Abstract: Embodiments of golf club heads and methods to manufacture golf club heads are generally described herein. In one example, a golf club head may include a body portion with a toe portion, a heel portion, a rear portion, a front portion with a strike face, a sole portion, and a top portion with a plurality of weight ports. The body portion may define a periphery of the golf club head. The golf club head may also include a plurality of weight portions with each weight portion disposed in one weight port of the plurality of weight ports. Other examples and embodiments may be described and claimed.

Abstract: Embodiments of golf club heads and methods to manufacture golf club heads are generally described herein. In one example, a golf club head may include a body portion with a toe portion, a heel portion, a rear portion, a front portion with a strike face, a sole portion, and a top portion with a plurality of weight ports. The body portion may define a periphery of the golf club head. The golf club head may also include a plurality of weight portions with each weight portion disposed in one weight port of the plurality of weight ports. Other examples and embodiments may be described and claimed.

Abstract: A method of manufacturing a golf club head with a variable thickness face having a central thickened region surrounded by a transition region tapering from the central thickened region to a thinner peripheral region. The method includes locating a ball end mill revolving about an axis generally normal to the inner surface of the face plate at an initial location on a circumferential intersection between the outer edge of the central thickened region and a transition region. The inner surface of the face plate is machined by moving the revolving ball end mill in a radial direction outwardly toward and through the transition region and the peripheral region to machine the inner surface of the face plate creating a tool channel having a width as the ball end mill traverses the transition region and thereby vary the thickness of the face plate in the tool path.

Abstract: Embodiments of methods of manufacturing a face plate for a golf cub are generally described herein. In one exemplary embodiment, a method for manufacturing a golf club face plate comprises: providing a face plate material, and milling the face plate material in an elliptical pattern to form a central region comprising, a first elliptical outer edge and a transition region extending from the first elliptical outer edge to a second elliptical outer edge. In this exemplary embodiment, each point along the second elliptical outer edge is displaced outward from the first elliptical outer edge by a predetermined distance. Other embodiments herein may be described and claimed.

Abstract: A club head is configured such that the toe thickness is greater than the heel thickness in order to compensate for the toe-down look encountered, for example, in extended-length putters. In accordance with a further aspect of the present invention, the club head body in the heel region is weight-compensated to substantially balance with the toe region. In accordance with one embodiment, a bore configured to accept the shaft is provided at substantially the center of the top rail. In accordance with one embodiment, cut-out regions are provided in the back of the club head body in the toe region and the heel region to provide the required weight compensation.

Abstract: An iron type golf club head includes a body having a front face arranged for impact with a golf ball, a back face, a heel portion and toe portion. A hosel is connected to the heel portion of the body. A perimeter weighting element protrudes rearwardly from the front face and defines a primary cavity in the back face of the body. The perimeter weighting element includes a top rail and a sole which extend between the body heel and toe portions along an upper portion and a lower portion, respectively, of the body. An interior wall extends from a first end connected to the perimeter weighting element adjacent the body heel portion through the primary cavity between the top rail and the sole to a second end connected to the perimeter weighting element adjacent the body toe portion to define an elongated secondary cavity or tuning port within the primary cavity.

Abstract: A golf club head includes a hollow body having a front wall, a crown and a sole. The crown has a thickness dimension measured between its inner and outer surfaces. An outer edge of the crown extends in a generally arcuate path between heel and toe ends of the hollow body. A plurality of thin regions in the crown is arranged in a matrix pattern. The plurality of thin regions includes a first row of thin regions disposed adjacent the outer edge of the crown and a second row of thin regions disposed inwardly of the first row of thin regions. The crown thickness dimension in the plurality of thin regions is reduced when compared with the crown thickness dimension in other regions of the crown.

Abstract: A weight adjustment member may be mounted in a tuning port in a golf club head and secured therein using adhesive. The weight adjustment member includes a lip which prevents excess adhesive from escaping the tuning port and hides adhesive that might otherwise be visible between the weight adjustment member and the tuning port. Locating devices that mate with each other are included in the tuning port and on the weight adjustment member. A method of mounting the weight adjustment member in the tuning port of a golf club head is also provided.

Abstract: The present invention provides an iron-type golf club head comprising a primary cavity that is approximately parallel to the ground when the club head is resting at normal address. A secondary cavity, positioned within the primary cavity, has a bottom wall that is approximately parallel to the club face and is positioned above the club head sole. An interior wall that forms the secondary cavity is uniform in height while increasing in width in a bottom segment thereof.

Abstract: A method of fabricating a golf club hosel includes the steps of: (1) providing a mold tool having a cavity corresponding to a hosel having a generally cylindrical boss portion coupled to a horizontal leg portion extending radially from the boss portion, wherein the horizontal leg portion has a width that is less than the outside diameter of the boss portion; (2) providing a mold tool insert slideably coupled to the mold tool along a sliding axis generally perpendicular to the horizontal leg portion; (3) sliding the mold tool insert to a first position such that the mold tool insert forms, within said cavity, a surface of the cylindrical portion and a surface of the horizontal leg portion; (4) filling the mold tool cavity with a material (e.g., a wax material); and (5) sliding the mold tool insert to a second position such that the mold tool insert disengages from the material in the mold tool cavity.

Abstract: A method of manufacturing a golf club head with a variable thickness face having a central thickened region surrounded by a transition region tapering from the central thickened region to a thinner peripheral region. The method includes locating a ball end mill revolving about an axis generally normal to the inner surface of the face plate at an initial location on a circumferential intersection between the outer edge of the central thickened region and a transition region. The inner surface of the face plate is machined by moving the revolving ball end mill in a radial direction outwardly toward and through the transition region and the peripheral region to machine the inner surface of the face plate creating a tool channel having a width as the ball end mill traverses the transition region and thereby vary the thickness of the face plate in the tool path.

Abstract: The present invention relates to certain weight adjustment members that can be used in connection with iron-type golf clubs. The weight adjustment members of the present invention comprise a relatively uniform and/or symmetrically configured width. In addition, the members comprise a substantially linear back-side. The weight adjustment members of the present invention, therefore, provide a consistent level of performance across the members and, moreover, can be mass produced using more simplified molds when compared to other members known in the art. Still further, the present invention provides iron-type golf heads and golf clubs that comprise the weight adjustment members of the present invention.

Abstract: A golf club head is machined from an extruded bar having an irregular cross-section that is near-net-shape to the vertical profile of the club. To form the club head, the extruded bar is sliced into a club head blank. The blank is secured to a machining fixture and machined into the final configuration. Because the club head blanks are formed from an extrusion that is already near-net-shape to the profile of the club, less metal is removed during the machining operations, which results in faster process times, less wasted material and therefore substantial cost savings over the prior art methods of manufacturing golf club heads.

Abstract: A golf club head is formed of a hollow metal body having a center of gravity that is above the geometric center of the club face. The hollow metal body of the club head has a sole plate that is smoothly contoured and devoid of any inefficient structures such as weight pads or other mass concentrations. By avoiding the use of inefficient structures such as weight pads, more material is available for the structural walls of the club head body while maintaining the club head within acceptable weight limitations. Moreover, placement of the center of gravity above the center line of the face ensures that sufficient backspin will be imparted to the golf ball when struck by the club.

Abstract: A golf club is manufactured by machining away a portion of the rear surface of a club face blank to form an elliptical central thickened region that tapers through a transition region to a thinner peripheral region. The elliptical central thickened region, transition region and the portion of the peripheral region surrounding the raised portion are formed in a single elliptical pass with a special cutting tool. The cutting tool, or “form cutter” has a conical lateral cutting surface, which forms the sloped transition region and the peripheral region surrounding it in a single operation.

Abstract: The present invention relates to an improved connection of a golf club shaft to the head of a golf club and methods for making the improved connection. A golf club according to the present invention includes a club head having a top surface, a bottom surface, a front face wall for impacting a golf ball, a heel portion and toe portion. A bore is disposed in the heel end of the club head and extends from the top surface of the club head toward the bottom surface of the club head. A shaft locating device is inserted into the upper end of the bore. A shaft locating bore, for accurately locating the shaft in a preferred and consistent location, extends through the entire length of the shaft locating device. The tip of a shaft is inserted in and extends through the shaft locating bore and into the bore in the club head.

Abstract: A no-draft putter club head is formed using an investment casting process, wherein one or more critical surfaces of the club head—i.e., surfaces with contours that affect the visual appearance of the club head when viewed from above—are formed substantially parallel to the draw direction of the mold. The mold includes an internal cavity corresponding to a putter club head shape, wherein the cavity includes a set of surfaces substantially parallel to the draw direction of the mold. This set of surfaces may include, for example, a toe surface, a heel surface, a top rail surface, and/or a hosel surface. A wax material is suitably poured or injected into the mold cavity to form a wax replica of the putter club head shape. The wax replica is then removed from the mold cavity along a line parallel to the draw direction.

Abstract: A putter club head generally includes a club head body having a leg portion extending from the club head body, wherein the leg portion includes an integral boss configured to accept a shaft along a shaft axis. The leg portion has a predetermined forward slant angle (for example, between about 1.0-6.0 degrees) with respect to a body axis, and is suitably configured to deform plastically to allow adjustment of the lie angle such that the leg portion is substantially concealed (e.g., by the boss) as the club head body is viewed from above during address. The leg portion remains substantially concealed witting a range of adjustment angles typically used during club fitting, thereby maintaining the club head's desirable visual cues during address.

Abstract: A club head is configured such that the toe thickness is greater than the heel thickness in order to compensate for the toe-down look encountered, for example, in extended-length putters. In accordance with a further aspect of the present invention, the club head body in the heel region is weight-compensated to substantially balance with the toe region. In accordance with one embodiment, a bore configured to accept the shaft is provided at substantially the center of the top rail. In accordance with one embodiment, cut-out regions are provided in the back of the club head body in the toe region and the heel region to provide the required weight compensation.

Abstract: An iron type golf club head includes a body having a front face arranged for impact with a golf ball, a back face, a heel portion and toe portion. A hosel is connected to the heel portion of the body. A perimeter weighting element protrudes rearwardly from the front face and defines a primary cavity in the back face of the body. The perimeter weighting element includes a top rail and a sole which extend between the body heel and toe portions along an upper portion and a lower portion, respectively, of the body. An interior wall extends from a first end connected to the perimeter weighting element adjacent the body heel portion through the primary cavity between the top rail and the sole to a second end connected to the perimeter weighting element adjacent the body toe portion to define an elongated secondary cavity or tuning port within the primary cavity.