portion of the casing 1430, including the front wall 1432 and the rear wall 1442. The cartridge 1450 is formed of a high- strength cartridge material that is more durable than the body material. As such, the cartridge 1450 reinforces the IRM 1420 and increases strike face deflection without compromising durability. In some embodiments, the cartridge 1450 houses and forms the entire casing 1430. In other embodiments, the cartridge 1450 forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 but may not form the entire casing 1430. In such embodiments, the cartridge 1450 locally reinforces the casing 1430 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1431 experiences higher impact stresses than the casing heel region 1435 or the casing toe region 1437. In such embodiments, the cartridge 1450 may form and reinforce the casing center region 1431. The casing heel region 1435 and the casing toe region 1437 may not require the same level of reinforcement and can therefore be formed by the body 1401, which comprises a lower- strength material.

[0120] The cartridge 1450 reinforces the IRM 1420 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1430, the cartridge 1450 is a separate, high-strength material component that forms and reinforces the casing 1430. Because the faceplate 1414 does not form any part of the complicated casing geometry, the cartridge 1450 can be combined with a faceplate 1414 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration not only reinforces the IRM 1420 but also reinforces other portions of the club head 1400 to further increase strike face deflection, as the returns (i.e., the crown return, sole return, heel return, or sole return) can have a reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process, (such as welding) between the cartridge 1450 and the faceplate 1414 or body 1401 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0121] In some embodiments, the separately formed cartridge 1450 is attached to both the faceplate 1414 and the body 1401 and houses at least a portion of the casing 1430. In the illustrated embodiment of FIG. 25, the cartridge 1450 is located in a forward portion of the sole 1412. The cartridge 1450 comprises a cartridge perimeter 1455 that includes a cartridge forward edge 1456 that couples to the faceplate 1414 and a cartridge rear edge 1457 that couples to the body 1401. In some embodiments, as illustrated in FIG. 25, the faceplate 1414 comprises a sole return 1416 extending rearward from the strike face 1402 and the cartridge forward edge 1456 couples to the sole return 1416. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the sole 1412. The cartridge 1450 is thereby located entirely within the sole 1412.

[0122] In alternative configurations, rather than the cartridge 1450 being located entirely within the sole 1412, the cartridge 1450 can partially extend onto the strike face 1402, as best illustrated in FIG. 26. In such embodiments, the juncture between the cartridge forward edge 1456 and the faceplate 1414 is located on the strike face 1402. The faceplate 1414 can be devoid of a sole return 1416 and the cartridge 1450 can wrap over the leading edge 1403 and form a lower portion of the strike face 1402. In both embodiments, the cartridge 1450 forms at least a portion of the sole 1412.

[0123] In the embodiment illustrated in FIGS. 24 and 25, the cartridge 1450 houses the entire casing 1430, thereby reinforcing the entire casing 1430 with high-strength material. The cartridge perimeter 1455 is continuously attached to either the faceplate 1414 or the body 1401 in this embodiment, such that there are no unattached cartridge edges. In such embodiments, the cartridge 1450 forms and encases the entire aperture 1440. In other embodiments, the cartridge 1450 is coupled to both the faceplate 1414 and the body 1401 and forms at least a portion of the front wall 1432 and at least a portion of the rear wall 1442 yet may not form the entire casing 1430. In some embodiments, the front wall 1432 and/or rear wall 1442 can comprise a support segment formed by the cartridge 1450 and a core segment formed by the body 1401, as described in further detail below. In such embodiments, the aperture 1440 is formed by a combination of the cartridge 1450 and the body 1401.

[0124] In some embodiments, the separately formed cartridge 1550 is attached only to the body 1501 and is not directly coupled to the faceplate 1514. The cartridge perimeter 1555 can be continuously coupled to the body 1501. As illustrated in FIGS. 27-29, both the cartridge forward edge 1556 and the cartridge rear edge 1557 are coupled to the body 1501, such that the cartridge 1550 is entirely housed by and isolated within the body 1501. This configuration can be especially useful in embodiments comprising face inserts, in which the faceplate 1514 is confined within an opening located on the strike face 1502. Further, in some cases, stresses concentrate near the casing front wall 1532, but not in the forwardmost portion of the sole 1512 or near the leading edge 1503. In such cases, the leading edge 1503 and the portion of the sole

1512 in front of the casing 1530 may not require high-strength reinforcement.

[0125] The cartridge 1550 can be located entirely within the sole 1512, as illustrated in FIGS. 27-29. In such embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the sole 1512. Further, the body 1501 forms a forward sole segment

1513 interposed between the cartridge forward edge 1556 and the leading edge 1503. In other embodiments, the juncture between the cartridge forward edge 1556 and the body 1501 is located on the strike face 1502. In such embodiments, the cartridge 1550 can wrap over the leading edge 1503 and form a lower portion of the strike face 1502. In both embodiments, the cartridge 1550 forms at least a portion of the sole 1512.

[0126] In the embodiment illustrated in FIGS. 27-29, the cartridge 1550 only partially forms the casing 1530. The portion(s) of the casing walls formed by the cartridge 1550 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1501 can be referred to as core segments. In the illustrated embodiment, the front wall 1532 comprises a front wall support segment 1568a formed by the cartridge 1550 and a front wall core segment 1569b formed by the body 1501. Similarly, the rear wall 1542 comprises a rear wall support segment 1568b formed by the cartridge 1550 and a rear wall core segment 1569b formed by the body 1501. In the illustrated embodiment, the respective support segments 1568a, 1568b are in the casing center region 1531 and extend into the casing toe region 1537, whereas the respective core segments 1569a, 1569b are primarily located in the casing heel region 1535. The cartridge 1550 comprises a cartridge heel edge 1558 that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b. Because the body 1501 and the cartridge 1550 combine to form the aperture 1540, the cartridge heel edge 1558 can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge heel edge 1558. [0127] In other embodiments, the support segments 1568a, 1568b and core segments 1569a, 1569b can have alternative configurations. For example, the support segments 1568a, 1568b can be primarily in the casing center region 1531. In such embodiments, the core segments 1569a, 1569b are located in both the casing heel region 1535 and the casing toe region 1537. In such embodiments, the cartridge 1550 further comprises a cartridge toe edge that couples to the body 1501 at the juncture between the respective support segments 1568a, 1568b and core segments 1569a, 1569b near the casing toe region 1537. As similarly described above, the cartridge toe edge in such embodiments can be discontinuous, such that the aperture 1540 interrupts a portion of the cartridge toe edge.

[0128] The front wall 1532 and rear wall 1542 can have combinations or configurations of support segments 1568a, 1568b and core segments 1569a, 1569b to produce a desired strike face deflection. The cartridge 1550 can form at least portions of the casing front wall 1532 and the casing rear wall 1542. In some embodiments, the front wall height of the casing can be greater in the front wall core segment 1569a than in the front wall support segment 1568a. The high- strength cartridge material allows the front wall height in the support segment 1568a to be reduced (thereby increasing strike face deflection) without compromising durability.

[0129] In other embodiments, by being coupled only to the body 1501 and not the faceplate 1514, the cartridge 1550 can house the entire casing 1530, thereby increasing IRM reinforcement. The cartridge perimeter 1555 is continuously attached to the body 1501 in such embodiments, such that there are no unattached or interrupted cartridge edges.

[0130] In the club head 1400 comprising a cartridge 1450, the faceplate 1414 forms no portion of the casing 1430. Instead, the casing 1430 is formed entirely by the cartridge 1450 or a combination of the cartridge 1450 and the body 1401, as described above. Similarly, the faceplate 1414 forms no portion of the aperture 1440. The cartridge 1450 separates the faceplate 1414 from the aperture 1440 and is either formed completely by the cartridge 1450 or by a combination of the cartridge 1450 and the body 1401.

[0131] As described above, manufacturing (and in particular forging) unitary, high-strength material components is limited by the number of bends the unitary component can have in a single direction (i.e., vertical, horizontal, etc.). In general, a single high-strength component can only be forged with a maximum of two bends in a single direction. The cartridge 1450 improves manufacture by forming the complex casing geometries separately from the faceplate 1414. Because the casing 1430 is separate from the faceplate 1414, the casing 1430 does not factor into the maximum number of faceplate bends. As such, the faceplate 1414 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1414 integrally forms the casing 1430. For example, the separately formed faceplate 1414 can comprise both a crown return 1415 and a sole return 1416 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1414 comprises a first bend at the juncture between the strike face 1402 and the crown return 1415 and a second bend at the juncture between the strike face 1402 and the sole return 1416. The cartridge 1450 can thereby be combined with a faceplate 1414 comprising a crown return 1415, a sole return 1416, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing key areas of the club head 1400 on the crown 1410, sole 1412, heel 1404, and toe 1406.

[0132] The cartridge 1450 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1401 or the faceplate 1414. In some embodiments, the cartridge 1450 is welded to the faceplate 1414 or the body 1401. In other embodiments, the cartridge 1450 can be coupled to the faceplate 1414 or the body 1401 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the cartridge 1450 is coupled to the body 1401 and the faceplate 1414 through a permanent fixing means. In some embodiments, the attachment means between the cartridge 1450 and the body 1401 is the same as the attachment means between the cartridge 1450 and the faceplate 1414. In other embodiments, the cartridge 1450 is coupled to both the body 1401 and the faceplate 1414 by identical means.

[0133] As described above, the cartridge 1450 is formed of a high-strength cartridge material. For example, in some embodiments, the cartridge material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431, Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0134] In other embodiments, the cartridge material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Til 85, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6A1-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-lOV- 2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9A1-2V (Ti-92), Ti-8A1- IMo-lV (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6A1- 2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-lCr-lFe (Ti-55511), Ti-13V-l lCr- 3A1, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti- 17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the cartridge material can be a high-strength composite or carbon fiber material.

[0135] Generally, the cartridge material is stronger than the body material. In some embodiments, the cartridge material is the same as the faceplate material. In other embodiments, the cartridge material and the faceplate material are different. The high-strength cartridge material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the cartridge material has a yield strength value of at least 175 ksi or more. In some embodiments, the cartridge material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises a cartridge strength ratio comparing the yield strength of the cartridge material to the yield strength of the body material. In some embodiments, the cartridge strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0. C. Body and Appendage Forming the Casing

[0136] In some embodiments, the club head 1600 comprises an appendage 1650 that integrally forms at least a portion of the casing 1630. Referring to FIGS. 30-33, the appendage 1650 is a separate component attached to the faceplate 1614 and the body 1601. Although the appendage 1650 and the faceplate 1614 are both high-strength material components, they are not the same component. The appendage 1650 integrally forms at least a portion of the casing front wall 1632. The appendage 1650 is formed of a high-strength appendage material that is more durable than the body material. As such, the appendage 1650 reinforces the IRM 1620 and increases strike face deflection without compromising durability. In some embodiments, the appendage 1650 forms the entire front wall 1632. In other embodiments, the appendage 1650 forms only a portion of the front wall 1632 rather than the entire front wall 1632. In such embodiments, the appendage 1650 locally reinforces the casing 1630 in high-stress areas without requiring excess high-strength material. For example, in some embodiments, the casing center region 1631 experiences higher impact stresses than the casing heel region 1635 or the casing toe region 1637. In such embodiments, the appendage 1650 may form and reinforce the casing center region 1631. The casing heel region 1635 and the casing toe region 1637 may not require the same level of reinforcement and can therefore be formed by the body 1601, which comprises a lower- strength material.

[0137] The appendage 1650 reinforces the IRM 1620 while improving manufacturability. Rather than a complicated sole return or faceplate geometry reinforcing the casing 1630, the appendage 1650 is a separate, high-strength material component that forms and reinforces the casing 1630. Because the faceplate 1614 does not have to form any part of the complicated casing geometry, the appendage 1650 can be combined with a faceplate 1614 that includes any combination of a crown return, a sole return, a heel return, or a sole return. This configuration allows for high-strength material reinforcement of not only the IRM 1620 but also other portions of the club head 1600 to further increase strike face deflection, because the returns (i.e., the crown return, sole return, heel return, or sole return) can have reduced thickness without sacrificing durability. These configurations can be easily manufactured by a simple joining process (such as welding) between the appendage 1650 and the faceplate 1614 or body 1601 and without the complex manufacturing processes required to provide a similar level of high-strength material reinforcement in a unitary component.

[0138] In some embodiments, the separately formed appendage 1650 is attached to both the faceplate 1614 and the body 1601 and integrally forms at least a portion of the casing front wall 1632. In the illustrated embodiment of FIG. 30, the appendage 1650 is located in a forward portion of the sole 1612. The appendage 1650 comprises an appendage perimeter 1655 that includes an appendage forward edge 1656 that couples to the faceplate 1614. The appendage perimeter 1655 further includes an appendage heel edge 1658 and an appendage toe edge 1659 each coupled to the body 1601. While the appendage 1650 forms at least a portion of the front wall 1632, the body 1601 forms the rear wall 1642. The aperture 1640 is thereby formed between the body 1601 and the appendage 1650.

[0139] In some embodiments, the appendage 1650 is located entirely within the sole 1612. As illustrated in FIGS. 30-31, the faceplate 1614 comprises a sole return 1616 extending rearward from the strike face 1602, and the appendage forward edge 1656 couples to the sole return 1616. In such embodiments, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the sole 1612. In alternative configurations, rather than the appendage 1650 being located entirely within the sole 1612, the appendage 1650 can partially extend on to the strike face 1602. In such embodiments, as best illustrated in FIGS. 32 and 33, the juncture between the appendage forward edge 1656 and the faceplate 1614 is located on the strike face 1602. In such embodiments, the faceplate 1614 can be devoid of a sole return 1616 and the appendage 1650 can wrap over the leading edge 1603 and form a lower portion of the strike face 1602. In both embodiments, the appendage 1650 forms at least a portion of the sole 1612.

[0140] In some embodiments, the appendage 1650 forms entities of both the front wall front surface 1634 and front wall rear surface 1636 of the casing 1630. This configuration increases high-strength material reinforcement along the entire front wall 1632. In some embodiments, the appendage 1650 can extend laterally past the extent of the aperture 1640. Such embodiments increase heel wall 1652 and toe wall 1654 reinforcement, where stress often pools within the casing 1630. In such embodiments, the appendage forward edge 1656 can be coupled to both the faceplate 1614 and the body 1601, because the appendage 1650 extends past the extent of the faceplate 1614 and/or the sole return 1616.

[0141] In other embodiments, such as that illustrated at FIG. 31, the appendage 1650 forms only a portion of the front wall 1632 and only a portion of the front wall rear surface 1636. The portion(s) of the casing walls formed by the appendage 1650 can be referred to as support segments, whereas the portion(s) of the casing walls formed by the body 1601 can be referred to as core segments. As illustrated in FIG. 33, the front wall 1632 comprises a support segment 1668 formed by the appendage 1650 and a core segment 1669 formed by the body 1601. In the illustrated embodiment, the support segment 1668 occupies the casing center region 1631 whereas the respective core segment 1669 primarily occupies the casing heel region 1635 and the casing toe region 1637. The appendage heel edge 1658 and the appendage toe edge 1659 couple to the body 1601 at the junctures between the support segment 1668 and the core segment 1669. The support segment 1668 locally reinforces high-stress areas in the front wall 1632.

[0142] In other embodiments, the support segment 1668 and core segment 1669 can have alternative configurations. For example, in some embodiments, the support segment 1668 can extend from the casing central region 1631 into either the casing heel region 1635 or the casing toe region 1637. The front wall 1632 and rear wall 1642 can have any configuration of the support segment 1668 and the core segment 1669 to produce a desired strike face deflection. The appendage 1650 can form any amount or portion of the casing front wall 1632. In some embodiments, the front wall height of the casing 1630 can be greater in the core segment 1669 than in the support segment 1668. The high-strength appendage material allows the front wall height FWH in the support segment 1668 to be reduced (thereby increasing strike face deflection) without compromising durability.

[0143] The appendage 1650 can define an appendage length LA measured in a heel-to-toe direction between the heelmost and toemost extent of the appendage 1650. In embodiments wherein the appendage 1650 forms less than the entirety of the front wall 1632, the appendage length LAP can be less than the aperture length LA. In such embodiments, strike face deflection and club head durability are improved without excess high-strength material being required to form the appendage 1650.

[0144] In the club head 1600 comprising an appendage 1650, the faceplate 1614 forms no portion of the casing 1630. Instead, the casing 1630 is formed entirely by a combination of the appendage 1650 and the body 1601, as described above. Similarly, because the casing 1630 forms the aperture 1640, the faceplate 1614 also forms no portion of the aperture 1640. The appendage 1650 separates the faceplate 1614 from the aperture 1640. Instead, the aperture 1640 is formed completely by a combination of the appendage 1650 and the body 1601 within the casing 1630.

[0145] As described above, manufacturing (particularly forging) high-strength material components is limited by the number of bends the unitary component can have in a single direction. The appendage 1650 improves manufacture by allowing the complex casing geometries to be forged separately from the faceplate 1614. Because the appendage 1650 is separate from the faceplate 1614, the front wall geometry does not factor into the maximum number of faceplate bends. As such, the faceplate 1614 itself can comprise a more complex geometry than it otherwise can in embodiments wherein the faceplate 1614 integrally forms the front wall. For example, the separately formed faceplate 1614 can comprise both a crown return and a sole return 1616 without exceeding the two-bend maximum in the vertical direction. In such embodiments, the faceplate 1614 comprises a first bend at the juncture between the strike face 1602 and the crown return and a second bend at the juncture between the strike face 1602 and the sole return 1616. The appendage 1650 thereby separately forms a third bend at the juncture between the sole 1612 and the front wall 1632. The appendage 1650 can thereby be combined with a faceplate 1614 comprising a crown return, a sole return 1616, a heel return, a toe return, or any combination thereof. This configuration further increases strike face deflection without compromising durability, by reinforcing areas of the club head 1600 on the crown 1610, sole 1612, heel 1604, and toe 1606.

[0146] The appendage 1650 can be individually forged, stamped, or otherwise formed by a suitable manufacturing process and subsequently coupled to the body 1601 and the faceplate 1614. In some embodiments, the appendage 1650 is welded to the faceplate 1614 or the body 1601. In other embodiments, the appendage 1650 can be coupled to the faceplate 1614 or the body 1601 by adhesive means, mechanical means, interference fit, press fit, brazing, chemical means, hybrid attachment means, or any other suitable means. In some embodiments, the appendage 1650 is coupled to the body 1601 and the faceplate 1614 through a permanent fixing means. In some embodiments, the attachment means between the appendage 1650 and the body 1601 is the same as the attachment means between the appendage 1650 and the faceplate 1614. In other embodiments, the appendage 1650 is coupled to both the body 1601 and the faceplate 1614 by identical means.

[0147] As described above, the appendage 1650 is formed of a high-strength appendage material. For example, in some embodiments, the appendage material can be a steel alloy such as Carpenter 455, Carpenter 475, HT1770, M455 (H900), M475 (H975), 4140, 4340, C300, C350, 6150 steel, K301, Carpenter 158, Carpenter 450, Carpenter 465, Carpenter 431 , Inconel 718, Aermet 100, Maraging Steel (MSL 350, MSL 450), H13 Tool Steel, 17-4 PH Stainless Steel, 18Ni (300M), S7 Tool Steel, D2 Tool Steel, 440C Stainless Steel, SKD11, SAE 9260, 10B21 Boron Steel, 52100 Steel, Tungsten Carbide Steel, Viking 80, or 4130 Chromoly Steel, or any other similar steel alloy.

[0148] In other embodiments, the appendage material can be can be a high-strength titanium alloy, for example, but not limited to Ti-3-8-6-4-4, Ti-10-2-3, Ti 15-3-3-3, Ti 15-5-3, Ti 185, Ti 6-6-2, Ti-7s, Ti-9s, Ti-92, Ti-6A1-4V (Ti-6-4), Ti-3Al-8V-6Cr-4Mo-4Zr (Ti-3-8-6-4-4), Ti-lOV- 2Fe-3Al (Ti-10-2-3), Ti-15V-3Cr-3Al-3Sn (Ti-15-3-3-3), Ti-15Mo-5Zr-3Al (Ti-15-5-3), Ti-185, Ti-6Al-6V-2Sn (Ti-6-6-2), Ti-7Al-4Mo (Ti-7s), Ti-9Al-2Mo (Ti-9s), Ti-9A1-2V (Ti-92), Ti-8A1- IMo-lV (Ti-8-1-1), Ti-5Al-5Mo-5V-3Cr (Ti-5553), Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2), Ti-6A1- 2Sn-4Zr-6Mo (Ti-6-2-4-6), Ti-6Al-7Nb, Ti-5Al-5Mo-5V-lCr-lFe (Ti-55511), Ti-13V-HCr- 3A1, Ti-1100, Ti-6Al-2.75Sn-4Zr-0.4Mo-0.45Si-0.1Y (IMI 829), Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti- 17), Ti-9-2-2, Beta-C Titanium (Ti-Beta C), or Ti-4Al-4Mo-2Sn-0.5Si (Ti-4-4-2-0.5Si). In other embodiments, the appendage material can be a high-strength composite or carbon fiber material. [0149] Generally, the appendage material is stronger than the body material. In some embodiments, the appendage material is the same as the faceplate material. In other embodiments, the appendage material and the faceplate material are different. The high-strength appendage material reinforces the IRM, thereby increasing strike face deflection without compromising durability. In some embodiments, the appendage material has a yield strength value of at least 175 ksi or more. In some embodiments, the appendage material comprises a yield strength greater than 175 ksi, greater than 185 ksi, greater than 195 ksi, greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, greater 230 ksi, greater than 240 ksi, or greater than 250 ksi. In some embodiments, the club head 1600 comprises an appendage strength ratio comparing the yield strength of the appendage material to the yield strength of the body material. In some embodiments, the appendage strength ratio can be greater than 1.25, greater than 1.35, greater than 1.45, greater than 1.55, greater than 1.65, greater than 1.75, greater than 1.85, greater than 1.95 or greater than 2.0.

EXAMPLES

D. Example 1 - Ball Flight Performance of Golf Club Head with IRM

[0150] The ball flight performance characteristics of an exemplary fairway-wood type club head comprising an Impact Response Modulator (IRM) were compared to those of a control club head without an IRM. The exemplary club head comprised a reverse L-cup faceplate with a crown return, but no sole return. The exemplary IRM included a casing formed by the body. The casing included a toe relief and formed an aperture that received a polymeric insert. The IRM allowed the sole to bend at impact, thereby increasing strike face deflection and delofting the strike face. The control club head was substantially similar to the exemplary club head, but was devoid of an Impact Response Modulator entirely.

[0151] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via a player test. The player test involved 19 golfers hitting a representative number of golf shots with the exemplary club head and the control club head. The ball flight results of the player test are displayed in Table 1 below.

TABLE 1 : Player Test Ball Flight Characteristics

[0152] As displayed in Table 1 above, the exemplary club head exhibited an increase in ball speed of 1.0 mph and a decrease in spin rate of 364 rpm in comparison to the control club head, with a similar launch angle. The decreased spin rate created a more piercing ball flight that cuts through the air and travels further. These improved ball flight characteristics increased carry distance by 3.4 yards on average.

[0153] In addition to the performance results obtained through player testing, robotic testing was used to compare ball flight characteristics between the exemplary club head and the control club head. A robotic swing apparatus tested both club heads at various locations along the strike face, including the face center (FC), and three “low” locations respectively located at 0.1 inch, 0.2 inch, and 0.3 inch below the face center (FC). Table 3 displays the results of the robotic testing at each location, as well as the averages over all locations.

TABLE 2: Robotic Testing Ball Flight Characteristics

[0154] At the face center (FC), the exemplary club head exhibited an increase in ball speed of 1.4 mph and a decrease in spin of 511 rpm, which creates a more piercing ball flight that cuts through the air and travels further. These improvements resulted in an increase in carry distance of 9.0 yards. On average across all locations, the exemplary club head exhibited an increase in ball speed of 1.3 mph and a decrease in spin of 522 rpm in comparison to the control club head, resulting in an increase in carry distance of 5.1 yards. Overall, results of both the player test and the robotic test illustrate the benefits of the IRM. The IRM increased strike face deflection in the exemplary club head, which improved ball speed, spin rate, and distance. E. Example 2 - Ball Flight Performance of IRM with High-Strength Material Reinforcement

[0155] The ball flight performance characteristics of an exemplary club head comprising an Impact Response Modulator with a casing reinforced by high-strength material were compared to those of a control club head comprising an Impact Response Modulator with a casing formed by the body material. The exemplary club head comprised a cartridge located on the sole and forming the entire casing, which allowed for reduced casing wall heights and decreased offset distance between the casing front wall and the strike face while maintaining durability. The casing also wrapped over the leading edge and formed a lower portion of the strike face, similar to the casing illustrated in FIG. 26. The control club head comprised an Impact Response Modulator with a casing formed by body material, which required increased casing wall heights and a greater offset distance to maintain structural integrity. The control club head had a front wall height FWH of 0.274 inch, whereas the exemplary club head had a reduced front wall height FWH of 0.192 inch due to the high-strength material reinforcement. The offset distance OD from the casing front wall to the strike face in the control club head was 0.24 inch, whereas the exemplary club head had a reduced offset distance OD of 0.177 inch. The reduced front wall height FWH and offset distance OD each increase the amount the casing bends at impact, thereby increasing strike face deflection.

[0156] Various ball flight characteristics, including ball speed, launch angle, and spin rate, were determined via Finite Element Analysis (FEA) simulations. The analysis simulated center strikes at 115 mph club head speed. The results are displayed in Table 3 below.

TABLE 3: Ball Flight Characteristics [0157] As displayed in Table 3 above, the exemplary club head exhibited an increase in ball speed of 3.2 mph compared, a decrease in spin rate of 387 rpm, and similar launch angle. The high-strength cartridge allowed the casing walls to be shortened and moved closer to the strike face, thereby increasing strike face deflection. The example demonstrates that reinforcing the casing with a high-strength component, such as the exemplary cartridge, results in measurable performance benefits. Physical testing (i.e., player testing and robotic testing) will be conducted on prototypes corresponding to the exemplary and control club heads of the present example. Similar ball speed and spin rate improvements are expected for the exemplary club head.

CLAUSES

[0158] Clause 1. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and a cartridge disposed in the sole, the cartridge formed as a separate component and coupled to both the body and the faceplate; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing including: a front wall at least partially formed by the cartridge, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall at least partially formed by the cartridge, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; and an insert disposed within the aperture.

[0159] Clause 2. The golf club head of clause 1, wherein the faceplate forms no portion of the casing.

[0160] Clause 3. The golf club head of clause 1, wherein the faceplate comprises a sole return extending rearward from the strike face, and the sole return couples to the cartridge.

[0161] Clause 4. The golf club head of clause 1, wherein a juncture between the cartridge and the faceplate is located on the sole.

[0162] Clause 5. The golf club head of clause 1, wherein the body is formed of a body material and the cartridge is formed of a cartridge material having a higher yield strength than the body material.

[0163] Clause 6. The golf club head of clause 5, wherein the cartridge material comprises a cartridge material yield strength greater than 175 ksi.

[0164] Clause 7. The golf club head of clause 6, further comprising a cartridge strength ratio defined as the ratio of the cartridge material yield strength divided by a body yield strength, wherein the cartridge strength ratio is greater than 1.25. [0165] Clause 8. The golf club head of clause 5, wherein the faceplate comprises a faceplate material that is different from the cartridge material.

[0166] Clause 9. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and a cartridge distinct from the faceplate and disposed in the sole, the cartridge coupled to both the body and the faceplate; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing entirely integral with the cartridge, the casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture entirely encased by the cartridge; and an insert disposed within the aperture.

[0167] Clause 10. The golf club head of clause 9, wherein the faceplate forms no portion of the casing.

[0168] Clause 11. The golf club head of clause 9, wherein the faceplate comprises a sole return extending rearward from the strike face, and the sole return is coupled to the cartridge.

[0169] Clause 12. The golf club head of clause 9, wherein a juncture between the cartridge and the faceplate is located on the sole.

[0170] Clause 13. The golf club head of clause 9, wherein a juncture between the cartridge and the faceplate is located on the strike face.

[0171] Clause 14. The golf club head of clause 9, wherein the body is formed of a body material and the cartridge is formed of a cartridge material having a higher yield strength than the body material.

[0172] Clause 15. The golf club head of clause 14, wherein the cartridge material comprises a cartridge material yield strength greater than 175 ksi. [0173] Clause 16. The golf club head of clause 15, further comprising a cartridge strength ratio defined as the ratio of the cartridge material yield strength divided by a body yield strength, wherein the cartridge strength ratio is greater than 1.25.

[0174] Clause 17. A golf club head comprising a body, a faceplate at least partially forming a strike face, a sole, and a cartridge formed as a separate component from the faceplate and the body and disposed in the sole, the cartridge coupled to the body; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; and an insert disposed within the aperture.

[0175] Clause 18. The golf club head of clause 17, wherein the cartridge is not coupled directly to the faceplate.

[0176] Clause 19. The golf club head of clause 17, wherein the casing includes a support segment integral with the cartridge and a core segment integral with the body.

[0177] Clause 20. The golf club head of clause 19, wherein the support segment forms at least a portion of the front wall and at least a portion of the rear wall.

[0178] Clause 21. A golf club head comprising: a body, a J-cup faceplate at least partially forming a strike face, a sole, and an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall, and a heel wall; wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; an insert disposed within the aperture; wherein the J-cup faceplate further comprises a sole return extending rearward from the strike face; the front wall is integral with the sole return; and the rear wall is integral with the body. [0179] Clause 22. A golf club head comprising: a body, a partial J-cup faceplate at least partially forming a strike face, a sole, and an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall, and a heel wall; wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; an insert disposed within the aperture; wherein the partial J-cup faceplate further comprises a sole return extending rearward from the strike face; the front wall front surface is integral with the sole return; and the front wall rear surface is integral with the body.

[0180] Clause 23. A golf club head comprising: a body, an underlapping J-cup faceplate at least partially forming a strike face, a sole, and an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall, and a heel wall; wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; an insert disposed within the aperture; wherein the underlapping J-cup faceplate further comprises a sole return extending rearward from the strike face; the front wall front surface is integral with the body; and the front wall rear surface is integral with the sole return.

[0181] Clause 24. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall, and a heel wall; wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; an insert disposed within the aperture; one or more bridges extending between the front wall and the rear wall; wherein the faceplate further comprises a sole return extending rearward from the strike face; and the front wall front surface is integral with the sole return. [0182] Clause 25. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, an appendage coupled to both the body and the faceplate, and an Impact Response Modulator (IRM) disposed in the sole, the IRM comprising; a casing including: a front wall integrally formed by the appendage, the front wall comprising a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall integrally formed with the body, the rear wall comprising a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall, and a heel wall; wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; and an insert disposed within the aperture.

Claims

1. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and a cartridge disposed in the sole, the cartridge formed as a separate component and coupled to both the body and the faceplate; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing including: a front wall at least partially formed by the cartridge, the front wall including a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall at least partially formed by the cartridge, the rear wall including a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; and an insert disposed within the aperture.

2. The golf club head of claim 1, wherein the faceplate forms no portion of the casing.

3. The golf club head of claim 1, wherein the faceplate comprises a sole return extending rearward from the strike face, and the sole return couples to the cartridge.

4. The golf club head of claim 1, wherein a juncture between the cartridge and the faceplate is located on the sole.

5. The golf club head of claim 1, wherein the body is formed of a body material and the cartridge is formed of a cartridge material having a higher yield strength than the body material.

6. The golf club head of claim 5, wherein the cartridge material comprises a cartridge material yield strength greater than 175 ksi.

7. The golf club head of claim 6, further comprising a cartridge strength ratio defined as the ratio of the cartridge material yield strength divided by a body yield strength, wherein the cartridge strength ratio is greater than 1.25.

8. The golf club head of claim 5, wherein the faceplate comprises a faceplate material that is different from the cartridge material.

9. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and a cartridge distinct from the faceplate and disposed in the sole, the cartridge coupled to both the body and the faceplate; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing entirely integral with the cartridge, the casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture entirely encased by the cartridge; and an insert disposed within the aperture.

10. The golf club head of claim 9, wherein the faceplate forms no portion of the casing.

11. The golf club head of claim 9, wherein the faceplate comprises a sole return extending rearward from the strike face, and the sole return is coupled to the cartridge.

12. The golf club head of claim 9, wherein a juncture between the cartridge and the faceplate is located on the sole.

13. The golf club head of claim 9, wherein a juncture between the cartridge and the faceplate is located on the strike face.

14. The golf club head of claim 9, wherein the body is formed of a body material and the cartridge is formed of a cartridge material having a higher yield strength than the body material.

15. The golf club head of claim 14, wherein the cartridge material comprises a cartridge material yield strength greater than 175 ksi.

16. The golf club head of claim 15, further comprising a cartridge strength ratio defined as the ratio of the cartridge material yield strength divided by a body yield strength, wherein the cartridge strength ratio is greater than 1.25.

17. A golf club head comprising: a body, a faceplate at least partially forming a strike face, a sole, and a cartridge formed as a separate component from the faceplate and the body and disposed in the sole, the cartridge coupled to the body; the cartridge integrally forming at least a portion of an Impact Response Modulator (IRM), the IRM comprising; a casing including: a front wall with a front wall front surface, a front wall rear surface, a front wall base, and a front wall top surface; a rear wall with a rear wall front surface, a rear wall rear surface, a rear wall base, and a rear wall top surface; a toe wall; and a heel wall, wherein the front wall, the rear wall, the toe wall, and the heel wall define an aperture; and an insert disposed within the aperture.

18. The golf club head of claim 17, wherein the cartridge is not coupled directly to the faceplate.

19. The golf club head of claim 17, wherein the casing includes a support segment integral with the cartridge and a core segment integral with the body.

20. The golf club head of claim 19, wherein the support segment forms at least a portion of the front wall and at least a portion of the rear wall.